Qirox Qrc-410 by Giovane Cardozo

Operating and Programming Manual Robot controller ROTROL® II - V04

- Standard - Options Version 7.06 As of: 02/07

Carl Cloos Schweißtechnik GmbH Industriestraße, D - 35708 Haiger Phone: 02773 / 85-0 FAX: 02773 / 85-275 Internet: http://www.cloos.de Author: Karl - Wilhelm Streit

Index - Standard

List of Blocks Block

Subject

Page

Basics

1 PREFACE ...................................................................................................................... 3 1 Operating and programming manual ...................................................................... 3 1.1 Training courses.................................................................................................. 3 1.2 Structure of the Programming manual ................................................................ 4 1.3 Service manual ................................................................................................... 5 1.4 Spare parts lists .................................................................................................. 5 1.5 Programming language ....................................................................................... 5 1.6 Notation of commands and instructions ............................................................... 5 1.7 Thermal limits .................................................................................................... 6 1.7.1 Thermal and air humidity limit of the controller .............................................. 6 1.7.2 Thermal limit of the teach pendant (PHG) ..................................................... 6 1.8 Changes in content ............................................................................................. 6

2 The industrial robot ..................................................................................................... 7 2 Structure of the industrial robot ............................................................................... 7 2.1 Working range and working area .................................................................... 9 3 Safety regulations ...................................................................................................... 11 3 Safety regulations ............................................................................................... 11 3.1 Safety symbols.............................................................................................. 11 3.2 Organising measures.................................................................................... 12 3.2.1 Conformity ............................................................................................... 12 3.2.2 Where to keep the operating manual ....................................................... 12 3.2.3 Supplements to the operating manual ..................................................... 12 3.2.4 How to keep the readability ..................................................................... 12 3.2.5 Personal protective equipment ................................................................ 12 3.2.6 Changes relevant to safety ...................................................................... 13 3.2.7 No modifications ..................................................................................... 13 3.2.8 Spare parts ............................................................................................. 13 3.2.9 Deadlines ................................................................................................ 13 3.2.10 Workshop equipment, tooling ................................................................ 13 3.2.11 Fire hazard ............................................................................................ 14 3.2.12 Fire extinguisher .................................................................................... 14 3.2.13 Fight against fire ................................................................................... 14 3.2.14 Use, disposal and recycling ................................................................... 15 3.2.15 Personal selection and qualification ...................................................... 16 3.2.15.1 Requirements ..................................................................................... 16

Programming Manual ROTROL速 II

Index - Standard 3.2.15.2 Personal training ................................................................................ 16 3.2.15.3 Control of the personal ....................................................................... 16 3.2.15.4 Responsibility of the system operators ............................................... 17 3.2.15.5 Duty to supervise ................................................................................ 17 3.2.15.6 Works on electrical equipments .......................................................... 17 3.2.15.7 Works on the system .......................................................................... 17 3.2.15.8 Safety instructions for certain operational phases............................... 17 3.2.15.9 Safety precautions in operating modes ADJUSTMENT T1 and T2 ..... 18 3.2.15.10 Safety precautions in AUTOMATIC mode ......................................... 18 3.2.15.11 Safety precautions for maintenance and repair work ........................ 19 3.3 Particular dangers......................................................................................... 21 3.3.1 Electric energy ........................................................................................ 21 3.3.2 Pneumatics ............................................................................................. 21 3.3.3 Gas, dust, steam, smoke ......................................................................... 21 3.3.4 Additional mounting instructions .............................................................. 22

Safety and system equipments ................................................................................... 23 4 Safety and system devices on the control .......................................................... 23 4.1.1 EMERGENCY-OFF switch ........................................................................ 23 4.1.2 Operation mode selection switch ............................................................... 24 Operating mode OFF ....................................................................................... 24 Operating mode ADJUST T1 ........................................................................... 24 Operating mode ADSJUST T2 ......................................................................... 25 Operating mode AUTO ..................................................................................... 25 4.1.3 General error message display .................................................................. 25 4.1.4 Ready for operation ................................................................................... 26 4.1.5 Power ON .................................................................................................. 26 4.1.6 Power OFF ................................................................................................ 26 4.1.7 START ....................................................................................................... 27 4.1.8 STOP ......................................................................................................... 27 4.2 Safety devices on the teach pendant: .............................................................. 27 4.3 Safety devices on the robot mechanics ........................................................... 28 4.4 Safety devices on the peripheral equipment .................................................... 28 4.4.1 General information.................................................................................... 28 4.4.2 Equipments ................................................................................................ 29 Switching on/off of robot system ................................................................................ 31 5.1 Switching on of the robot system ....................................................................... 31 5.2 Switching off of the robot system ....................................................................... 32 Manual Movement of the robot mechanics ................................................................ 33 6 Manual movement of the robot mechanics ...................................................... 33

Programming Manual ROTROL速 II

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Index - Standard

Block

Subject

Page

The Teach Pendant

The teach pendand ......................................................................................................... 2 1 Teach pendant = PHG ............................................................................................ 2 1.1 Teach pendant keys ........................................................................................ 2 1.2 Touchscreen ................................................................................................... 3 1.3 Program set up ............................................................................................... 6 1.4 Archiving and managing of programs ............................................................. 7 1.5 Testing of programs ........................................................................................ 8 1.6 Automatic mode ............................................................................................. 8 1.7 Help functions ................................................................................................. 9 1.8 Terminal simulation ......................................................................................... 9 1.9 Printing of programs ..................................................................................... 10 2 System set up ...................................................................................................... 10 2.1 Digital in/outputs ........................................................................................... 11 2.2 System information ....................................................................................... 12 2.3 Error messages ............................................................................................ 13 2.4 The service menu .......................................................................................... 14 2.5 Offline programming ..................................................................................... 15 2.6 The HOME-Position ...................................................................................... 15

Teach 1 Adjustment and check of the welding torch ............................................................. 2 1.1 Alignment of the welding torch ......................................................................... 3 2 Mode TEACH ........................................................................................................ 4 2.1 Keys and touch screen .................................................................................... 5 2.2 Move the robot mechanics .............................................................................. 6 2.3 Change the robot speeds ............................................................................... 7 2.4 Storage of points ............................................................................................ 8 2.5 Point information during storage ..................................................................... 9 2.6 Approach of memorised points ..................................................................... 11 2.7 Additional functions ....................................................................................... 11 3 Coordinate systems ............................................................................................. 12 3.1 Robot coordinate system .............................................................................. 12 3.2 Base coordinate system ............................................................................... 13 3.3 Hand coordinate system ............................................................................... 14 3.4 Workpiece coordinate system ...................................................................... 15 4 Tool Center Point (TCP) ....................................................................................... 17 4.1 Determination of the TCP value .................................................................... 17 4.2 Input of the determined TCP values ............................................................... 18 4.3 External TCP ................................................................................................ 19 5 Tool Orientation Vector (TOV) ............................................................................. 21 5.1 Input of the TOV ............................................................................................ 22 Programming Manual ROTROL速 II

Index - Standard

Block

Subject

Page

The Editor

The editor ......................................................................................................................... 2 1 The editor ............................................................................................................... 2 1.1 Keyboard ........................................................................................................ 4 1.2 Cursor movements .......................................................................................... 4 1.3 Special characters .......................................................................................... 5 1.4 Editor commends ........................................................................................... 5 1.5 Help functions in the text editor ........................................................................ 6 1.6 User examples ................................................................................................ 7 1.7 Leaving the text editor ..................................................................................... 8

Mode PROG

1 PROG mode .................................................................................................................. 2 1.1 Inserting command lines ...................................................................................... 3 1.1.1 Simple movement commands ...................................................................... 4 1.1.2 Circle and partial circle functions.................................................................. 7 1.1.2.1 Full circle ................................................................................................ 8 1.1.2.2 Partial circle ........................................................................................... 9 1.1.2.3 Amount of looped partial circles .............................................................. 9 1.1.2.4 Circle interpolation and additional axe .................................................. 10 1.1.2.5 Circle orientation .................................................................................. 10 1.1.2.6 Additional functions for programming circles ........................................ 11 1.1.3 Weld parameter lists .................................................................................. 11 1.1.4 Sensor functions ........................................................................................ 11 1.1.5 Movement characteristics .......................................................................... 12 1.1.5.1 Looping of points - looping vector ......................................................... 12 1.1.5.2 Path looping ......................................................................................... 13 1.1.5.3 Changing the maximum PTP- speed .................................................... 14 1.1.6 Leaving the PROG mode ........................................................................... 15 1.2 Editing Command lines ..................................................................................... 16 1.3 Program cursor positioning ............................................................................... 17 1.4 Deleting of command lines ................................................................................ 18

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Subject

Page

Program execution

Program execution ......................................................................................................... 2 1 Test ........................................................................................................................ 2 1.1 EXE ................................................................................................................ 2 1.2 EST ................................................................................................................ 3 1.2.1 Usage .......................................................................................................... 3 1.2.2 Selection options in EST-Mode ................................................................... 4 1.2.3 Selection options following a STOP command ............................................ 5 1.2.4 Trace memory .............................................................................................. 5 2 AUTOMATIC-Mode ................................................................................................ 6 3 Leeway of operating modes .................................................................................. 7 4 Line start ............................................................................................................... 8 5 Overlapping start .................................................................................................. 11 5.1 Termination of executed programs during weld process ............................... 11 6 File Autoexec ....................................................................................................... 15

Weld technic functions

Weld parameter lists ....................................................................................................... 2 1 Weld parameter lists ............................................................................................. 2 1.1 Definition of weld parameter lists ....................................................................... 3 1.2 Activation of weld parameter lists ($, $S, $E, $H)................................................ 4 1.3 Parameters of MIG/MAG- power sources ........................................................... 5 1.4 Start list ............................................................................................................. 12 1.5 End crater list .................................................................................................... 14 1.6 Spot weld list ..................................................................................................... 15 1.7 Tandem welding ................................................................................................ 17 1.7.1 Parameter and signal transfer .................................................................... 18 1.7.2 Limitations of tandem welding .................................................................... 18 1.7.3 Additional parameters in the weld parameter list ....................................... 19 1.7.4 Program example ...................................................................................... 20 1.8 Power supply MC3R ......................................................................................... 21 1.8.1 Parameter and signal transfer .................................................................... 22 1.8.2 Changed parameters of the MC3R: ........................................................... 22 1.8.3 Weld parameter changes ........................................................................... 23

Programming Manual ROTROL速 II

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Block

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Page

2 Parameter of WIG- weld power supplies 30 2.1 Normal list ..................................................................................................... 30 2.2 Start list ......................................................................................................... 34 2.3 End crater list ................................................................................................ 35 2.4 Cold wire feed .............................................................................................. 36 2.5 PPAW .......................................................................................................... 37 2.5.1 Normal list ............................................................................................... 37 2.5.2 Start list ................................................................................................... 37 2.5.3 End list .................................................................................................... 38 2.6 Weld parameter changes ............................................................................. 39 3 Weld parameter changes in automatic mode .......................................................... 41 4 Global list definitionsl ................................................................................................ 42 5 Serial transfer of weld parameter lists ..................................................................... 43 5.1 Table for serial data transfer.............................................................................. 45 5.2 PHG (teach pendant) Menu for serial data transfer ........................................... 55 6 Free list access .......................................................................................................... 61

Arc monitoring

Arc monitoring................................................................................................................. 2 1 Ignition monitoring .................................................................................................. 3 1.1 Ignition monitoring ARCCON .......................................................................... 3 1.2 Ignition routine ARCIGNIT ............................................................................... 4 2 Monitoring during the welding process .................................................................. 5 2.1 ONLCON ....................................................................................................... 5 2.2 Monitoring function SDSTOPCP - SDSTOP ................................................... 6 FUNCON_SDSTOPCP,x,y ................................................................................. 6 SDSTOP_(nr) .................................................................................................... 7 2.3 Recognition of porous weld seams ................................................................. 7 3 Final monitoring ..................................................................................................... 7 3.1 Extension arc monitoring................................................................................. 8 3.2 Status information from the power source ..................................................... 10 4 Causes for mal functions ...................................................................................... 11 5 Heat input ............................................................................................................. 12 Programming Manual ROTROL速 II

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Subject

Page

9 Program functions Program functions .......................................................................................................... 3 1 Summary of the program functions ...................................................................... 3/4 2 Linkage operations ................................................................................................ 5 2.2 Jump command .............................................................................................. 6 2.3 Linkages to digital inputs ................................................................................ 8 2.4 Linkages to variables ...................................................................................... 9 2.5 Alternative instruction after next instruction ...................................................... 9 2.6 Program examples ....................................................................................... 10 2.7 Other applications ......................................................................................... 11 3 Subroutines .......................................................................................................... 12 3.1 Summary ...................................................................................................... 12 3.2 Handling and commands .............................................................................. 13 3.3 Program example ......................................................................................... 14 3.4 Enlarged subroutine technology .................................................................... 16 3.4.1 Commands in comparison ...................................................................... 16 3.4.2 Program example .................................................................................... 16 3.5 Additional functions ....................................................................................... 17 3.5.1 Copying points from external programs ................................................... 17 3.5.2 Definition of variables .............................................................................. 17 4 Online parallel shift ............................................................................................... 18 4.1 Cartesian shift of spatial points ..................................................................... 18 4.2 Online transformation and imaging................................................................ 19 5 Digital inputs and outputs ..................................................................................... 20 5.1 Switching of digital outputs via program command ....................................... 20 5.2 Interpolated switching on and off of digital outputs ......................................... 21 5.3 Binary coded interrogation of digital inputs ................................................... 22 5.4 Binary coded switching on of digital inputs .................................................... 23 5.5 Digital input/output menu ............................................................................... 24 5.6 Digital outputs with reserved functions .......................................................... 25 6 Define, positioning und parameterisation of external axes ................................... 26 7 Changing the TCP and TOV during program run .................................................. 26 7.1 Temporary change of the TCP value ............................................................. 26 7.2 Temporary change of the TOV value ............................................................. 27 7.4 Read existing TCP values ............................................................................. 28 7.5 Online transformation due to a determined TCP deviation ............................ 28

Programming Manual ROTROL速 II

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Block

Subject

Page

8 Keypad simulation................................................................................................ 29 9 Processing point information ............................................................................... 29 10 Program interruption .......................................................................................... 29 11 Wait commands ................................................................................................. 29 12 Read and write run times ................................................................................ 31 12.1 Read in a time ............................................................................................ 31 12.2 Write a time ................................................................................................ 33 12.3 Read and write a time in the parallel task .................................................... 33 13 Multi-layer technology ......................................................................................... 34 14 CEBS Production Data Acquisition ................................................................... 34 14.1 Parallel task ............................................................................................... 34 14.2 Production Data Acquisition ....................................................................... 34 14.3 Program creation and linkage ..................................................................... 34 14.3.1 Start programs from the main memory................................................... 35 14.3.2 Reload and start programs from disk, hard disk or PC .......................... 36 14.3.3 Creation of program names for the automatic reload of programs ........ 37 14.3.4 Delete programs ................................................................................... 38 14.3.5 Save programs...................................................................................... 38 15 Messages and entry of variable values ............................................................... 39 15.1 General ....................................................................................................... 39 15.2 Command WRITE ....................................................................................... 39 15.3 Command GOTOXY ................................................................................... 40 15.4 Command READ and WREAD .................................................................. 40 16 Oscillation .......................................................................................................... 41 16.1 General view ............................................................................................... 41 16.2 Oscillating amplitude (oscillating width) ....................................................... 41 16.3 Oscillating frequency ................................................................................... 43 16.4 Oscillating direction .................................................................................... 44 16.5 Current oscillation ....................................................................................... 45 16.6 Oscillating orientation to be defined ............................................................ 45 16.7 Oscillating form ........................................................................................... 46 16.8 Axis oscillation ............................................................................................ 47 16.9 Manual axis oscillation ................................................................................ 47 16.10 Oscillating synchronous signals ................................................................ 48 17 Operational mode MASTER-SLAVE ................................................................. 48 18 Subroutine call ..................................................................................................... 4

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19 Error messages and procedure call in case of errors ......................................... 49 19.1 Summary .................................................................................................... 49 19.2 Extended error message output .................................................................. 49 19.3 ONERROR ................................................................................................. 50 19.4 Switching of digital outputs in case of error messages ............................... 52 20 Online point shift in the workpiece coordinate system ........................................ 52

10 Variables Variables ........................................................................................................................... 2 1 Variables ............................................................................................................... 2 1.1 Declaration of variables .................................................................................. 2 1.2 Commands for the variables ........................................................................... 5 1.3 Arithmetic operations ...................................................................................... 5 1.4 Relational inquiries ......................................................................................... 6 2 Counting loops ....................................................................................................... 8 3 Generating points during program run .................................................................. 10 3.1 Storage of point information .......................................................................... 10 3.2 Reading of point information ......................................................................... 11 3.3 Ambiguity of robot axes ................................................................................ 20 3.4 Determination of the next point number ......................................................... 23 4 Changing the preset point resolution .................................................................... 25 5 Copying external points ....................................................................................... 26 5.1 External Point ................................................................................................ 26 5.2 Command COPYP ....................................................................................... 26 5.3 Generating points during path travel .............................................................. 27

11 Archiving 1 Archiving and administration of user programs ............................................. 2 1.1 General ........................................................................................................... 2 1.2 Formatting of disks ......................................................................................... 3 1.3 Standard disk drive ......................................................................................... 4 1.4 Directory (Index) .............................................................................................. 5 1.5 Copy ............................................................................................................... 6 Programming Manual ROTROL速 II

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Page

1.6 Rename (changing program names)............................................................... 7 1.7 Delete (deleting programs) ............................................................................. 7 1.8 Load (loading programs) ................................................................................ 8 1.9 Save (saving programs) .................................................................................. 9 2.0 SAVE ALL (saving all user programs) ............................................................ 9 2.1 LOAD ALL (loading a working set) ............................................................... 10

List of Commands List of commands ...................................................................................................... 2 Alphabetical index ..................................................................................................... 6

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Index 1 PREFACE ...................................................................................................................... 3 1 Operating and programming manual ...................................................................... 3 1.1 Training courses.................................................................................................. 3 1.2 Structure of the Programming manual ................................................................ 4 1.3 Service manual ................................................................................................... 5 1.4 Spare parts lists .................................................................................................. 5 1.5 Programming language ....................................................................................... 5 1.6 Notation of commands and instructions ............................................................... 5 1.7 Thermal limits .................................................................................................... 6 1.7.1 Thermal and air humidity limit of the controller .............................................. 6 1.7.2 Thermal limit of the teach pendant (PHG) ..................................................... 6 1.8 Changes in content ............................................................................................. 6

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3.2.15.7 Works on the system .......................................................................... 17 3.2.15.8 Safety instructions for certain operational phases............................... 17 3.2.15.9 Safety precautions in operating modes ADJUSTMENT T1 and T2 ..... 18 3.2.15.10 Safety precautions in AUTOMATIC mode ......................................... 18 3.2.15.11 Safety precautions for maintenance and repair work ........................ 19 3.3 Particular dangers......................................................................................... 21 3.3.1 Electric energy ........................................................................................ 21 3.3.2 Pneumatics ............................................................................................. 21 3.3.3 Gas, dust, steam, smoke ......................................................................... 21 3.3.4 Additional mounting instructions .............................................................. 22

Safety and system equipments ................................................................................... 23 4 Safety and system devices on the control.......................................................... 23 4.1.1 EMERGENCY-OFF switch ........................................................................ 23 4.1.2 Operation mode selection switch ............................................................... 24 Operating mode OFF ....................................................................................... 24 Operating mode ADJUST T1 ........................................................................... 24 Operating mode ADSJUST T2 ......................................................................... 25 Operating mode AUTO ..................................................................................... 25 4.1.3 General error message display .................................................................. 25 4.1.4 Ready for operation ................................................................................... 26 4.1.5 Power ON .................................................................................................. 26 4.1.6 Power OFF ................................................................................................ 26 4.1.7 START ....................................................................................................... 27 4.1.8 STOP ......................................................................................................... 27 4.2 Safety devices on the teach pendant: .............................................................. 27 4.3 Safety devices on the robot mechanics ........................................................... 28 4.4 Safety devices on the peripheral equipment .................................................... 28 4.4.1 General information.................................................................................... 28 4.4.2 Equipments ................................................................................................ 29

Switching on/off of robot system ................................................................................ 31 5 Switching on of the robot system .......................................................................... 31 5.1 Switching off of the robot system ....................................................................... 32 Manual movement of the robot mechanics ................................................................ 33 6 Manual movement of the robot mechanics ........................................................... 33

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Programming Manual ROTROL速 II /2003

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Basic information

PREFACE Programming and operating manual

The complete literature on CLOOS ROMAT® industrial robot systems with ROTROL® II controller consists of: -

Programming instructions Part 1 = Standard version Part 2 = Options Service manual List of spare parts

Persons who have to work on the robot system must have read and understood the respective documentations. This also applies to employees who work on the system only sometimes, for example in case of maintenance. The programming manual is available on a programming course and the service manual on a service course. The programming instructions should at all times be available at the control cabinet. Corresponding operation manuals will be available for other equipment. Regular trainings qualify the operators to work with the robot system.

ATTENTION !! The robot system may only be operated according to the directives of the EN 775 and as a result from these directives only by - trained and instructed personnel - and in accordance with the instructions and regulations in the manuals. Before starting the operation and programming of the industrial robot, the operator should read the programming instructions very carefully, as incorrect operation can result in personal injuries and damage to the robot system. For robot systems, which are not linked to other control cabinets and / or peripheral equipment, these programming instructions can be regarded as operating instructions according to EN 775 (see also chapter „Safety regulations“ in this block).

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1.1 Training courses Messrs. Cloos are offering training courses especially in regard of the customers' requirements which are held in our own training centre and which enable our customers to quickly learn the different operating methods. Contact address:

CARL CLOOS SCHWEISSTECHNIK GmbH Industriestr. , D-35708 P. O. Box 11 61, D-35701 Haiger Tel. 02773 / 85-213 FAX: 02773 / 85-346 E-Mail: training@cloos.de Internet:http://www.cloos.de

Robots: Information course: Robot technology Basic course for operations Control: ROTROL RII, R32T Basic programming course (Part 1) Control: ROTROL RII, R32 R32T Extended programming course (Part 2) Control: ROTROL RII, R32T Service and Maintenance for electrical engineers Control: ROTROL RII, R32T Service and Maintenance for mechanical engineers ROMAT: R260, R310, R320 ... Programming course Robo Plan NT Offline programming system for welding robots Programming course META - Laser sensor Power sources: Information course Welding technology Operation, programming and setting reference MIG/MAG and TIG welding machines Types: Quinto II, Quinto Profi, MC3, C-series Service and Maintenance for electrical engineers MIG/MAG and TIG power sources Types: Quinto II, Quinto Profi, MC3, C-series Page 4

Programming Manual ROTROL速 II /2003

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Basic information

The ROTROL速 II programming manual describes all the measures required for operators for programming and practical operation of a CLOOS industrial robot system. The last part of the programming manual shows a summary of the commands and instructions. The structure of the programming manual and the order of contents were selected according to the programming courses taking place in the CLOOS company. In order to find the different commands functions and instructions as quickly as possible, the content of the programming manual has been divided into individual blocks.

1.3 Service manual The service manual ROTROL速 II describes measures to be taken for service or repair/ maintenance. The service manual refers to the basic equipment of the robot system. Additional equipment is described separately in the corresponding documentation. The concept of the service manual relates to the contents of the service courses and has been divided into individual blocks describing complete subjects.

1.4 Spare parts lists The spare parts list shows a listing of all components with parts numbers for the procuremental spare parts.

1.5 Programming language The programming language of the CLOOS robot systems is

CAROLA

Cloos Advanced RObot LAnguage

In order to formulate the robot program the CAROLA programmming language is supplied by the programming system of the ROTROL速 II controller. The operating system generates programming commands, which formulate the program run, by touching the corresponding symbols on the touchscreen of the teach pendant (PHG) as well as by inputs via keyboard.

1.6 Notation of the commands and instructions All commands, functions or instructions are written in CAPITAL LETTERS. Prescribed spaces are identified in the programming manual by an underlined space, e. g. : GC_(...).

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1.2 Structure of the Programming manual

Basic information

Block 1 - Standard

1.7 Temperature limits 1.7.1 Temperature and air humidity limit of the controller No matter which temperature: the air humidity must not exceed approx. 85-95%, above all no condensation! The air conduction is sufficient for the cooling until 40°C ambient temperature. A roof cooling unit is necessary in case of temperatures between 40°C and 55°C. Temperatures of more than 55°C require an air-condition or an external cooling system. There are many temperature measuring points inside the controller which are always under supervision: a) PC - internally at the PCIF - Ambiance PC rack b) Drive system - internally in each axis controller A1...An - in each output stage A1...An - in the supply module interior space - in the supply module cooling body The limits are defined in each component group. The messages/reactions are made in two steps, i.e. there is a message in the status line on the display when exceeding the first limit and a power switch-off (Emergency-Off) when reaching the second limit.

1.7.2 Temperature limit of the teach pendant (PHG) You must not operate the teach pendant under 0°C, from 40°-60°C the readability on the display can be affected.

1.8 Changes in content We reserve the right to change the content. Messrs. Carl Cloos Schweisstechnik GmbH are not reliable for possible errors in this documentation. The responsibility for indirect damages which may arise in the connnection of the delivery or the use of this documentation is excluded as far as it is legally admissible. Property note according to DIN 34: Transmission and reproduction of this document as well as use and information about its content are not permitted unless otherwise stated. Non-compliances oblige to compensation for damages. All rights reserverd in case of issue of a patent or model registration utility.

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Basic information

The industrial robot 2 Structure of the industrial robot CLOOS robots in the ROMAT® series are supplied in different sizes: ROMAT® 260,310,360 ROMAT® 320,350,410 ROMAT® 500 The differences between the robots are the working range and the carrying load. The construction of the axes of ROMAT® industrial robot result in a robot in so-called revolute joint design or articulated arm construction. The principle of the revolute joint design allows a hemispheric working range.

View:

ROMAT® 320 and controller Rotrol II

Robot mechanics - robot axes The moving parts - called robot axes - are guided components driven independently from each other and executing controlled movements. Robots in revolute joint design are "similar to" or "modelled on" the human arm with hand and fingers. We often speak therefore of a "robot arm" when describing the robot mechanics. Each robot axis of the robot represents a degree of freedom for the movement of the body and the axes of a robot are therefore also called "degrees of freedom". Three axes or degrees of freedom are required to reach any point in a rectangular/spherical space. Three more degrees of freedom are needed for the different angle adjustments of a body on any point.

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ROMAT速 industrial robots have six degrees of freedom and consist of a combination of - three degrees of freedom for positioning

base axes (1 - 3)

- three degrees of freedom for angle orientation

manual axes (4 - 6).

and

Many of the robot systems are equipped with additional axes, - external axes

(axes 7 - 18)

which move the robot or the workpiece. The so-called external axes are the movement units of the peripheral equipment e.g. turn-tilt tables, manipulators, linear tracks, gantry-type systems etc. Their control is integrated in the movement run of the robot axes and they are freely programmable. External axes can be linear or rotatory. They can move the robot, thus enlarging its working range as well as the welding workpieces, thus improving the accessibility of the welding torch to the workpiece. The ROTROL速 controller can move and manage max. 18 freely programmable axes at the same time.

View: Base, manual and external axes

Axis 3

Axis 4 Axis 5 Axis 6 External axis 7 External axis 8

Axis 2

Axis 1

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Basic information

2.1 Working range and working area

2.1.1 Unrestricted working range The unrestricted working range is the zone where a workpiece can be handled by the tooling (welding torch, gripper) without restrictions.

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2.1.2 Restricted working range The restricted working range comprises the moving range of the robot axes and of the respective tooling (welding torch). The working range is reduced (restricted) depending on the torch position.

2.1.3 Maximum area acc. to EN775:1992 3.2.13 The maximum area is the range which is touched by the moving parts of the industrial robot incl. workpieces and tooling. The area should be clearly marked during commissioning or missing fence so that the operating and commissioning staff knows within which radius the robot works.

2.1.4 Restricted area acc. to EN775:1992 3.2.18 (not shown in the picture) This is the part of the maximum area which is restricted by limitation devices. These devices determine the limits which are not exceeded in case of an anticipated breakdown of the robot system. The largest distance the robot can move after actuation of the limitation devices forms the basis for the definition of the restricted area. (ISO/TR 8373:1988, 4.5.3)

2.1.5 Area limited by protective devices acc. to EN775:1992 3.2.23 The area defined by protective devices includes the restricted area.

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Safety regulations 3 Safety regulations CLOOS robots are designed according to the safety standard EN 775

Technical safety requirements for the construction, equipment and operation of industrial robots.

Industrial robots can create dangerous movements. It is essential that attention is paid to the relevant regulations for operation, the EMERGENCY-OFF units, limit switches or safety contacts may not be bypassed or deactivated. Maintenance, operation and programming of the robot systems should only be carried out by appropriately trained staff in order to avoid operating errors. Cloos offers training courses in our own training centre which are adapted to customers' requirements to enable them to learn quickly the different operation procedures. As well as complying with the applicable safety regulations, the following safety instructions must be strictly adhered to.

.1 Safety symbols

Danger

immediate danger which can lead to death, major injuries or big material damages.

Warning

possibly dangerous situation which may lead to death, major injuries or big material damages.

Attention possibly dangerous situation which may lead to minor injuries or material damages.

Warning note Danger of injury in case of manual movement of the robot mechanics

Information Application notes and ther useful information

Warning note Attention: hot surface

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3.2 Organising measures 3.2.1 Conformity When the system is completely installed and commissioned, the standards and regulations listed in the conformity declarations are met. The machine is provided with the sign:

Ĺ&#x2019; 3.2.2 Where to keep the operating manual

Always keep the operating manual to hand at the location of the system!

3.2.3 Supplements to the operating manual You have to add internal directions (e.g. in regard of supervision and status signals of company features such as work organisation and routine, staff etc.) to the operating manual. General, legal and other obligatory regulations regarding prevention of accidents and environmental protection are to be observed and instructed! This may also refer to the handling of hazardous products or disposal and wear of personal protective equipment.

3.2.4 How to keep the readibility All the safety and danger signals at and on the system must be kept complete and readable!

3.2.5 Personal protective equipment As far as it is necessary of required by regulations, personal protective equipments are to be used! The operators must not wear long and open hair, loose clothing or jewellery incl. rings. There is a danger of injury, e. g. getting stuck or drawing in. Wear protective gloves. There is a burning danger because of hot surfaces after welding.

Wear suitable safety glasses during welding when adjusting the cell. There is a danger of eye injuries due to the arc.

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Programming Manual ROTROLÂŽ II /2003

Block 1 - Standard

Basic information

Shut down the system immediately in case of changes o the system or system performance being relevant to safety. Inform the person in charge immediately!

3.2.7 No modifications You are not allowed to carry out modifications, extensions or retrofittings at the system which could influence the safety without the approval of the manufacturer! This also applies to the assembly and adjustment of safety devices and valves and for welding on the supporting structure. Do not change the system data!

3.2.8 Spare parts Spare parts must correspond to the technical requirements that have been determined by the manufacturer. Original spare parts always grant to meet these requirements.

3.2.9 Deadlines Deadlines for recurrent tests/inspections which are given or indicated in the operating manual are to be met!

3.2.10 Workshop equipment, tooling It is absolutely necessary to have an adequate workshop equipment for maintenance works. You must only use technically perfect and suitable tooling, in some cases only the prescribed tooling (e.g. to open the maintenance doors).

Programming Manual ROTROL速 II/2003

Page 13

3.2.6 Changes relevant to safety

Basic information

Block 1 - Standard

3.2.11 Fire hazard When using welding system there is always the danger that a fire breaks out. Take care that no combustible material is stored in the cell.

3.2.12 Fire extinguisher Suitable fire extinguisher should be mouplaced near the robot system. Inform the staff about their location and operation! Train the operators how to use the fire extinguisher in case of a fire or deflagration.

We recommend to put up an operating instruction showing the following paragraph: In the case of fire immediately establish a safe operating status by actuating the main switch, rescue injured persons, call the factory fire brigade (phone no.: ...... ) or actuate the fire alarm system.

3.2.13 Fire fight

The fire alarm and fire fighting possibilities are to be observed!

3.2.14 Use, disposal and recycling

When using oils, greases, cooling agents and other chemicals please ensure that they do not corrode the system lacquer. Messrs. Cloos do not accept any liability for system damages caused by the use of unsuitable substances! Observe the safety regulations of your country when dealing with oils, greases, cooling agents and other chemicals!

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Programming Manual ROTROL速 II /2003

Block 1 - Standard

Basic information

3.2.15 Personal selection and qualification 3.2.15.1 Requirements The machine must only be operated by trained or instructed personal. Pay attention that activities on the robot systems are only carried out by correspondingly qualified personal.

Only instructed personal must work on the system. Clearly determine the personal's responsibility for operation, set-up and maintenance. Personal which shall be trained must only work on the system under supervision of an experienced person. Ensure that only appointed personal works on the system! Observe the legally admissible minimum age!

Activities

Instructed persons

Transport Commisioning Operation Fault finding Set-up Trouble-shooting electrical Trouble-shooting mecanical Maintenance Repair

Persons with technical education

Persons with electrotechnical education

X X X X X X X X X

The personal that shall work on the system must have read the operating manual, especially block 1 "Safety instructions". Reading it during work is too late. This especially applies to personal that works only sometimes on the system, e.g. during adjustment or maintenance. 3.2.15.2 Personal training Please especially consider to inform the personal about the dangers and the security measurements during training. This information must be repeated in regular order (at least once per year). 3.2.15.3 Control of the personal Control from time to time that the activities on the system are carried out in consideration of the safety instructions of the operating manual!

Programming Manual ROTROL速 II/2003

Page 15

Basic information

Block 1 - Standard

3.2.15.4 Responsibility of the system operators Determine the responsibility of the system operator. Enable him/her/them to refuse instructions of third parties which do not respect the safety! 3.2.15.5 Duty to supervise Persons who shall be instructed, introduced, trained on the system or in general must only work on the system under constant supervision of an experienced person!

3.2.16.6 Works on electrical equipments Works on electrical equipments of the system or resources must only be carried out by electricians or by instructed persons headed and supervised by an electrician and in compliance with the electrotechnical rules. 3.2.15.7 Works on the system Only specialists are allowed to carry out works on the system. Specialists are qualified persons who 路 have special training, knowledge and experience, 路 have knowledges of the corresponding terms, standards, regulations and rules for the prevention of accidents, 路 are able to recognised and avoid possible dangers. 3.2.15.8 Safety instructions for certain operational phases Do not work in a way that may contain safety risks! Take measurements to ensure that the system is only operated in safe and functional condition! Only operate the system when all protection devices and safety-relevant equipments such as detachable protective devices, EMERGENCY-OFF systems, sound insulations are existing and operative. Inspect the system at least once per shift for recognisable damages and defects! Immediately inform the person in charge of changes (incl. change of operational behaviour)! If necessary, stop and secure the system immediately (e.g. by locking the main switch)! Immediately stop and secure the system in case of malfunctions! Have the malfunctions eliminated as soon as possible! Ensure that nobody can be endangered by the starting system before switching it on/starting! Do not open any protection device (flaps, doors, coverings) as long as the system is running. Only one person is allowed to work on the system. When there are abnormal noises, interrupt the work at once. It may be that the tooling or the workpiece is not correctly clamped or damaged. Continue working only when the error cause is eliminated.

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Programming Manual ROTROL庐 II /2003

Block 1 - Standard

Safety precautions in operational modes ADJUSTMENT T1 and T2 -

If possible, avoid entering the robot operation area when the arm power is "ON".

If you have to enter the operation area while the arm power is "ON": * * * *

Never step directly under the robot. Avoid the narrow spaces between robot and other equipment. Enge Räume zwischen Industrieroboter und anderen Einrichtungen meiden, Always be ready to operate the EMERGENCY OFF switch on the teach pendant (PHG). Achten Sie darauf, dass an heißen Teilen im Fertigungsbereich Verbrennungsgefahr besteht.

When initiating movement processes, ensure that there is no-one in the robot working area.

Continual observation of the robot is necessary to prevent possible collisions in the event of faulty operation.

Always check manually before rotating whether the workpiece is clamped.

Before switching on the drives ensure that the protection devices are on and that nobody stays inside the enclosure or the robot working area.

Wear suitable safety glasses during welding in the cell. There is a danger of injuring the eyes by the arc.

The set-up must only be made by persons who are familiar with this kind of system due to their training or experience. Only carry out the set-up after having read the operating manual carefully. Set-up requires special care! Only one person is allowed to stay within the protectively enclosed area.

3.2.15.10 Safety precautions in AUTOMATIC mode -

Before switching on the drives, ensure that the guarding emergency switches are working properly and that there is no-one inside the enclosure or in the robot working area.

Actuation of the safety guarding (e. g. light barriers, opening of maintenance doors etc.) must activate the safety devices and cause an EMERGENCY STOP of the whole robot system. Protection devices may not be switched off. Programming Manual ROTROL® II/2003 Page 17

3.2.15.9

Basic information

Block 1 - Standard

3.2.15.11 Safety precautions for maintenance and repair work The basic requirement for the satisfactory performance of the robot system is its proper handling by the operator. In order to ensure long lasting satisfactory performance, regular maintenance of the robot system is essential. The first service should be carried out after 1.000 operating hours and then every 5.000 operating hours (the maintenance interval only relates to the robot mechanics and the control cabinet only, not to the peripheral equipment). The service maintenance should be carried out by specially trained personnel using the "Maintenance Check List" and the maintenance kit. Regular and correct maintenance on robot systems is a pre-condition for warranty claims. It is also imperative that the maintenance intervals specified for CLOOS ROMAT welding robots are strictly adhered to, otherwise no warranty claims can be accepted. Excluded from the warranty are consumables such as teach pendant, screen, keyboard, welding wire guiding parts, welding torches, external cable connections, cable assemblies, oils and lubricants.

Carry out maintenance and repair work on the robot only when the drives are switched off.

The robot system must be protected from being switched on again by selection of the operational mode OFF and locking the operation mode selector switch (see operation mode selector switch in this block). - When releasing the mechanical connection between drive unit and robot axis, it must be ensured that the brakes which prevent the robot axes dropping, are contained in this unit.

By releasing the mechanical connection, the braking effect is made inoperative. If necessary, protect the robot axes from falling down by means of ropes, beams or other aids.

Only specialists are allowed to carry out these works. Inform the operators before starting maintenance. Name the supervisory persons! Switch on and off as described in the operating manual. Observe the information regarding repair works in case of: -

Retooling Set-up on the system and on protective equipments Inspection Maintenance Repair

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Programming Manual ROTROL速 II /2003

Basic information

Secure the maintenance area widely, if necessary! If the system is completely switched off during maintenance and repair, protect it from unexpected switching on: Lock the main command unit and take out the key. The person who carries out the maintenance or repair works should keep this key! If the main command unit cannot be locked, switch off the main switch and the EMERGENCY-OFF switch and put up a danger sign on both switches. Protect the main switch from switching on. Fix and secure single parts and bigger components carefully on the lifting tools in case of exchange so that there is no danger. Only use suitable and technically perfect lifting tools and load suspension devices with enough carrying power! Do not stay or work under suspended loads! Only experienced persons are to be appointed to mount loads and to direct crane drivers! The directing person must be in sight or in speaking contact of the crane driver. Remove oil or other care mediums from the system (especially from connections and screwings) before starting maintenance or repair! Do not use aggressive cleaning agents! Use fibre-free cloths! Check all screwings with regard to leakage, abrasion, damages and fixture! Eliminate found defects immediately. Always tighten the screw connections which were unscrewed during maintenance and repair works. When it is necessary to detach safety equipment during adjustment, maintenance and repair you have to reassemble and check the safety equipment immediately after having finished the maintenance and repair works. Take care of a safe and nonpolluting disposal of process materials and replaced parts!

Programming Manual ROTROL速 II/2003

Page 19

Block 1 - Standard

Basic information

Block 1 - Standard

3.3 Particular dangers 3.3.1 Electric energy Only use original fuses with prescribed amperage! Switch off the system immediately in case of malfunctions of the electric energy supply. Works on electrical equipments of the system or resources must only be carried out by electricians or by instructed persons headed and supervised by an electrician in compliance with the electrotechnical rules. Switch the system parts where inspection, maintenance and repair works must be carried out off-voltage. Check these parts by using a double-pole voltage tester, then earth and shortcircuit them and insulate neighbouring parts which are under voltage! For off-voltage switching, set the main switch to Â´0Â´ and secure with a padlock. The electrical equipment must be regularly inspected or checked. Defects such as loose connections or scorched cables must be eliminated at once. When it is necessary to work on parts under voltage, call a second person who actuates the main switch in case of emergeny. Block off the working area with a red-white safety chain and a danger sign. Only use insulated tooling. When working on high-tension components connect the supply cable to earth after disconnection of the voltage and short-circuit the components, e.g. capacitors, by using an earth rod!

3.3.2 Pneumatics Inspect all lines, hoses and screwings for leakages and recognisable damages! Immediately eliminate damages! Depressurise system sections and pressure pipes to be opened before starting the repair! Install and mount the compressed air lines professionally! Fittings, length and quality of the hoses have to meet the requirements of the respective regulations. 3.3.3 Gas, dust, steam, smoke Only weld, burn and grind at the system when it is expressly permitted. There is the dange of fire and explosion, for example! Clean the system and its ambiance from dust and combustible substances before starting to weld, burn and grind and take care of a sufficient ventilation (explosion hazard)! When working in narrow rooms consider national regulations which may exist!

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Programming Manual ROTROLÂŽ II /2003

Block 1 - Standard

Basic information

3.3.4 Additional mounting instructions

3.3.4.1

Professional lifting

Lift the system only in accordance with the instructions of the operating manual by using professional lifting devices.

3.3.4.2

Securing the load

Secure the load carefully. Use suitable mounting points.

3.3.4.3

Dismounted parts

Carefuly remount and fix the parts that have been dismounted for transport or assembly before re-operation!

3.3.4.4

Fall down of parts

Take precautions against the fall of toolings or parts to be mounted or dismounted during maintenance and inspection.

3.3.4.5

Danger of squeezing

Be aware of the danger of squeezing with every rotating part.

3.3.4.6

Remove the assembly tooling

Remove the assembly tooling and auxiliaries when the works are finished.

Programming Manual ROTROL速 II/2003

Page 21

Basic information

Block 1 - Standard

Safety and system devices 4 Safety and system devices on the controller The internal safety devices for the robot controller are located on the operating panel in the front door, the teach pendant (PHG) and the robot mechanics. The safety devices on the operating panel of the robot control include:

EMERENCY-STOP switch

Operating mode selection switch (OFF - T1 - T2 - AUTO)

Indicator lamp "READY FOR OPERATION"

Trigger switch "ARC ON/OFF"

Illuminated push button "POWER ON"

Illuminated push button "START"

Illuminated push button "POWER OFF" or "ERROR"

Push button "STOP" Customer specific options

4.1.1 EMERGENCY-STOP SWITCH

Actuation of the EMERGENCY STOP switch causes the drives and pheriphal equipments to stop immediately. However, the computer remains active. The EMERGENCY OFF situation is treated differently depending on the selected operational mode. If the EMERGENCY STOP interrupted a positioning procedure, the positioning can be stopped or continued by eliminating the cause, switching on the power and pressing the START switch. To abort, use the ESC switch in the operational mode ADJUSTMENT T1. In operation mode AUTO or ADJUSTMENT T2 it is necessary to switch to the operation mode OFF. The EMERGENCY OFF situations caused by overloading the drives (correcting variable error) are treated in the same way. When the Emergency-Off switch has been actuated the robot system must only be re-started by an authorised and trained operator who has to make sure in advance how the situation is and which movements he can release.

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Programming Manual ROTROL速 II /2003

Block 1 - Standard

Basic information

4.1.2 Operation Modes selector switch

The operation mode selector switch is located on the operating panel and can also be locked with a key. One of the four operation modes available OFF, ADJUSTMENT T1, ADJUSTMENT T2 and AUTOMATIC is selected using the operating mode selector switch. The programmer can take out the key in each operation mode to prevent change-over to another operation mode. If the operation mode is changed during a robot movement, the robot stops and the error message appears on the display and teach pendant

"Please switch back to the operation mode AUTOMATIC". The ROTROL速 multi processor controller has four basic operation modes. Positions of the operation mode selector switch: 1 2 3 4

OFF ADJUSTMENT T1 ADJUSTMENT T2 AUTOMATIC

Operation mode OFF -

Protects service and maintenance staff during maintenance work on robot mechanics The power supply of the robot drives is blocked No keyboard and teach pendant entries can be made

Operation mode ADJUSTMENT T1 -

This operation mode is only released for authorised personnel Complete working programs are created and tested; The weld parameter lists defined in the program can be adapted during operation. Travel speed is limited to 250 mm/s (safety speed acc. to EN 775). Robot drives are only switched on when a movement key has been activated The robot movement must be confirmed by pressing the deadman's switch on the teach pendant . Safety devices on the peripheral equipment are not active

Programming Manual ROTROL速 II/2003

Page 23

Basic information

Block 1 - Standard

Operation mode ADJUSTMENT T2 -

This operation mode is only released for authorised personnel Working programs are tested (robot movements are carried out with maximum speed) Robot drives are only switched on when the deadman's switch has been activated Weld parameter lists can be adapted No safety devices are active (Exception: EMERGENCY-OFF switch) Adjustment works should be done outside the protective area if possible

Operation mode AUTOMATIC Operation mode AUTO corresponds to the production mode of the robot. All safety devices are active. The robot program can only be changed via teach pendant if the operation mode is changed.

Before the deadman's switch is actuated the operator must choose a position from where the robot working range can be clearly seen and overlooked. This especially applies to the operation modes Adjustment T1 and Adjustment T2.

4.1.3 General error message display The red illuminated push button "Power OFF" or “Malfunction” indicates an EMERGENCY OFF situation in the system. Reasons can be:

Leistung AUS Störung

Pushing an EMERGENCY-STOP switch Opening the EMERGENCY-OFF circuit on the system Error message from a servo controller (delaying movement, collision) Error message from the computer

Computer errors cause the following reactions: -

Switching off the drives Actuation of the error lamp Appearance of an error message on the teach pendant display

The illuminated push button is extinguished after the cause of the EMERGENCY OFF has been eliminated and the power switched on or the error acknowledged with the key "ESC".

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Programming Manual ROTROL® II /2003

Block 1 - Standard

Basic information

The green push button “Ready for operation” is illuminated when the controller is ready to switch on the power. Reasons for the absence of this message may be: -

EMERGENCY-OFF circuit is not closed: o EMERGENCY-STOP switch in the system is not released. o Teach pendant is not connected. o Insufficient operating pressure in the pneumatic supply. o Torch shutdown of the welding torch is active. o Intermediate controller is still switched off. o AUTOMATIC operation is selected and the robot is not in parking position or the safety circuits of the peripheral equipments have been interrupted. No voltage supply

4.1.5 Power ON The key “Power ON” creates the "Readiness for operation" for the robot drives. The robot drives (power) are switched on depending on the operation mode selector switch.

General condition: The system is ready for operation. Operation mode Deadman's switch T1 T1 T2 AUTO

actuated actuated -

Travel switch

Drives on

actuated -

ON ON ON ON

Readiness for operation is indicated via a green lamp in the switch. The brakes are released when the drives are switched on. Now the axes are held in position by the servo motors.

4.1.6 Power OFF The key “Power OFF” switches off the drives. The axes can be moved manually when the power is off. In order to release the axis groups press the corresponding switch "Release brakes" on the robot (see chapter "Manual movement of the robot mechanics").

Programming Manual ROTROL® II/2003

Page 25

4.1.4 Ready for operation

Basic information

Block 1 - Standard

4.1.7 START The “START” switches start the program run. The movements, which have been interrupted by EMERGENCY-OFF, by pressing the STOP switch or by the command PAUSE will continue. When the controller has been started, the green lamp in the switch is illuminated. There are two START switches on the robot controller: -

START switch on the operating panel START switch on the teach pendant

active in AUTOMATIC operation active in ADJUSTMENT operation T1/T2

Each controller condition which requires the actuation of the START switch will send a short note to the operator. 4.1.8 STOP The “STOP” switch interrupts the program run. The arc is switched off. With path operation (GC) the controller immediately stops the robot. With point-to-point operation (GP) the axes are braked with the maximum admissible deceleration. The drives remain switched on. STOP is always active on the teach pendant or the operating panel regardless of the switch position of the operation mode selector switch.

4.2 Safety devices on the teach pendant: - EMERGENCY-STOP switch - STOP switch - Deadman's switch Movement of the robot during Adjustment mode is only possible if the deadman's switch has been activated. (Except if displacement keys are used in PROGmode or TEACH mode!) The deadman's switch has three positions: 1. Off- Position (drives Off) 2. Release position (drives ON) 3. Panic position (drives OFF)

The maximum travel speed in T1 Adjustment mode is 250 mm/sec.

Switching off the robot drives Robot drives are switched on by activating a displacement key. They are automatically switched off after ten seconds if no displacement push button is activated. Page 26

Programming Manual ROTROL® II /2003

Block 1 - Standard

Basic information

4.3 Safety devices on the robot mechanics:

Anti-collision sensor Collision protection for robot mechanics and torch

Workplace or shutdown monitoring The safety limit switches on the robot axes are installed according to the special requirements of a system and guarantee personal protection when crossing welding stations.

Example: Safety limit switch on axis 2

4.4 Safety devices on the peripheral equipment 4.4.1 General information There is always the danger of accident when works must be carried out in bad lighting. The illumination within a robot cell prescribed by GUV 17.9 must be at least 500 lux. Only in this case the operation modes Adjustment T1 and T2 are allowed. There is also a danger of accident when entering a robot cell. Mark the edges of the mounting plate and the cable channels in yellow/black to avoid stumbling. Regularly clean the interior of the robot cell because of slip risk.

The warning "Attention! Robot movements" should be at the outside of the robot system.

Programming Manual ROTROL速 II/2003

Page 27

Basic information

Block 1 - Standard

4.4.2 Equipments The peripheral safety devices on a system consist of various measures to protect operators, programmers and service staff. This includes: Fig.1 -

Adequately high safety guarding probably provided with light protection panels. There is a burning risk of skin and eyes by the UV radiation during welding.

Maintenance doors "EMERGENCY OFF" is activated if a maintenance door is opened during operation mode Automatic. The maintenance door must be built according to the standards EN 775 and EN 953. It disposes of an electrical locking device ensuring that the robot stops when the door is opened. It must not be locked and it always has to be opened from inside.

Safety doors -

Page 28

Safety doors Protection when entering a welding station. Start preselection is cancelled when the safety door is opened.

Programming Manual ROTROL速 II /2003

Block 1 - Standard

Basic information

- Swing doors "EMERGENCY OFF" is activated if a swing door is opened during operation mode Automatic. - Light barriers (3 beams) Light barriers are activated by pressing the start preselectors. The start preselection becomes invalid in all operation modes when the welding station is entered. EMERGENCY OFF is released in the operation mode Automatic and by a rotation of the manipulator.

Start preselector

A welding station with the relevant working program is preselected for treatment. The selection becomes invalid when the welding station is entered.

Programming Manual ROTROL速 II/2003

Page 29

Swing doors and light barriers

Basic information

Block 1 - Standard

Switching on/off of the robot system 5

Switching on of the robot system

Procedure to switch on the installation: -

Switch on the main switch on the peripheral cabinet (if existing)

Switch on the main switch (at the side of the controller). Switching on the main switch only activates the computer. The selftest of the controller is started. The drives are not switched on. The robot axes are held in position by the brakes.

Check the readiness for operation of the system. The illuminated lamp - Ready for operation - should indicate the general readiness for operation of the system. If this is not the case, you have to check whether an EMERGENCY-OFF situation is to be expected. To activate the readiness for operation see chapter "EMERGENCY-OFF" and "Ready for operation".

Make sure that nobody is in the danger area of the robot system.

Switch on the robot drives (Switch "POWER ON").

Select the requested operation mode. In mode AUTOMATIC the preselected program is started by pushing the START switch.

Pay attention to the corresponding safety instructions. Starting moving equipments may cause injuries!

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Programming Manual ROTROL速 II /2003

Block 1 - Standard

Basic information

5.1 Switching off the robot system To switch off the system, pay attention to the following: -

Stop a running program by pushing the STOP switch and abort it as per operation mode. Please note that it can be necessary to go to the initial position when restarting a complex system. Therefore you should approach it in the corresponding working mode before switching off the system.

Quit the selected working mode (TEACH, EDITOR).

Switch off the power.

Ensure that there is no disk in the drive!

Switch off the main switch on the controller.

The system can be protected against "unauthorized use" by switching the operation mode selector switch to the position "OFF" and locking the key.

Programming Manual ROTROL速 II/2003

Page 31

Basic information

Block 1 - Standard

Manual movement of the robot mechanics 6

Manual movement of the robot mechanics

Normally the robot is moved by activating the displacement keys on the teach pendant. After programming the robot controller takes over the movements and position changes of the robot. It may be that the robot position has to be changed manually, i. e. by moving the different robot axes "by hand". This may occur in certain EMERGENCY-OFF situations for example, where the practical application of the program run can no longer be continued. By pushing the correspondingly marked keys "Release brakes" when the power is switched off there is no brake effect on the robot axis groups or the corresponding external axis. Release the key and the axis is immediately braked. The robot keys "Release brakes" are placed at the angle foot (axis 1).

Brake keys of the axis groups axes 1, 2 and the axes 3 - 6

Procedure when robot is switched off: -

Turn main switch to the position "ON". Move the robot axes manually after pushing the switches "Release brakes".

Procedure when robot is switched on: -

Switch off the power (Switch OFF Power). Move the robot axes manually after pushing the switches "Release brakes". Switch on the power (Switch ON Power).

When releasing the robot brakes by means of the switches "Release brakes", the robot arm may fall down depending on its position (especially axes 2, 3, 5 and possibly the external axes). Before actuating the keys you have to absolutely make sure that nobody can be injured by the axes. If necessary, the axis must be secured with ropes or wooden beams. When the Emergency-Off switch has been actuated the robot system must only be re-started by an authorised and trained operator who has to make sure in advance how the situation is and which movements he can release.

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Programming Manual ROTROL速 II /2003

The Teach Pendant

Block 2 - Standard

Index

The Teach Pendant

1 Teach pendant = PHG .................................................................................................. 2 1.1 Teach pendant keys ........................................................................................... 2 1.2 Touchscreen ...................................................................................................... 3 1.3 Program set up ................................................................................................... 6 1.4 Archiving and managing of programs ................................................................ 7 1.5 Testing of programs ........................................................................................... 8 1.6 Automatic mode ................................................................................................. 8 1.7 Help functions .................................................................................................... 9 1.8 Terminal simulation ............................................................................................ 9 1.9 Printing of programs ......................................................................................... 10 2 System set up............................................................................................................. 10 2.1 Digital in/outputs ............................................................................................... 11 2.2 System information .......................................................................................... 12 2.3 Error messages ................................................................................................ 13 2.4 The service menu............................................................................................. 14 2.5 Offline programming ........................................................................................ 15 2.6 The HOME-Position .......................................................................................... 16

Programming Instructions ROTROL速 II V7.0X/S/12.03

Page 1

The Teach Pendant

Block 2 - Standard

The teach pendant 1 Teach pendant = PHG EMERGENCY STOP BUTTON

PHG- Display (TOUCHSCREEN)

Displacement keys

1.1

Teach pendant keys

Creating or editing programs can be accomplished by the combined use of the touch screen and teach pendant keyboards. A detailed description about the function of the teach pendant and its keys, except for functions previously described, can be found in Block 3, chapter "Mode TEACH".

In the T1/T2 setup mode, a program can be activated by pushing the "START" button and deactivated by switching to the "AUTOMATIC" mode. Please follow all SAFETY INSTRUCTIONS! The program will be halted when the "STOP" button is pushed. For safety reasons, this button is active in all operating modesv. Once the reason for an Emergency Stop situation has been determined and resolved, the robot drives can be reactivated by pushing the "POWER" button. Page 2

Programming Instructions ROTROL速 II

The Teach Pendant

START key

Memory key

STOP key

Abort key

Power on

Transfer key

RC operation

Block 2 - Standard

Speed preselection

CC operation

Cursor left

Change-over axes EXTERNAL / INTERNAL

Cursor right "Minus" key

Moving to points Seletion of point number Call of a welding parameter list

"Plus" key Factor x 10

1.2 Touchscreen There are several symbols shown on the PHG-Display after the control cabinet power up. This symbol area (Picture 1.4) is called Main Menu. By touching the displays elevated buttons, additional windows (menus) with additional symbols will open and appear. Each symbol or button indicates an action, function, or robot control command. The creation of programs is menu based and therefore minimizes erroneous inputs.

Picture 1: First page of Main Menu Available Buttons Scroll to the next page Programming mode Program managing Test mode Off / Please switch Power on !

Preselection for automatic operation

Programming Instructions ROTROL速 II V7.0X/S/12.03

Page 3

The Teach Pendant

Block 2 - Standard

Picture 2: Second Page of Main Menu Available Buttons Scroll to the previous page Scroll to the next page Selection of the editor Printer Input of TCP/TOV values

Off / Please switch Power on !

Selection of the input/output menu

Picture 3 : Third Page of Main Menu Available Buttons Scroll to the previous page Display of system information Display of error messages Selection of the service menu Commands for offline programming

Off / Please switch Power on !

Picture 4 : Fourth Page of Main Menu Available Buttons Scroll to the previous page Moving to the "HOME" position Compile all programs

Page 4

Programming Instructions ROTROL速 II

Block 2 - Standard

Function

Block

Programming mode Program set up in the TEACH / PROG mode

3,5

Program management Program saving, deleting, displaying and more

Program executions Testing of complete programs in the EXE / EST mode

Program pre-selection for automatic and user cycle

Calling up and using the Editor Text inputs and text editing in executed programs

Printing of programs

TCP / TOV value inputs System setup

3/9

Digital In/Outputs Activation and deactivation of digital outputs

2/9

Displaying System information

Displaying of error messages

The service menu Choosing a language, referencing the robot, configuration and more

Offline programming Transforming, copying, mirror, moving of programs External axes manual drives Parallel task (Option â&#x20AC;&#x201C; specific documentation) Moving to the HOME- position Zeroing the robot

2 -Option- 4 -Option- 1

Compile all programs Programming Instructions ROTROLÂŽ II V7.0X/S/12.03

Page 5

Button

The Teach Pendant

Block 2 - Standard

1.3 Editing of Programs The Button "Programming mode" will open a window in which one has the option to choose between the "TEACH" and "PROG" mode. It is possible to choose, create, or edit a new or existing program of which the name itself cannot be longer then eight digits.

TEACH: The "TEACH" mode allows the user to operate the robot from within a chosen program and gives him the opportunit to save any robot position as points in the program. In addition existing points can thus be approached, reprogrammed, and stored as new points.

PROG: The "PROG" mode combines storing of the robot positions ("TEACH" mode) and program text editing within the Editor. The picture shows what will appear when one of the twomodes has been chosen. On this screen, all aailable programs for a maximum of 32 programs are This button accepts a selection depicted. - this button dismisses a selection. The creation of new programs takes place via the touch screen keboard, which will appear after the "NEW" button has been pushed.

MASTER

MENUE

KOERNER AUTOEXEC TEST

A0045

PRG1 SD B0046

PRG2

PRG3

SDSTOP NAHTSUCH AB00

AB01

Keyboard key simulation:

Text description field "Backspace"- eraseing characters befor cursor position

shift Cursorposition right or left

After you have entered a new program name, you have to accept your selection with . This is followed by a new window, which will depict the "TEACH" and "PROG" modes. (see Block 3 chapter "TEACH" and Block 4 chapter "PROG")

Page 6

Programming Instructions ROTROL速 II

Block 2 - Standard

The Teach Pendant

The archive system allows the user to store CAROLA programs to the hard drive or onto floppy diskettes (3.5") and execute them from there. In addition to data transfer functions, one has also the opportunity to manage disk directories and copy, rename or delete user program files. File types and program segments are also accessible from here. All user programs are stored in a buffered user memory and thus save from power failure and an inadvertent robot controller power loss. User programs which need to be stored for longer periods of time should be saved to floppy disks.

For safeguarding of programs we recommend the: -

Propfer handling of diskettes. Proper handling and no manipulation while disk drive is operating (Drive LED is lit). Proper storage of diskettes. Creating user program diskettes for daily use. Creating backup copies which are stored in safe locations. Additional copies of valuable programs as single program on specific diskettes.

The following picture shows available options.

Copy Directory

Delete Rename

Function Directory Copy

Select source drive

Select target drive Save all programs as working set (Save All)

Store Load

Rename

Delete

Load

Save

source

target

Set Default

Load all programs from working set (Load All)

Format diskettes

Select standard drive

Programming Instructions ROTROL速 II V7.0X/S/12.03

Page 7

1.4 Archiving and Managing of User Programs

The Teach Pendant

Block 2 - Standard

1.5 Testing programs It is advisable to test a newly created program in the T1 setting before switching to the AUTOMATIC mode. The reduced speed in the TEST mode will give the operator enough time to react to possible crash situations. In addition, it makes it easier to follow and understand the program flow as well as provide the opportunity to adjust weld parameters. After activating the function buttons, the following options are selectable: -

EXE EST

Executing programs Step by step execution of programs (does not apply in the T2 mode)

You can choose the program in the window, which will open at this point. The basic difference between the EST- and EXE-mode is the fact that every program step needs to be acknowledged by pushing a button before it can be executed.

1.6 Automatic Mode Once this mode has been selected, the controller will ask for the program name, which has to be pre-selected for the automatic mode. After selection of key „F5“ in the main menu, the desired automatic program can also Selected via „Arrow keys“. For safety reasons and to make sure that no programming errors have been made, one should always test the program in the "setup " mode first. Please refer to the safety instructions in Block 1. After you have made your choise by pushing you can turn the “mode selector switch” to the 4th position (AUTO). This will start the pre-selected program in AUTOMATIC mode. The pre-selection of a program is only valid until o o

the pre-selected program has been deleted a different program was pre-selected

Therefore, you do not have to pre-select a program again before executing it in the AUTOMATIC Mode.

Page 8

Programming Instructions ROTROL® II

Block 2 - Standard

The Teach Pendant

A Help function is available in the text editor. Within it functions and syntaxes are explained. (see also chapter 4 „Hilfefunktionen im Texteditor“).

1.8 Terminal simulation The Terminal simulation allows the user to quickly enter text and commands into programs. The following choices are available after pushing the function button:

TEXT: PUNKTS:

Text editor Point editor MASTER

MENUE

KOERNER AUTOEXEC TEST

A0045

PRG1 SD B0046

PRG2

PRG3

SDSTOP NAHTSUCH AB00

AB01

Once the next window has opened, one can chose between Programm or Key simulation

After you have made your choice, the PHG (teach pendant) will function as moitor only ! You will have to use the "standard" keypad in order to enter other commands.

Programming Instructions ROTROL® II V7.0X/S/12.03

Page 9

1.7 Help functions

The Teach Pendant

Block 2 - Standard

1.9 Printing of Programs

For easy reference purposes, it is a good idea to print out the user programs. The printer has to be plugged into the printer port on the Rotrol cabinet. Cloos is using the EPSON LX-300 as defaut printer. Thus, the Program text can be printed out.

The point positions and point information can be printed out.

Note: The used printer interface - serial (RS232) or parallel (LPT1) - is preset in the service menu. Standard setting is the parallel interface. In case of the serial interface indicate the side length in „Inch“. The IP-address is the identification key for networks.

IP#

Printer

LPT1

RS232

page/lenght

System configuration The Robot drive system needs to know where the tip of the welding wire is at any given time in order to execute exact axes movements. This wire tip center position is alsoknown as the "Tool Center Point". In addition to the TCP, the TOV (Tool Orientation Vector) is very important. This is the direction the wire tip is pointing at.

After pushing the button, a Table appears: 0 1 2 3 4 5

2 0 0 0 0 0

5 0 0 0 0 0

-4950 0 0 0 0 0

-1

Page 10

TCP TOV

Tool Center Position Tool Orientation Vector

(see block 3 - Standard - Chapter „Tool Center Point - Tool Orientation Vector“ and Block 9 -Standard - Chapter „Changing the TCP and TOV during program run.)

Programming Instructions ROTROL® II

Block 2 - Standard

The Teach Pendant

Digital In-/Outputs are used to control peripheral components. The user has 64 in- and outputs available to him.

ATTENTION!! While triggering In- and Outputs manually, dangerous situations could develop. Axes might move and parts could fall. Danger Digital outputs setting and re-setting Digital input indications

OUT IN

Select the digit number area with the arrow keys. 1 65 193 209

- 64 - 80 - 208 - 216

Available I/O's for the user Optional for MANAX/QUINTO digital Internal system I/O's Internal I/O's for GLC command signals

The activation and deactivation of an output can be performed directly by pushing the assigned output button or by pushing the SET/RESET button. The selected choise can be entered through the numerical keypad. The activation of multiple outputs will have to be entered with commas in-between. A yellow signal will indicate an activated output as well as an active input signal.

The input/output layout for the control of the peripheral equipments (e.g. torch cleaning, torch changing system) is listed in the respective circuit diagram of the peripheral equipment.

Programming Instructions ROTROL速 II V7.0X/S/12.03

Page 11

2.1 Digital In-/Outputs

The Teach Pendant

Block 2 - Standard

2.2 System Information When pushing the "Info" button the screen will indicate the current robot system status. 1. Display window

custoumer name

Configuration date

Control number

Robottype

Program run time weld time aktiv paralell task srcoll

storing Systeminformationen

abortion

2. Display window (Axes information) This display window shows the current status of all robot axes. - Axis number - Resolver resolution - Amplification factor - Pulse per degree or 1/10 of mm - Rotations per minute - Negative end limit positions - Positive end limit positions - Reference position - Current position - Status

16384

0.199951

18507.851563

2510 1047

16384

0.199951

18640.050781

2220 2237

3 4

16384 16384

0.199951 0.100098

-14409.685547 13182.433594

2180 851 3620 1834

16384

0.100098

8067.878906

2220 3105

16384

0.100098

9310.746094

3410 1401

3. Display window (Version tabe)

4. Display window (Bus-Data/Information)

Page 12

Programming Instructions ROTROL速 II

Block 2 - Standard

The Teach Pendant

2.3 Error Messages

The Function "ERRORS" will show a list of the last 128 error messages, including date, time of day, program name and line number.

This will help to localize system faults and faulty equipment.

30/08/02 24/08/02 24/08/02

07:47:30 13:05:45 11:21:15

TEST

Arrow keys will enable you to scroll though lines up and down.

xxx GLC- Stoerung: GAS xxx! POWER ON / SYSTEM RESET F1504: Werkstueck- Bezugs.-Koord.-System nicht defin

Leaving the Error list.

Save this Errorlist to disk Print out this Errorlist Scroll bar: The picture will move by pulling the horizontal scroll bar to the right and therefore will enable the operator to see the remainder of the error message.

Errors are shown in numerical order and are sorted by occurrence or the time of day. Once the maximum amount of error messaes has been reached, the oldest will be replaced with the most current one.

Programming Instructions ROTROL速 II V7.0X/S/12.03

Page 13

The Teach Pendant

Block 2 - Standard

2.4 The Service menu

The Service menu allows for the set up and inspection of system specific data. For example, one can change the language, time of day and robot reference positions.

Attention

Incorrect changes within the service menu can lead to damage of the robot system and should therefore only be performed by properly trained personnel or service technicians.

Setting of brightness, contrast and sensitivity of touch sreen

Function test of the key pad

actual date and time

Change password

Configuration of the printer and LAN interfaces

Load, memorise of configuration files, selection of the language Setting of the drive regulators Systeminformation

First Aid Delete C-Mos memory

Execute REX - Files Update operating system

Detect, load and memorise machine data Teach pendant update

The proper use of the service menu and its options and possibilities is being explained in the maintenance manual. In addition, CLOOS offers training for it.

Page 14

Programming Instructions ROTROL速 II

Block 2 - Standard

The Teach Pendant

Contrary to the online programming where functions and commands are only processed during the program run, the functions and commands of the offline programming are executed directly after input.

Transformation

Info

External axis

Errors

Extras

Service

The OFFLINE - Programming is used for the manipulation of point informations, synchronisation and movement of external axes, starting and ending of background programs as well as the indication of used variables in the program runs.

Offline

- Transformationen The transformation allows for the handling of point informations. (see options - block „Point Transformation“)

- External axes MPE..: Manipulation on point informations in case of eexternal axes Manax: (manual movement of external axes) External axes can be activated by means of external control consoles. Chsyn: (change Synchronisation) Activation and deactivation of external axes synchronisation (electrical wave - timely synchronised external axes -). (see options - block „External axes“)

Programming Instructions ROTROL® II V7.0X/S/12.03

Page 15

2.5 Offline programming

The Teach Pendant

Block 2 - Standard

- Extras VAR: List of all defined variables of current user program. VAR + Partask: List of all used variables in parallel tasks. VAR + Static:

List of all static variables.

VAR + Prog:

List of all defined variables in called up user program.

- Start and end of background programs BKJOB: Starting a user program in the background (Parallel task). Ending an active parallel task

KILL:

(see special documentation „Paralell task“)

2.6 The HOME-Position

This function allows the operator to have the robot reach its zero position very quickly. The individual markings on the robot axes indicate this position as well.

From software version V7.00.31 a freely selectable axis position (e.g. the loading position of external axes for tool equipment) can be determined which is valid as robot zero position after executing the command FUNCON_HOMEPOS,1 programmed point in Carola program

and which can be approached by pushing the button „HOME“. This robot zero position remains valid until deactivation of the control or until processing the command FUNCOFF_HOMEPOS. After deactivation of the function the original home position is valid again. Point informations of existing user programs are not influenced and will be correctly approached.

Page 16

Programming Instructions ROTROL® II

Block 2 - Standard

The Teach Pendant

Example:

MAIN WPSPAR (1;1;0,3,4) FUNCON HOMEPOS,1 END Point number „1“ is determined as home position. The programmed home position is active until deactivation of control or processing the command FUNCOFF_HOMEPOS.

Once the release button is pushed, all axes will move simultaneously towards the zero position. You can stop the movement by releasing the button and reactivating it by pushing the ESC button. Increased danger of collision!

Programming Instructions ROTROL® II V7.0X/S/12.03

Page 17

Block 3 - Standard

TEACH

Index

The mode TEACH

1 Adjustment and check of the welding torch ............................................................. 2 1.1 Alignment of the welding torch ........................................................................... 3 2 Mode TEACH ................................................................................................................ 4 2.1 Keys and touch screen ...................................................................................... 5 2.2 Move the robot mechanics ................................................................................. 6 2.3 Change the robot speeds................................................................................... 7 2.4 Storage of points ................................................................................................ 8 2.5 Point information during storage ........................................................................ 9 2.6 Approach of memorised points ........................................................................ 11 2.7 Additional functions .......................................................................................... 11 3 Coordinate systems .................................................................................................. 12 3.1 Robot coordinate system ................................................................................. 12 3.2 Base coordinate system ................................................................................... 13 3.3 Hand coordinate system .................................................................................. 14 3.4 Workpiece coordinate system.......................................................................... 15 4 Tool Center Point (TCP) ............................................................................................ 17 4.1 Determination of the TCP value....................................................................... 17 4.2 Input of the determined TCP values ................................................................ 18 4.3 External TCP .................................................................................................... 19 5 Tool Orientation Vector (TOV) ................................................................................. 21 5.1 Input of the TOV ............................................................................................... 22

Programming Manual ROTROL速 II

V7.0X/S/12.03

Page 1

TEACH

Block 3 - Standard

Adjustment and check of the welding torch 1 Adjustment and check of the welding torch

The welding torch being a "tool" of the industrial robot has a fixed geometry. The points at the workpiece are approached and programmed with this torch, which is attached to the industrial robot. If the welding torch is deformed, e.g. due to a collision, the user must align the deformed torch using a torch setting jig to avoid a misalignment on the wire tip.

In the following cases the welding torch must be checked and aligned again, if necessary: -

after collision with a workpiece before editing a new program during maintenance work when changing the workpiece

The repeatability of the program points and, thereby, the quality of the weld seams depend on the fact that the welding torch keeps its preset geometry.

Page 2

Programming Manual ROTROL速 II

Block 3 - Standard

TEACH

Remove welding torch from the robot (orange union nut)

Remove gas nozzle and install a new current tip

Install the welding torch into the alignment gauge

Check the welding torch geometry

1.1 Alignment of the welding torch

Push the "control coneâ&#x20AC;&#x153; which is enclosed to the setting jig over the current tip. If this is not possible because the "control cone" touches the current tip, the welding torch must be bent manually until the "control cone" can be pushed over the current tip without any notable resistance. The front end of the control cone has to touch the nozzle base of the welding torch.

Mount welding torch to the robot flange

Approach reference point, check position of robot and welding torch

Programming Manual ROTROLÂŽ II

V7.0X/S/12.03

Page 3

TEACH

Block 3 - Standard

The mode TEACH 2 Mode TEACH In the mode TEACH it is possible o o

to move the robot mechanics, to program and change points.

The robot axis positions are stored as points. They contain the information how fast and with which kind of travel these positions are to be approached. The points determine the contour of a component as well as coordinate systems and workpiece positions. Up to max. 9999 points can be defined per program. The limit is determined by the storage capacity of the controller. After selection of the Teach mode the touch screen shows the following information and selection possibilities:

Display field of the axis position values

Selection of the travel kind and coordinate systems

Display field for point and teach speed

Display field for weld parameter list Point number Internal/external switch

Page 4

Buttons to - approach points - select the point number - select a weld parameter list - switch on and check digital inputs/outputs - change the point state

Programming Manual ROTROL速 II

Block 3 - Standard

TEACH

2.1 Keys and touch screen As already mentioned in block 2 chapter "Teach pendant keys", further keys and their functions shall be described in the mode TEACH. Some of these functions can also be selected on the touch screen, therefore, please find below a comparison ("Touch screen" - "Teach pendant keys") of keys and buttons. Teach pendant keys

Touch screen: Mode Teach

Selection of the cartesian coordinate system (base coordinate)

Selection of the incremental coordinate system (robot coordinate)

Change-over axes (Internal / External)

Activate synchronous movement of external axes

Moving to points

Selection of point numbers

Call of a weld parameter list

Transfer key

Programming Manual ROTROL速 II

V7.0X/S/12.03

Page 5

TEACH

Block 3 - Standard

2.2 Move the robot mechanics There are the following kinds of travel Travel in robot coordinates (RC operation) The corresponding axes are moved by pushing the respective displacement keys (1-6) in the RC operation. Moving an axis causes circular movements of the axis due to the robot construction (rotary joint robot). Key 1+ Key 1-

= =

positive rotary direction of axis 1 negative rotary direction of axis 1

Travel in cartesian coordinates (CC operation)

In CC operation (cartesian coordinates) the definition X, Y, Z, alpha, beta, gamma is allocated to the key pairs 1 to 6 on the PHG, i.e. all robot movements are carried out in cartesian coordinates (X, Y, Z) and angular settings (alpha, beta, gamma), in relation to the wire tip of the welding torch. By pressing the keys X, Y, Z the robot tip is moved in straight line. By pressing the keys alpha, beta, gamma, the angular setting of the welding torch varies. However, the position of the wire tip does not change.

RC operation

Page 6

CC operation

Programming Manual ROTROL速 II

Block 3 - Standard

TEACH

Up to 18 axes can be moved by means of the teach pendant. The selection is effected via the key EXT / INTon the teach pendant “INT” = internal for axes 1 - 6 “EXT” = external (pushed 1x) for axes 7 - 12. „EXT“ = external (pushed 2x) for axes 13-18 Axis 1 - first external axis Axis 2 - second external axis etc. is allocated to the displacement and number keys after change-over. 2.3 Change of the robot speeds The robot speeds are 1.

the Point speed Depending on the operating mode, points are approached with the stored point speed (to be selected between 1-100%, preset to 100%).

the Teach speed Actually set travel speed for point teaching (to be selected between 1-100%, preset to 10%).

The change of the operation speed (OVerride) can be effected: a.

by means of the key pair "+ / -" or simultaneous pressing of the key "x10" and "+ / -";

by actuating the key for preselection of the speed. The key for preselection of the speed gives three standard speeds: -

10 %

low speed (green LED)

50 %

medium speed (yellow LED)

100 %

high speed (red LED).

The selected speed is indicated on the display of the teach pendant (PHG), as well as by means of three LED’s in the colours green, yellow and red. The speed with which a point is stored can be modified in this way. The standard speed is 100%. The selected speed (point or TEACH-overide) is marked with an arrow on the display of the teach pendant (PHG). By pressing the keys "<" and ">" you can change between the two speeds. Programming Manual ROTROL® II

V7.0X/S/12.03

Page 7

Travel of external axes EXT / INT

TEACH

Block 3 - Standard

2.4 Storage of points The point describes a position (axis position) of the robot mechanics in the space. The contour of the workpiece is described with the aid of points.The robot is moved to the corresponding positions using the key pairs on the teach pendant (PHG). These positions are stored as a point - as described below.

A point number can be freely defined by pressing the "P" key and the displacement keys or the numerical keypad. The point number range is between 1 and 9999. With the "ENT" or the key the entered point number is confirmed. The chosen point number is displayed as actual point.

In principle all points are input in the TEACH or PROG operation mode. This is done by simultaneously pressing the keys "MEM" and "P" on the teach pendant (PHG). It must be noted that always the point is stored which is indicated on the display below the "actual point number". The actual point number is increased by "1" automatically. The information "*" behind the point number indicates that a "new" point or a "new" position is concerned. If this information does not appear, this point number is already occupied. There is a danger of overwriting, i.e. a position which is needed in the program run might be deleted! actual point number

A new position or information can be assigned to an already programmed point when storing again. The old position / information will be deleted. There is a danger of overwriting a position which is still needed in the program run!

Page 8

Programming Manual ROTROL速 II

Block 3 - Standard

TEACH

2.5 Point information during storage If a point is stored via the teach pendant, further information, except for the position, is assigned to this point.

internal outputs: Output numbers from left to right 209,210,211,212

Point speed

Point To Point (PTP) and Path Control (CP) Internal outputs: The digital outputs are occupied as follows: Output Output Output Output

209 210 211 212

= = = =

Welding on Impulses in (for impulse power sources) Gas preflow Blowout torch

If a digital output has to be used at this point, it must be switched on before storing the point (Attention!! The status of a weld parameter list is of higher ranking). E.g. the point, from which the torch should be blown out, is stored using output 212 (blow out torch). The blow out remains active up to the next point which is stored without output 212 .

Point speed: (Range 0 - 100%) There is no need to pay further attention to the speed in the middle of the seam or at its end as it will be overwritten by the welding parameter list. Normally, all spatial and seam points are stored with 100 % speed.

Programming Manual ROTROL速 II

V7.0X/S/12.03

Page 9

TEACH

Block 3 - Standard

Point To Point and Path control Depending on the selection of the button PTP or CP a point is stored in: 1.

PTP control

(PTP = Point to point)

The aim of the PTP control is to carry out the movement between start and end point as quickly as possible. Each robot axis has its technically limited maximum values for acceleration and angular velocity. Under these secondary conditions the computer calculates the min. displacement time for the movements and controls all necessary axes to start and end at the same time with their movement. Due to the revolute joint construction a bent path form naturally results with regard to the central workpiece point (TCP).

Path control

(CP = Continuous path = CP control)

The robot controller links the different axis movements so that the effector can be moved on straight or circular pathes. When reaching a target point in the cartesian coordinates (see chapter "coordinate systems") the workpiece center is to be moved on a straight line from the start to the end point. The control of the spatial angles alpha, beta and gamma also forms part of the CP movement. If the spatial angles need to be modified when reaching a spatial point, this is done in linear interpolation simultaneously to the movement of the workpiece center on the straight line. The angular velocities are selected in such a way that the path movement and the angle modification start and end at the same time. If the spatial angles are identical with regard to start and target point of the movement, they will remain identical over the complete distance. Because of the robot design and the turning range limits, a programmed CP point cannot be reached in a straight line from all positions of the fixture. During movement the computer checks whether the working range is left or a turning range limit is crossed. In this case the movement is stopped.

It is not necessary to allocate the information "Welding on", "Impulse on" or "PTP/CP" to each point. The controller obtains this information later or recognises it automatically.

Page 10

Programming Manual ROTROL速 II

Block 3 - Standard

TEACH

2.6 Approach of memorised points

1. 2.

Press the "G" key (G = go to point) or the "Go" button. Input the point number with the displacement and number keys or using the numerical keyboard which appears on the touch screen or the keys "+" or "-" for the following or previous point. The selected point number appears on the display.

In the case of of an incorrect input, the number can be deleted by pressing the button

and can be re-entered.

The points can be approached in straight or circular movement irrespective of the kind of travel in which they were stored (PTP/ CP).

Point is approached in PTP movement.

Point is approached in CP movement.

When following the weld seam in circular movements (GP), there is the danger to collide with the component. In this case please select the straight movement (GC).

2.7 Additional functions

Actuate a weld parameter list

Switch of digital outputs - status indication of digital inputs (see block 9 - chapter "Digital inputs/outputs")

Programming Manual ROTROL速 II

V7.0X/S/12.03

Page 11

The approach of a point is as follows:

TEACH

Block 3 - Standard

Coordinate systems 3 Coordinate systems The robot controller disposes of another three coordinate systems to ease the programmation, e.g. the programmation of points on workpieces which are not aligned parallely to the base coordinate system. Each coordinate system has an identification number thus being available for commands (e.g. GETPOS / STORPOS) and functions (point editor) for Offline programming. The base coordinate system is actuated as standard. It is also switched on automatically after an EMERGENCY-OFF situation. The selected coordinate system remains active until another one will be selected or the mode TEACH or PROG will be quit. The coordinate systems:

Coordinate system

Identification number

Robot coordinate

Base coordinate

Hand coordinate

Workpiece coordinate

External / synchronous externa

4 / 5 (see block 1 - Options chapter „external axes“)

3.1 Robot coordinate system The axes 1 - 6 are moved independently from each other.

Page 12

Programming Manual ROTROL® II

Block 3 - Standard

TEACH

3.2 Base coordinate system

The origin for the base coordinate system of all robot systems in the ROMAT速 series lies in the robot foot. In case of upright robot design the direction of axis 2 defines the positive "Z" direction and axis 3 defines the positive "X" direction. This is only valid in case of reference positon (marking of the axes). The positive "Y" direction results from the "X" and "Z" directions. Diagram:

Base coordinate system

During CC operation the robot moves the torch tip parallel to the cartesian coordinates X, Y, Z. This movement is carried out using the X, Y, Z keys of the teach pendant (PHG). This results in straight travel movements. During this movement the robot controls all axes simultaneously, so that the position of the torch tip is kept on a straight line at all times.

Programming Manual ROTROL速 II

V7.0X/S/12.03

Page 13

The three basic directions of the base coordinate system X, Y, Z are turned 90O to each other. Since the current tip (effector) moves parallel to this coordinate system, any position can be reached. With the aid of the angle orientation in the hand axes (alpha, beta, gamma) it is also possible to set any torch position required (angular setting to the workpiece).

TEACH

Block 3 - Standard

3.3 Hand coordinate system The origin of the hand coordinate system is the center of the robot hand axis and orientates itself as its respective position. Adjustment of position or orientation of the hand axes alpha, beta and gamma necessarily involves a change in the coordinates' direction for the reference system.

Diagram:

Hand coordinate system

The manually referenced rotation angles are defined as alpha (rotation around the X1 axis), beta (rotation around the Y1 axis) and gamma (rotation around the Z1 axis). The hand coordinate system is relative to the respective position of the robot tool (e.g. welding torch). Update is efffected after each movement automatically by changing the hand axes. The Z1 direction is subject to the positionof the hand axis flange which corresponds to the torch shaft direction. The X1 direction corresponds to the position of axis 6. The Y1 direction is turned 90Â° to the X direction. It is also dependant on the position of axis 6.

Page 14

Programming Manual ROTROLÂŽ II

Block 3 - Standard

TEACH

3.4 Workpiece coordinate system With the workpiece coordinate systems, the origin and position of the coordinate system are determined by the workpiece.

This coordinate system can be freely selected by the operator. With this system a reference to a current position of a workpiece to be programmed can be created. For example the workpiece coordinate system can be set in relation to a workpiece or a working table. Consequently, the robot can be moved within these coordinates manually in the TEACH mode. The coordinate system is aligned with its three base axes (X, Y, Z) and the hand axes (alpha, beta, gamma) to the position of the workpiece to be programmed. As shown on the next page, three definition points are programmed at the workpiece. Programming of these points can be effected in PTP or in CP operation. Also the speed is not important for this purpose. Definition of the workpiece coordinate system in TEACH mode -

Storage of the three definition points P1, P2 and P3 Call up the dialogue box to input the definition points by selecting the button "WKS"

Confirm the question with "YES"

Enter the three definition point numbers P1, P2 and P3

The workpiece coordinate system thus defined remains valid until a new definition is made or until the TEACH mode is quit. Programming Manual ROTROL速 II

V7.0X/S/12.03

Page 15

Movement in cartesian coordinates requires - unlike other types of movement - the definition of a so-called workpiece coordinate system.

TEACH

Block 3 - Standard

Definition of the workpiece coordinate system in the user program see block 9 chapter 21 "Online point shift in the workpiece coordinatesystem" Diagram:

Definition of the workpiece coordinate system

workpiece coordinate systems

The coordinate system is constructed around the positions of the programmed points P1, P2 and P3. The definition point P 1 forms the origin. The path P1 - P2 defines the new positive X direction. The path P2 - P3 defines the new positive Y direction. From that results the new Z direction.

Selection of definition points

The definition points P1, P2 and P3 should form a triangle with as large as possible leg lengths. Select hereby a high point number in order to avoid to delete the definition points.

Page 16

Programming Manual ROTROL速 II

Block 3 - Standard

TEACH

Tool Center Point - Tool Orientation Vector

In order to perform exactly defined movements with the effector center (wire tip), the robot operating system has to know this center. It is called “Tool-Center-Position” (abbreviation TCP). The reference point for the TCP values is the middle of the wrist joint of the robot mechanics. The geometry of the effector is indicated from this point in the direction of the hand coordinate system. The components X1, Y1 and Z1 show the position of the effector tip (wire tip) in 1/10 mm from the centre of the manual axis head.

The importance of an exact determination of the TCP for the welding torch and for the quality of the path control is pointed out. First, the welding torch has to be checked and corrected, if necessray, in the setting jig. The TCP value should be noted down in to be able to compare the original value with the actual value at any time.

4.1 Determination of the TCP value There are two ways of determining the TCP of the welding torch:

Determination of the TCP by measuring

To determine the TCP, move the robot axes so that the mounting flange of the robot is parallel to a level, e.g. to the working table. The wire protruding from the nozzle should have a length of 12 mm. The robot is positioned so that the wire tip just touches the level surface. The welding wire should not be deformed when doing this. The distance of the turning point of axis 5 to the level should then be measured.

TCP

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4 Tool Center Point (TCP)

TEACH 2.

Block 3 - Standard

Determination of the TCP via program points

As a manual measurement (by tape) would inevitably lead to inaccurate measuring results, the TCP is determined via a program. The robot needs 4 - 10 points to determine the TCP. The accuracy grows with the increasing point number. In one program these points are taught with constant position of the wire tip and different setting angle of the torch, e.g. program "TORCH", points 1 - 10.

4.2 Input of the determined TCP values After pressing the function button the following window appears where you can input the TCP values. Five more TCP will be displayed in addition to the system TCP. They are to be used, for example, with a torch changing system which works with different welding torches and therefore with different TCP (see Online TCP-Transformation).

Selection of the requested TCP number

0 1 2 3 4 5

2 0 0 0 0 0

5 0 0 0 0 0

-4950 0 0 0 0 0

-1

Input the known TCP by selecting the number field. The following window enables you to enter the respective value for the directions X, Y and Z via the simulated keypad.

In case of determining the TCP during programming the system has to calculate the values for the directions X, Y, Z. After selection of the button "DEFTCP" the program containing the definition points and then the points being necessary for calculation (see "Determination of the TCP via program points") must be indicated. The calculated values are filed as system TCP after confirmation.

The system TCP is always active during the manual travel of the robot axes (TEACH, PROG).

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Programming Manual ROTROL速 II

Block 3 - Standard

TEACH

4.3 External TCP

Due to production and handling reasons it may be necessary that the robot has to lead the workpieces to be welded along a fixed welding torch. To do this, the position and orientation (TCP and TOV) of the fixed welding torch must be determined in relation to the robot base coordinate system by means of the definition command. The specific travel guide must also be able to be switched on and off.

4.3.1 External torch definition When having a normally adjusted robot TCP, four points are needed to define the external welding torch. - The point P1 defines the working point (TCP) of the torch. - The points P2 and P3 determine the wire direction (TOV) from P2 to P3. - P4 determines the level where the torch is situated. The points P2 to P4 only determine directions und must not be placed physically on the torch. Command: EXTTOOL (P1,P2,P3,P4)

Functions for switching on and off Switch on command: EXTTCPON Switch off command: EXTTCPOFF The special movement mode is switched on or off by means of these two commands. Please absolutely pay attention that the robot TCP with which the points P1 to P4 were taught is active for the command EXTTOOL! To be sure, it can be adjusted by a STCP command. The adjusted robot TCP is not relevant within the handling CP travel mode between EXTTCPON and EXTTCPOFF.

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TEACH

Block 3 - Standard

Example: The definition points of the external torch are 100 to 103. They were taught by a defined robot TCP (0,0,4000). Point 100 determines the position, the wire direction is from 101 to 102 and point 103 describes the level. The travel mode is switched on for the straight lines to P2 and P3, the graduated circle and the straight line to P6. Then the mode is switched off. MAIN LISTE1 = (...) STCP (0,0,4000) EXTTOOL (100,101,102,103) GP (1) $ (1) EXTTCPON GC (2,3) ARC(3,4,5) GC (6) EXTTCPOFF GP (10) END

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Programming Manual ROTROL速 II

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TEACH

5 Tool Orientation Vector (TOV) In addition to the TCP, which describes the position of the wire tip and which is needed when moving along straight paths, TOV describes orientation, i.e. the direction of the wire. - oscillating - arc sensor controlled seam tracking and - sensor functions.

It is needed for

The TOV Tool Orientation Vector describes the direction of the wire tip of the welding torch and is measured from the top of the tool - which is in this case the wire tip of the welding torch. The values X1, Y1 and Z1 (hand coordinate system) are input. Since only the direction of the vector and not its length is necessary, the proportion of the components and not their absolute size is relevant. Therefore, the values to be input in X1, Y1 and Z1 are only proportional numbers and not absolute values. Determination of the TOV X-

Wire direction

Z-

The angle of the welding torch - 35 degrees - and the torch bracket - 10 degrees - is added and multiplied by the tangent. The result is the value for direction "X". As the controller only accepts integral values the decimal place of the X- and Zcomponent is correspondingly shifted to the right. Z+

Example: Angle of torch 35 degrees Angle of torch bracket 10 degrees

X+ Calculation: 45 degrees * tan a = 1

Determination of the preceding signs: Viewing direction

ng di el W

ire w

n io ct re i d

The wire direction points to the negative X and negative Z direction considering the viewing direction. This means that the preceding signs are negative for a robot in upright position.

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TEACH

Block 3 - Standard

The TOV values for the 450 bent CLOOS welding torch (incl. torch bracket) are: - for upright robot:

X1 -1 1

- for overhead robot:

Table:

Y1 0 0

Z1 -1 -1

TOV values

Angle of torch 90° 75° 60° 45° 30° 15° 0°

upright robot -1 -3732 -1732 -1 -5773 -2679 0

0 0 0 0 0 0 0

overhead robot 0 -1000 -1000 -1 -10000 -10000 -1

1 3732 1732 1 5773 2679 0

5.1 Input of the TOV The TOV is input in the same way as the TCP.

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Programming Manual ROTROL® II

0 0 0 0 0 0 0

0 -1000 -1000 -1 -10000 -10000 -1

Block 4 - Standard

The editor

Index

The Editor

1.1Keyboard ............................................................................................................. 4 1.2Cursor movements ............................................................................................... 4 1.3Special characters ............................................................................................... 5 1.4Editor commends ................................................................................................. 5 1.5Help functions in the text editor ............................................................................. 6 1.6User examples ..................................................................................................... 7 1.7Leaving the text editor .......................................................................................... 8

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1 The Editor ..................................................................................................................... 2

The editor

Block 4 - Standard

The editor 1 The Editor It is the editor’s function to provide the user with a simple way of manipulating program text and data and can be accomplished through the keyboard (see following description). The touch screen will function as monitor. The user has the following options available to him upon pressing the „Editor“ button: Text editor (Entering program text) Point editor (Optional manipulation of point information - see also options „Point editor“)

The „Text editor“ makes it possible to edit the user programs. A new program will be created by pushing the „ „ button.

MENUE

TEST

MASTER

KOERNER

PRG1

PRG2

Program description field

SD1 RESTART VAR SD,SD1,SD2,EING VAR CSKOMM,CSFOLG,CRET,CERET,CSRET,CVRET,CEKOMM,CSTAT,CEFOLG VAR CBUSY,KANAL,NVAR,T1 LIST 1 = (5311,3,0,60,199,153,700,36,9,0,70,222,532,0,0,0,0,0,100,0,0,0) LIST 2 = (5311,3,0,200,57,12,700,36,0,0,44,13,500,0,0,0,0,0,100,0,0,0) PROC TE T1:=EING NVAR:=1 KANAL:=1 CSKOMM:=918 COMM (2;KANAL;CSFOLG,CSKOMM,CSTAT,NVAR;CRET,CSRET,CERET,CEFOLG,& CBUSY,T1) WAIT: IF CBUSY=1 THEN JUMP WAIT ENDP

set up a new program

Program name

PROC TESTSD GETSDSTAT (SD) ! SD - STATUSINFORMATION HOLEN FUNCON SDSTOPCP,10

Line number

Help function

CZC- Exit* Exit**

* Leaving the text editor and compiling of user program. The command run edited in clear text (Source-Code) is converted into the machine language (Zwischen-Code=intermediate code) which is the basis for the run of the computer. Page 2

Programming Manual ROTROL® II

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The editor

** Leaving the text editor without compiling of user program. Changings of the user programs (Source-Code) become valid only by compiling. During program run they are not taken into consideration and can cause the error message Source-Code unequal Z-Code, please compile again!!

The system will automatically insert the following commands upon creation of a user program:

(see chapter 1.7 " Leaving the text editor")

RESTART MAIN

and END Except for the command „RESTART“, all other commands are used for the identification of the main program part and the user program. Therefore, a deletion of these commands is not allowed and will cause an error message upon leaving the program. The command RESTART causes the current program to be stored (= Sum of all program information) during execution of the first part of the program. You can read more about this in the chapter ”line start” in block 6. The command MAIN separates the program parts and definition parts. For example, if run commands are entered (GP_(1...3)) in the definition part (weld parameter lists) within the main program of the user program, then the compiler will issue an error like: command within this part of the program is not allowed! The command END completes the main program part.

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The editor

Block 4 - Standard

1.1 Keyboard The alphanumeric keyboard is used for the input of commands and the more comfortable modification of existing user programs. The keys are arranged acc. to the American standard (QWERTY). Please find below the description of the keyboard layout. Keys with special functions -

Key "BACK SPACE" Delete letters

Key "ESC" Confirmation of PC error messages and abortion of function

Key "ENTER " Confirmation of the command

Key "SHIFT" Shift key for keys with double function

Key "Blank" Key for the input of blanks

Cursor key Positioning of the input mark (cursor)

1.2 Cursor movements The following cursor movements are possible in the "EDTOR": Function

Key

Description

Cursor up

Sets the Cursor one line up without changing the column. Cursor down Sets the cursor one line down without changing the column. Cursor right Moves the cursor one step to the right. Cursor left Moves the cursor one step to the left. Cursor home Home Sets the cursor at the start of the text. The first page of the text will be displayed. Page up PgUp Scrolls up for one page. Page down PgDn Scrolls down for one page. Delete character BACKSPACE Moves one step to the left of the cursor while deleting the character on the left of the cursor. Delete character DEL Deletes the character on the right of the cursor.

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Programming Manual ROTROL速 II

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The editor

1.3 Special characters There are several special characters in addition to the alphanumeric characters, which will execute specific functions: For example: = = = = = =

Program line will be by-passed Call a weld parameter list Definition of number inputs Jump definition (Apostrophe) Commentary margins commands WRITE- and WREAD (Comma) separator between parameters i.e. text and variable values for the WRITE command.

! $ () : â&#x20AC;&#x2DC; ,

There are certain editing commands available in order to edit program texts. They are identical with word processing program commands like the ones used by Microsoft Word. Keys und key stroke combinations

results

Shift key + arrow keys Ctrl+C Ctrl+V Ctrl+X Ctrl+Z Ctrl+F F3 Ctrl+H Ctrl+J Ctrl+L Del

Highlighting of text and text lines Copying highlighted text Inserting highlighted text Cutting of text Undo last step Finding text or special characters Continue search Find and replace text Jump command Weld parameter list editing Deletion of text

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1.4 Editing commands

The editor

Block 4 - Standard

1.5 Help functions in the text editor The function „HELP“ within the text editor explains all key combinations and keystroke short cuts as well as other useful keyboard functions.

First page: Basic functions Text-Editor Functions: General functions: Help: Copy: Cut out: Add: Delete: Reset: Search: Cont. search: Replace: List Editor: Jump menu

F1 STRG(CRTL) + C STRG(CRTL) + X STRG(CRTL) + V ENTF(DEL) STRG(CRTL) + Z STRG(CRTL) + F F3 STRG(CRTL) + H STRG(CRTL) + L STRG(CRTL) + J

Second Page: Marking and positioning Text-Editor Functions: Mark and position: Page down: Page up: Cursor at line start: Cursor at line end: Cursor at text st.: Cursor at text end: Mark: Mark line up to start: Mark line up to end: Mark text up to start: Mark text up to end:

Picture down (Page Down) Picture up (Page UP) POS1 (HOME) ENDE (END) STRG(CRTL) + POS1 (HOME) STRG(CRTL) + ENDE (END) STRG(CRTL) + arrow keys SHIFT + POS1 (HOME) SHIFT + ENDE (END) STRG(CRTL)+SHIFT+POS1 (HOME) STRG(CRTL)+SHIFT+ENDE (END)

More information about the number of parameters, notation and allocation of value is displayed on the screen after activating the key "F1" . A brief description is given on the command which was selected with the cursor. If there is no clear allocation, the controller lists all possible commands from which the requested command can now be selected. If no command (line space) was selected, the complete command of the Rotrol will be listed.

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Programming Manual ROTROL® II

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The editor

1.6 Example The following explains how to copy, for example the program text lines 22 und 23 to the lines 16 und 17 1. Step Using the arrow keys, the cursor has to be moved to the line 22.

2. Step Highlight the text line by pressing the SHIFT- + cursor down

ENDP TESTSD GOTOXY (10,13) WRITE (‘SD STATUS IST’,SD,’ERGEBNISS’,SD1,’VERGLEICH’,STOER) WAITS (2) GOTOXY (10,14) IF SD1 = 64 THEN WRITE (‘**** SD STOERUNG SPANNUNG ***’) GOTOXY (10,16) IF SD1 = 256 THEN WRITE (‘**** SD STOERUNG GAS ***’) GOTOXY (10,17) IF SD1 = 512 THEN WRITE (‘**** SD STOERUNG DRAHTVORRAT ***’) STOER:=STOER*2 IF SD1 = 32 THEN WRITE (‘**** SD STOERUNG STROM ***’) GOTOXY (10,15)

MAIN $ (1) ST: GP (1,2,3) GC (4)

ENDP TESTSD

3. Step Cut the text by pressing the buttons Ctrl+X

MAIN $ (1) ST: GP (1,2,3) GC (4)

GOTOXY (10,13) WRITE (‘SD STATUS IST’,SD,’ERGEBNISS’,SD1,’VERGLEICH’,STOER) WAITS (2) GOTOXY (10,14) IF SD1 = 64 THEN WRITE (‘**** SD STOERUNG SPANNUNG ***’) GOTOXY (10,16) IF SD1 = 256 THEN WRITE (‘**** SD STOERUNG GAS ***’) GOTOXY (10,17) IF SD1 = 512 THEN WRITE (‘**** SD STOERUNG DRAHTVORRAT ***’) STOER:=STOER*2

4. Step Move the cursor to the target position (line 16). Press the keys Ctrl+V in order to insert the text

ENDP TESTSD MAIN $ (1) ST: GP (1,2,3) GC (4)

GOTOXY (10,13) WRITE (‘SD STATUS IST’,SD,’ERGEBNISS’,SD1,’VERGLEICH’,STOER) WAITS (2) GOTOXY (10,14) IF SD1 = 32 THEN WRITE (‘**** SD STOERUNG STROM ***’) GOTOXY (10,15) IF SD1 = 64 THEN WRITE (‘**** SD STOERUNG SPANNUNG ***’) GOTOXY (10,16) IF SD1 = 256 THEN WRITE (‘**** SD STOERUNG GAS ***’) GOTOXY (10,17) IF SD1 = 512 THEN WRITE (‘**** SD STOERUNG DRAHTVORRAT ***’) STOER:=STOER*2

ENDP TESTSD MAIN $ (1) ST: GP (1,2,3) GC (4)

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The editor

Block 4 - Standard

1.7 Leaving the text editor Before you can leave the text editor, the control will offer you two ways of doing so (EXIT und COMPILE/EXIT) before returning to the main menu. EXIT

RESTART LIST 1 = (5211,3,0,86,116,214,700,0,0,10,50,0,0,0,0,0,0,5,35,30,5,0) LIST 2 = (5211,3,0,42,116,214,700,0,0,10,50,0,0,0,0,0,0,5,35,30,5,0) LIST 3 = (5211,3,0,42,116,214,700,0,0,10,50,0,0,0,0,0,0,5,35,30,5,0) MAIN ST: !************* QUELLPUNKTE KOPIEREN ****************! COPYP (3..8,13)! 1. SCHWEISSNAHT COPYP (3..8,23)! 2. SCHWEISSNAHT COPYP (3..8,33)! 3. SCHWEISSNAHT COPYP (3..8,43)! 4. SCHWEISSNAHT !********* RELATIVTVERSCHIEBUNG DER EXT.ACHSE *******! MPE (1,8,100,103,13,18)!VERSCHIEBEN DER EXT.ACHSE 8 1.SCHWEISSNAHT MPE (1,8,100,203,23,28)!VERSCHIEBEN DER EXT.ACHSE 8 2.SCHWEISSNAHT MPE (1,8,100,303,33,38)!VERSCHIEBEN DER EXT.ACHSE 8 3.SCHWEISSNAHT MPE (1,8,100,403,43,48)!VERSCHIEBEN DER EXT.ACHSE 8 4.SCHWEISSNAHT

This should only be attempted if you have not made any changes to the program and would like to return to the main menu. The processor needs to translate the program into an intermediate version (code) it can understand. Program changes will not be acknowledged for the program run. COMPILE/EXIT (COMPILE = Translating)

$ (1)

The COMPILE/EXIT command will convert the before mentioned code of the program. This will enable the processor to save all changes made to the program and execute them during the following program run. The second task of it is to check the program for ”Syntax errors”. Syntax errors are errors in the command structure or misspellings, commands in a wrong program location, absolute necessary parameter have not been entered yet and so on. The compiler cannot control errors leading to a bad program run (i.e. robot crash). Errors, which have been encountered, will be entered into an error list (see following picture) and the line and error number (i.e. „Unknown command or: = expected“) are shown. Pressing the acknowledge button will take you back to the main menu. No corrections will be made and the program is not executable.

Highlight the error by moving the cursor to that line; once you press the button „Goto Error“, you will be brought back to the text editor. The errors will be highlighted in red. Repeat this process until the compiler cannot find any more.

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Block 5 - Standard

PROG mode

Index

1 PROG mode .................................................................................................................. 2 1.1 Inserting command lines .................................................................................... 3 1.1.1 Simple movement commands ........................................................................ 4 1.1.2 Circle and partial circle functions ................................................................ 7 1.1.2.1 Full circle ............................................................................................... 8 1.1.2.2 Partial circle ........................................................................................... 9 1.1.2.3 Amount of linkable arcs .......................................................................... 9 1.1.2.4 Circle interpolation and additional axe .................................................. 10 1.1.2.5 Circle orientation .................................................................................. 10 1.1.2.6 Additional functions for programming circles ........................................ 11 1.1.3 Weld parameter lists ...................................................................................... 12 1.1.4 Sensor functions ............................................................................................. 12 1.1.5 Movement characteristics............................................................................... 12 1.1.5.1 Looping of points - looping vector ........................................................... 12 1.1.5.2 Path looping ............................................................................................ 13 1.1.5.3 Changing the maximum PTP- speed ...................................................... 14 1.1.6 Leaving the PROG mode ........................................................................... 15 1.2 Correction of command lines ............................................................................ 16 1.2.1 Correction "Parameter" ............................................................................. 16 1.2.2 Correction "Line" ....................................................................................... 17 1.3 Program cursor positioning ............................................................................... 18 1.4 Deletion of command lines ................................................................................ 19 1.5 Selection of the Teach mode ............................................................................. 19

Programming instructions ROTROL速 II V7.0X/S/12.03

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PROG mode

Block 5 - Standard

The PROG mode 1 PROG mode In the PROG mode one can create new programs or modify existing ones. This mode is a combination of the TEACH and EDITOR functions and thus offers a simple way of creating programs. Erroneous inputs are minimized since the program text is largely created automatically. The components of a program are: 1. Program text (Source code) 2. Points (Point code) 3. Machine code (Z-Code)

describes the program run in cooperation with all peripherals defines the robot position program text converted into machine language

After choosing or creating a program, the first level of the PROG mode will appear on the screen. Program name

Program text display current path indicator current cursor position

Line up scroll

Insert

Correction

Jump

Delete

Line down scroll

Teach

Line number Leaving the PROG mode EXIT = Abortion of mode PROG

The following basic commands are used to:

Page 2

Insert a comand line at the current cursor position

Mark command lines in the operational program

Positioning the cursor in the run program

Cut command lines out of the operational program

Editing the current comand line

Copy command lines in the operational program

Deletion of current comand line

Insert command lines into the operational program

Select TEACH mode (see Block 3)

Save and load program blocks

Programming instructions ROTROL速 II

Block 5 - Standard

PROG mode

1.1 Inserting of command lines The command menu below, will appear when pushing the "Insert" button. The menu will show the entire command button collection for the control. The depiction does not differentiate between: basic commands and

Even more important than what you insert, is where you insert it. The processor will always default the insertion location of a new program line above the current program line or cursor position. In the example below, a new program line was inserted above line 3 (END). All other lines will automatically be moved downwards. Make sure you have chosen the right command line before you add lines to an existing program. You can check that by scrolling up and down or by using the function "JUMP" (see chapter "Cursor positioning within programs").

-Page 1-

RESTART MAIN END

Command and function buttons

Insertion completed

scroll to next page

-Page 2-

RESTART MAIN END END

scroll to previous page

Programming instructions ROTROL速 II V7.0X/S/12.03

Page 3

optional command functions (described in part 2 -Options-)

PROG mode

Block 5 - Standard

1.1.1 Simple movement commands In order to move along a weld path in a straight line, you would need the following: 1.

a command to approach the weld seam, see illustration 1 GP_(..) = Go Point to Point

and 2.

a command for the seam itself, see illustration 2 GC_(..)=

Go continuous path

Refer also to "PTP-Control" and "Path control" in Block 3!

Moving the robot axes and the storing of points into memory is basically the same in the PROG mode as well as in the Teach mode (see Block 3).

The chosen drive command and the stored point numbers will be shown and remain in the button is pushed. Only then will the data be transferred data input preview bar until the into the program text above and the screen will return to the previous one. Illustration 1

Illustration 2

RESTART MAIN END

GP (

GC (

Data input preview bar

Points will be approached in the order they are shown in the brackets. The movement characteristic is based upon the command in front of the brackets (GP / GC). Once a valid weld parameter list has been activated, the "arc" will switch on automatically as soon as a command change from "GP" to "GC" is called for. The "arc" will be switched off when the command changes from "GC" to "GP".

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Programming instructions ROTROL速 II

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PROG mode

Additional information and function buttons: Information: display of current point number, oscillation frequency (see oscillation) and weld parameter list (see Bloc 6)

RESTART MAIN END

current speed correction side and hight during seam search (see option "arc sensor / analog sensor")

Function buttons: selectable functions for movement type "GP" Position the different axes irrespectively of the stored points and moving commands via the command DRIVEA_(axis,value)

in an absolute position

and via the command DRIVER_(axis, value)

in a relative position.

The values of the two DRIVE commands are entered in 1/10 degrees starting from the position of the reference point in case of the command DRIVEA and from the actual axis position in case of the command DRIVER. Examples: DRIVEA_(3,-450) DRIVER_(5,900)

Moves axis 3 to a position which is 45° away from the reference point in negative direction. Moves axis 5 from the actual position for 90° in positive direction.

If too high values in the command DRIVE cause a malfunction of the limit stop, the corresponding message only appear when reaching the command PTPMODE

(see "additional documentation").

Programming instructions ROTROL® II V7.0X/S/12.03

Page 5

Teach/point speeds

PROG mode

Block 5 - Standard

Selectable functions for movement types "GP", "GC", "CIR/ARC"

Coordinate systems (see Bloc 3 chapter "Coordinate systems" and "External Axes") Sensor functions (see part 2 options chapter "Arc sensor", "parallel shift with sensor" and special documentation "Laser")

Digital outputs

(see chapter "Digital outputs" in Bloc 9)

Defining and activating weld parameter lists

Approach of point positions

(see Bloc 7)

(see Bloc 3 " Teach mode")

Defining point numbers

Setting a point number range

RESTART MAIN END

18..20 GP (

The number pad will allow you to enter point numbers. In this mode it will not change or store axes positions. Those would have to be taught, stored and processed before they can become part of a program line. Point numbers have to be entered separated by a comma(,) and point number ranges separated by two dots (..) Entered data will first be shown inside the data input preview bar before they will be

inserted into the program.

Display of point information

Page 6

(see Bloc 3 "Teach mode")

Programming instructions ROTROL速 II

Block 5 - Standard

PROG mode

1.1.2 Circle and partial circle functions It is possible to move around a circular or partially circular path by teaching three points. Circle.S RESTART MAIN GP (1..3) END

CIR (

These three points (definition points of circumference) are needed for calculating a full or partially circular paths. One has to chose these point in such a way that it will clearly indicate the shape of a circle or partial circle.

Four rules for programing circles: 1.

Circle definition points cannot be placed along a straight line.

No point should be identical to a previous or following point.

The definition points should be placed as evenly spaced as possible along the weld path. (For a full circle, the definition points should be placed about 120 degrees apart).

The smallest programmable diameter is about 10 mm or 0.39 inch Programing of circles

Illustration:

5 4

incorrect

5 4

correct

The robot has to be positioned above the first definition point if it has to follow a programmed full or partial circle. Programmed circular path points will be approached in a direct line with GPand GC-commands. Therefore, collisions with work parts are possible!

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PROG mode

Block 5 - Standard

1.1.2.1 Full circle

Command: CIR_(....) = Circle

Example:

= Full circle

CIR_(3,4,5,50) 1. Definition point = Point No. 3 2. Definition point = Point No. 4 3. Definition point = Point No. 5 4. Overlap in 1/10 mm (5 mm in example below)

This command describes a full circle. The three definition points are separated by a comma. The last entry (50) indicates the length of circle overlap in 1/10 mm.

In any case, the overlap value has to be entered. It can be for example "0" or even have a negative value. A negative value will stop the robot by that distance before reaching the original start position again.

Programming example:

RESTART LIST 1 = (5211,1,0,50,200,0,700,0,0,0,50,0,0,0,0,0, MAIN $ (1) GP (1,2) CIR (2,3,4,50) GP (5,6) END

3 4

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Programming instructions ROTROL速 II

Block 5 - Standard

PROG mode

1.1.2.2 Partial circle

Command: ARC_(...)

Example:

Arcus

Partial circle

= arc

ARC_(3,4,5) 1. Definition point = Point No. 3 2. Definition point = Point No. 4 3. Definition point = Point No 5

This command describes a partial circle. The three definition points are shown separated by commas. the e 1st point defines the start of circle, the 3rd defines the end of it and the 2nd defines the halfway point between the 1st and 3rd definition points.

ARC (

1.1.2.3 Amount of linkable arcs It is possible to program a link of up to 16 consecutive arcs. In case more arcs are needed, a "read-ahead"- processor function (see chapter 1.1.5 "linking of points) will allow you to do so by entering the following command: FUNCON _ARCNO,22 only values between 16 and 127 are allowed.

RESTART LIST 1 = (5211,1,0,50,200,0,700,0,0,0,50,0,0,0,0,0,0,5,35,30, MAIN $ (1) FUNCON ARCNO,22 GP (1,2,3) ARC (3,4,5) ARC (5,6,7) ARC (7,8,9) GC (10) ARC (10,11,12) GC (13,14) ARC (14,15,16) ARC (16,17,18) GC (19)

In this example the amount of linkable arcs has been increased to twenty-two. Entering more than twenty consecutive arc commands will result in the following error message: Max. 16 arcs can be linked together!

Programming instructions ROTROL速 II V7.0X/S/12.03

Page 9

Partialcircle.S RESTART MAIN GP (1..3) END

PROG mode

Block 5 - Standard

1.1.2.4 Circular interpolation and additional axes Additional axes can be positioned simultaneously with circular movements. To achieve this, the external axes have to be synchronized (see chapter "Synchronization of external axes"). 1.1.2.5 Circular orientation

Available circular orientation options are:

with or without moving axis 6 moving axis 6 without moving axis 6

—> fillet welds —> butt welds

with or without actualization of torch orientation with actualization The torch orientation will be based on the three circle definition points without actualization The torch position will be based on only the first circle definition point.

The command to determine the circle orientation must be placed in front of the Circleor partial circle command. Commands: CIRO_(0)

without rotating axis 6 The torch orientation for the first circle definition point will remain. (Should only be used if the torch is place vertically to the circle area).

CIRO_(1)

with rotation of axis 6 The torch orientation for the first circle point will remain the same.

CIRO_(2)

with and without rotation of axis 6 The torch orientation will be updated between the 1st and 2nd; the 2nd and 3rd; the 3rd and 1st circle definition point.

CIRO_(3)

without rotating of axis 6 The torch orientation in relation to the circle will remain the same, the torch push angle will remain constant throughout the entire path. The command “CIRO_(0)” will be sufficient if the torch is oriented exactly vertical to the circle area

These commands must be placed before the circle command. In case no “CIRO” command was entered, then "CIRO_(2)” will be used. A “CIRO”- command will remain valid to the end of a program or until a new command took effect.

Page 10

Programming instructions ROTROL® II

Block 5 - Standard

PROG mode

Illustration: Torch positions and their proper circle area orientations

CIRO_(0) or CIRO_(2) or CIRO_(3)

CIRO_(1) or CIRO_(2)

1.1.2.6 Additional functions of circle programming Center point oriented circle programming In part 2 - options - of the programming instructions, the function "center point oriented circle programing" has been fully explained.

Notes:

Programming instructions ROTROL速 II V7.0X/S/12.03

Page 11

PROG mode

Block 5 - Standard

1.1.3 Weld parameter lists Switch to dialogue field "Weld parameter lists" (see Bloc 7 chapter "Weld parameter lists."

1.1.4 Sensor functions Switch to dialogue field "Sensor functions" (see part 2 - options - chapter "arc sensor", "parallel shifting with sensor" and special documentation "laser")

1.1.5 Movement characteristics 1.1.5.1 Linking of points - linkage vectors To avoid pausing at every point until the next points location has been determined, the system controller will compute these locations before the first move is executed. This is called "preliminary computation". Furthermore, the controller distinguishes between preliminary computable and none computable commands, which means that the program lines are scanned ahead until a none computable command has been found.

Preliminary computation has different meanings for PTP- and CP- moves. Without preliminary computation, the robot would pause at every point and the controller would have to determine the position of the next point before continuing along the weld path. The advantage of preliminary computation will allow for a "short cut" along a three point path and a smoother transition between the first and third points. This means that the point in the middle will not be approached precisely.

Page 12

Programming instructions ROTROL速 II

Block 5 - Standard

PROG mode

The command STON activates the smooth transition, STOFF deactivates it again. The command STV determines the GP move preciseness with which the points will be approached, for example: (Smooth Transition Value)

STV_(30)

The value in the STV command will influence the transition radius between two points. Values between 1 and 100 are permissible. Higher values will create a shallower radius, approaching a short cut, and lower values a more pronounced radius, approaching the precise location of all points. The default value is 1.

The entered value is valid until the program ends or until a different STV- value takes command.

1.1.5.2 Path looping Similar to smotth transitioning air moves, it is also possible to influence weld moves in such a way. The robot will try to keep weld movements over several point constant but if there is a change in direction or orientation of the torch at any point, a controlled movement at those corners cannot always be assured, but with the command SETDD it is possible to define a path in which the robot will slow down before reaching a specific point and speeding up again after passing it. Another parameter of the SETDD - command defines a path, similar to the STV command, and how sharp a movement is to cut a corner in that path. The entered values of these two parameters are in 1/10 mm.

Programming instructions ROTROL速 II V7.0X/S/12.03

Page 13

PROG mode

Block 5 - Standard

Example: SETDD_(30,20) Distance to point at which the robot is to take a short cut (20 = 2 mm). Distance to point at which the robot is to slow down and speed up again.

The maximum input value for both parameter is 500 (50 mm).

The SETDD command will also have an effect on the external axes once the external axes synchronization has been enabled. The SETDD command will reduce their speed before reaching a point and cause them to speed up once they have passed it. Please refer to Block 8, External axes.

1.1.5.3 Changing the PTP- maximum speed

Within your program it is possible with this command PTPMAX_(Value) to reduce the maximum PTP- speeds for all the following moves. The values are in per centages. Once the processor has for example calculated the following PTPMAX_(70) command, the speed with which the PTP movements will be executed are relative to this maximum PTP- speed setting. In the "T1-Mode", this value is only effective if the velocity in the center of the robot wrist is less than 250 mm/s.

Page 14

Programming instructions ROTROL速 II

Block 5 - Standard

PROG mode

1.1.6 Leaving the PROG mode The PROG mode will be exited, just like the Text editor, in the following two ways (EXIT and COMPILE/EXIT).

Insert

Correction

Jump

Delete

Teach

You should only exit in this way if you haven't made any program changes. In order for the computer to execute a program, it needs to look at a specific code which was created by translating the program into a language the computer can understand. If changes had been made but have not been compiled after exiting, they will not have any effect on the executed program.

COMPILE/EXIT (COMPILE = to translate) The program will be checked for Syntax (vocabulary program) errors. Once an errors has been detected, it will be added to the error list. it will jump If you acknowledge these with the button back to the main menu. No cor rections will be made to the program and the program will not be executable unless the program is free of syntax errors. Chose one of the errors on the screen by manipulating the up or down arrows and by pushing the "Goto Error" button, you will be taken back to the PROG mode and the line with the syntax error to be corrected.

Repeat these steps until the compiler cannot find any more errors.

Programming instructions ROTROL速 II V7.0X/S/12.03

Page 15

EXIT

PROG mode

Block 5 - Standard

1.2 Correction of command lines Existing command lines can be supplemented, changed and completely overwritten by the function "Correction".

The control offers the selection possibilities PARAMETER and LINE. Supplement or change an existing command line by selecting PARAMETER. Overwrite (exchange) an existing command line by selecting LINE.

1.2.1 Correction "Parameter" The display of the correction menu "Parameter" differs depending on the command line which has been selected in the program run (see pictures). Picture1: Correction of the movement command "GP"

selected inserting position in the preview bar

- Marking of the parameters in the preview bar: Mark parameter, Mark the inserting select inserting position or the parameter position to be changed (point number or weld Delete parameter list) via arrow marked parameter keys.

current point number

- Adding of parameters: A new point number is added at the selected inserting position when it is entered in the numerical field (DefNo), or a new point (MEM+P) is programmed like in mode "Teach".

Please consider the current point number when saving points!! Risk of overwriting! Page 16

Programming instructions ROTROL速 II

Block 5 - Standard

PROG mode

- Changing of parameters Change a marked point number by entering a point number or by reprogramming, as described above. Change a call for a weld parameter list by

Marked parameter of the preview bar

actuating the button "Dollar" . Select the new weld parameter list from the following menu and confirm your selection.

Marked parameters can be removed from the command line via the button "Delete"

Picture 2: Command lines with a determined number of parameters This correction menu is displayed if command lines with a determined number of parameters were selected. The marked parameter is replaced by the parameter which was entered un the numerical field. Select the numerical field via . the button "Exchange parameter"

1.2.2 Correction "Line" After selection of the "Correction line" the complete command menue of the "PROG" mode is displayed. A new command line overwrites the command line which is marked in the user program.

Programming instructions ROTROL速 II V7.0X/S/12.03

Page 17

- Deletion of parameters

PROG mode

Block 5 - Standard

1.3 Program cursor positioning JUMP

START

MAIN

END

In order to edit a program line with the KORR function, the line has to be currently on the screen. Paging through programs can be achieved with the JUMP functions

LINE

START Jump to program start The first line (line number indication = 1) will appear as the current line. END Jump to end of program Jumping to the command line "END".

LINE Jump to any line which line number is to be entered by the LINE command. The requested line will have to be entered by means of key strokes. Instead of using the JUMP button, one can also use the arrow keys in order to scroll through program lines. scroll to previous line. scroll to next line.

MAIN Jump to a line with the word MAIN in it. If multiple sub menus are used, weld parameter lists and others, you can jump with this function directly to the beginning of the program.

Page 18

Programming instructions ROTROL速 II

Block 5 - Standard

PROG mode

1.4 Deletion of command lines

Command lines which are no longer needed for the current program can be removed with the function button "delete". Select the line by placing the cursor on it. Push the "delete" button in order to remove the line from the program. The deletion of command lines which contain the words "MAIN" or "END" is not permitted and will be ignored. Since the deletion command cannot be undone, lines which have been deleted by mistake can only be reinserted by means of the "insert" function.

In order to avoid important data loss, changes within large programs should be performed within a copy of that program.

Should you want to deactivate a command line temporarily, you can do so by adding an exclamation mark in front of the command. (!GP_(1..3)) The system will disregard such commands but it will remain part of the program until you decide to reactivate or delete it.

1.5 Selection of the Teach mode see block 3 - Standard - Chapter TEACH

Programming instructions ROTROL速 II V7.0X/S/12.03

Page 19

Bloc 6 - Standard

Program execution

Index

Program execution 1 Test ................................................................................................................................ 2 1.1 EXE .................................................................................................................... 2 1.2 EST ................................................................................................................ 3 1.2.1 Usage .......................................................................................................... 3 1.2.2 Selection options in EST-Mode .................................................................. 4 1.2.3 Selection options following a E-STOP command....................................... 5 1.2.4 Trace memory ............................................................................................. 5 2 AUTOMATIC- Mode ...................................................................................................... 6 3 Leeway of operating modes ....................................................................................... 7 4 Line start ...................................................................................................................... 8 5 Overlapping start ....................................................................................................... 11 5.1 Termination of executed programs during weld process ................................. 11 6 File AUTOEXEC .......................................................................................................... 15

Programming instructions ROTROL速 II V7.0X/S/12.03

Page 1

Program execution

Bloc 6 - Standard

Program execution 1 Test Before executing any newly created program, it is important to test it in the TEST- mode before switching to the AUTOMATIC-mode. Because of the reduced axes movement velocity there is enough time for the operator to react to possible crash situations. In this mode, the program flow is still easy to follow. In addition, it allows for the fine adjustment of weld parameters.

You can chose between the following test modes: EXE = EXEcute and EST = Exe STep = Step by step execution OFF / Please switch Power on !

1.1 EXE

START, switch OFF or function button STARTFROM

START, switch OFF or function button F1: LINESTART

F5: ENDLINE

Right after the EXE or EST function, the controller will ask for the name of the program you would like to execute. The program will be executed by pushing the "Start" button, which for safety reasons can only be activated in the T1 mode by means of the PHG. If the line start (button: F1) function has been selected, a program can be executed from any chosen line (see chapter 4 "line start

In both operating modes, EXE and EST, it is possible to change the most important active weld list parameters during a weld movement (see Bloc 7 "chapter - weld parameter lists").

Page 2

Programming instructions ROTROL速 II

Bloc 6 - Standard

Program execution

If during a weld move a valid parameter list has been called up, it will be indicated as shown on the screen below: current point number

current weld parameter list

current program line

LINE No. Command 1 VAR A 2 LIST 1=(4711,1,0,50,100,0,700,0,2,0,50,0 3 MAIN 4 $ (1) 5 GP (1,2) 6 GC (3,4,5) 7 ARC (5,6,7) 8 GC (9) 9 GP (10,11)

MAIN-Prog A1 A1 A1 A1 A1 A1 A1 A1 A1

SUP-Prog

active Main-/ Subprogram

Actuel target point number: 1 K: -4500 4300 15677 0 900 900 R: 2538655 3516151 4194154 3007965 3468317 3197324 Press release key, change operation mode or abort with [ESC]

In order to change weld list parameters, please refer to bloc 7 chapter "changing weld parameters."

1.2 EST The basic difference between the EST- and EXE- mode is the fact that every single program step has to be acknowledged by pushing the arrow keys . Corrections within the program text and point positions can be made by using the selection options. 1.2.1 Usage

<- back PROG LINE No.

Toggle-Taste DELETE KORRPAR

fwd -> Stop TEACH

command

MAIN-Prog

1 VAR A 2 LIST 1=(4711,1,0,50,100,0,700,0,2,0,50,0 3 MAIN 4 $ (1) 5 GP (1,2) 6 GC (3,4,5) 7 ARC (5,6,7) 8 GC (9) 9 GP (10,11) K: R:

A1 A1 A1 A1 A1 A1 A1 A1 A1

-4500 4300 15677 0 900 900 2538655 3516151 4194154 3007965 3468317 3197324

SUB-Prog

The arrow keys allow the user to execute the program step by step, either forward or backwards. As soon as the robot has reached the next point, it will key again will stop. Pushing the cause the robot to move to the next point. If the robot should move to the previous point then pushing the key will cause him to do so.

PGM-Mode T1

Circular movements can only be executed as a whole, which means that no stop is possible at individual circle identification points. Programming instructions ROTROL速 II V7.0X/S/12.03

L: 1 P: 1 + / - V: 50 1DR: 200 2 L:__U 3 H: 700 4AMP: 0 >> DEADMAN SWITCH NOT PRESSED << Change operation mode, abort [ESC,OFF]

Status messgaes

arc ON/OFF

Page 3

Program execution

Bloc 6 - Standard

1.2.2 Selection options in the EST- mode - F1 (PROG) <- back PROG

Toggle-key DELETE KORRPAR

fwd -> TEACH

Stop

LINE No. Command MainProg 1 VAR A A1 2 LIST 1=(4711,1,0,50,100,0,700,0,2,0,50,0 A1 3 MAIN A1 4 $ (1) A1 5 GP (1,2) A1 6 GC (3,4,5) A1 7 ARC (5,6,7) A1 8 GC (9) A1 9 GP (10,11) A1

K: R:

-4500 2538655

4300 3516151

15677 0 4194154 3007965

900 900 3468317 3197324

SubProg

The F1 button will allow you to make changes in the program source code. The usual functions are available to you. - F2 (DELETE) The F2 functions allows you to delete the indicated command.

PGM-MODE T1

Before you can leave the EST mode, you will be asked if you want to save the changes and insert them into the source code and program.

- F3 (KORRPAR) The function KORRPAR (F3) will only be offered if the current command includes weld parameters. For example; with the "Pause" command, this function will not be available. - F4 (TEACH) Once the robot has reached a point, you can select the teach mode by pressing the F4 key. All key functions are now TEACH enabled, which means that you can either move the robot or memorize new points. Pressing the ESC key will return you to the STEP mode.

The 2nd identification point of a partial circle and the 2nd and 3rd identification point of a full circle as well as program segments, which have been created through an "ONLINE- Program manipulation" (CHANGE, TRAN, MIRROR) cannot be changed within the EST program mode.

Page 4

Programming instructions ROTROL速 II

Bloc 6 - Standard

Program execution

1.2.3 Selection options following the STOP- command

LINE No. Command MainProg 1 VAR A A1 2 LIST 1=(4711,1,0,50,100,0,700,0,2,0,50,0 A1 3 MAIN A1 4 $ (1) A1 5 GP (1,2) A1 6 GC (3,4,5) A1 7 ARC (5,6,7) A1 8 GC (9) A1 9 GP (10,11) A1 actuel target point number: 1 K: -4500 4300 15677 0 R: 2538655 3516151 4194154 3007965

SubProg

900 900 3468317 3197324

F0004: STOP-button operated ! START key, change op. mode or abort [ESC] PGM-MODE T1

1.2.4 Trace memory

<- back PROG

Toggle-key DELETE

5 GP (1,2)

fwd ->

Stop

TEACH

Up to twenty program steps can be stored in the TRACE-memory and this will allow you to retrace that many robot movements. Once the limit has been reached, the following message will be displayed: F0292: TRACE- memory completed execution or empty

F0292: TRACE-MEMORY PROCESSED OR EMTY ! Please acknowledge with ESC-Key or switch OFF !

Follow the displayed information PGM.-MODE T1

The robot needs to be returned to its initial position in order for you to continue with the program run. The robot will have reached this position as soon as the word "TRACE" has disappeared from the screen.

End the function EST with STOP and ESC.

Programming instructions ROTROL速 II V7.0X/S/12.03

Page 5

START, change operation mode, abort [ESC,OFF] EST INTERR. POINT TEACH

- F1 button will allow you to switch back and forth between the EST and EXE mode. - F2 button interruption position, will allow you to change the current robot position in order to change the torch current tip for example. After pushing it once again, the robot will return to the previous position. - F4 The TEACH will be activated. One can only move the robot's mechanics.

After the Stop button has been pushed, the

Program execution

Bloc 6 - Standard

2 AUTOMATIC- mode The controller will start the program, which has been pre-selected for the automatic mode by means of turning the operating mode selector switch. You can select this function by pushing the AUTO button. The controller will ask you for the name of the program (which has been pre-selected) to be executed in the AUTOMATIC- mode.

Once you made your selection, you can switch the “operating selector switch” to position 4 (AUTO). The pre-selected program will start. The maximum speeds of the robot axes are in the Romat 320 example: Axis 1 = 151 º/s ; axis 2 = 151 º/s; Axis 3 = 176 º/s ; axis 4 = 290 º/s; Axis 5 = 338 º/s ; axis 6 = 410 º/s.

Caution!! In connection with peripheral equipment, all safety interlocks must be active. Safety doors have to be closed, light beam curtains activated and external axes have to be in the initial start positions etc..

A pre-selected program is only valid as long as it has not been deleted or another program has been selected. Therefore you will not have to select a program again if you want to start it in the automatic mode.

2.1 Operation of the robot system in automatic mode without teach pendant: -

Remove the teach pendant from the robot system and replace it by a dummy plug. Select the operation mode "AUTOMATIC" via operating selector switch. Switch on the robot system. Acknowledge the error message "Teach pendant communication disturbed" by the key ESC after having set the operating selector switch to "OFF" and then to "T1". Switch on power and go back to the operating mode "Automatic".

The user program which was selected at last in the automatic pre-selection is started.

Page 6

Programming instructions ROTROL® II

Bloc 6 - Standard

Program execution

3 Leeway of operating modes

LINE No. Command

MainProg

1 VAR A 2 LIST 1=(4711,1,0,50,100,0,700,0,2,0,50,0 3 MAIN 4 $ (1) 5 GP (1,2) 6 GC (3,4,5) 7 ARC (5,6,7) 8 GC (9) 9 GP (10,11) actual target point number: K: R:

SubProg

A1 A1 A1 A1 A1 A1 A1 A1 A1

This Leeway of operating modes has the advantage that you do not have to start over again if the program was interrupted.

L: 1 P: 1 + / - V: 50 1DR: 200 2 L:__U 3 H: 700 4AMP: 0 >> DEADMAN SWITCH NOT PRESSED << Change operation mode, abort [ESC,OFF]

-4500 4300 15677 0 900 900 2538655 3516151 4194154 3007965 3468317 3197324

Press release key, change operating mode or abort with ESC

Example: AUTOMATIC

SET UP T1

Should you have interrupted the program with the Stop button, turning the selector switch to T1, pushing the START button and the dead man switch, will enable you to continue the program run in the EXE mode. SET UP T2

AUTOMATIC

Should you have interrupted the program by letting go of the PHG dead man switch or by pushing the Stop button, turning the operating mode switch to AUTOMATIC and pushing the START button, will enable you to continue the program run in the AUTOMATIC mode. In this function, the program does not have to be pre-selected for the AUTOMATIC, however, after executing this function, it will be pre-selected for the AUTOMATIC mode. SET UP T1

SET UP T2

Should you have interrupted the program by letting go of the PHG dead man switch or by pushing the Stop button, turning the operating mode switch to T2, pushing the START and Dead man switch, will enable you to continue the program run in the SET UP T2 mode.

Programming instructions ROTROL速 II V7.0X/S/12.03

It is possible in the operating modes SET UP T1, SET UP T2 and AUTOMATIC, to switch into any other operating mode without leaving the current program, i.e. if a STOP button has been pushed. An exception is the "OFF" mode.

Page 7

Program execution

Bloc 6 - Standard

4 Line start If one had to interrupt the program for any reason, especially with complex and larger programs, it would be very time consuming and therefore unreasonable to restart the entire program from the beginning again. If the line start function would only be good for starting or stopping at a certain line, the disadvantage would be that some important parts of the program might be skipped. One example for such a command would be the call of weld parameters ($). The sum of all the information, which is defined by this kind of command, shall be called program state and will be described in the following although a more detailed account of subsequent information will not be explained, since one can easily refer to it on the monitor display.

Selection of line start function

START, switch off or function key STRFROM

Selection of end line

Caution!! whenever attempting a line start, one has to make sure that the robot can safely execute the program from that specific line.

START, switch off or function key F1: LINESTART

F5: ENDLINE

In order for the system to enable the line start in the first place, the program would have to be processed as a whole and during that process the program state will be stored and saved in a special memory location. The storage of the program state will be enabled though the RESTART command which has to be positioned above the line word MAIN. It will automatically be added while editing or creating a new program. When interrupting the program, the computer will automatically insert the following line: !ZSTART-LABEL

Page 8

Programming instructions ROTROL速 II

Bloc 6 - Standard

Program execution

Line.Nr

Command:

[c:]

MainProg

1 VAR A 2 LIST 1=(4711,1,0,50,100,0,700,0,2,0,50,0 3 MAIN 4 $ (1) 5 GP (1,2) 6 GC (3,4,5) 7 ARC (5,6,7) 8 GC (9) 9 GP (10,11)

AUTOMATIC

Subprog

A1 A1 A1 A1 A1 A1 A1 A1 A1

STEP- START WITHOUT SIMULATION STARTLINE: 5

(UP,Dn,PgUp,PgDn),continue (ENT),

previous (ESC)

The "!ZSTART-LABEL" is indicating a previously aborted program in line 4. The line start function will automatically offer this line as the start line to continue the process. The cursor is positioned on the point to which the robot was about to move before the interruption took place. In case of no program interruption , the processor would continue to the last program line and display the word (END).

CARL CLOOS SCHWEISSTECHNIK ROTROL-II V 7.00 L: 1 P: 1 + / - V: 50 1DR: 200 2 L:__U 3 H: 700 4AMP: 0 >> FREIGABETASTE GELOEST <<A1 ROTROL Z-INTERPRETER PROGRAMM: Betriebsartwechsel, Abbruch [ESC,AUS]

| F5: EXECUTION

Your options in this menu are: and

with the arrow keys

with the ENT button, you can jump to the next menu. The current line will now be accepted as the start line.

with the ESC button you will be returned to the previous menu.

with the F5 (EXE) button, you will start the program which will run to the end.

or keyboard cursor keys you can chose the start line.

After a start line has been selected or acknowledged, the ENT command will get you to the next menu (unless you have already pushed the F5 button).

CARL CLOOS SCHWEISSTECHNIK ROTROL-II L: 1 P: >> FREIGABETASTE ROTROL Z-INTERPRETER Betriebsartwechsel, Abbruch Line.Nr

GELOEST PROGRAMM: [ESC,AUS]

Command:

V7.00 1

[c:]

MainProg

1 VAR A 2 LIST 1=(4711,1,0,50,100,0,700,0,2,0,50,0 3 MAIN 4 $ (1) 5 GP (1,2) 6 GC (3,4,5) 7 ARC (5,6,7) 8 GC (9) 9 GP (10,11)

AUTOMATIC

<<A1 Subprog

A1 A1 A1 A1 A1 A1 A1 A1 A1

STEP-START WITHOUT SIMULATION STARTLINE: 5 (UP,Dn,PgUp,PgDn), previous (ESC) F1: STARTLINE | F2:ENDLINE | F3: PROGSTATE | F4: STARTP | F5: EXECUTION

Once the F1 (Z-START = Line start) key has been pushed, the screen will show:

The F1 and F2 function keys will allow you to define the Start or End line. IN this case however, contrary to the previous menu were the selection was carried out by "scrolling" with the and arrow keys, you will now have to enter the line number instead. After termination with the ENT button from either function, one is returned to the above shown menu.

Programming instructions ROTROL速 II V7.0X/S/12.03

Page 9

Program execution

Bloc 6 - Standard

F3 (PROGZU = Program state) The program state, which was saved by means of the RESTART, can now be edited by pushing the F3 (PROGZU) button. Once you have pushed the Y key , you can move the cursor to the individual parameters for editing purposes. Please keep in mind that some parameter spaces need to have values in them while others simply have to be answered with Y or N (yes or no) in order to be turned on or off. Changes are temporary, which means that they are valid only for the current program run. Illustration of 1st page CARL CLOOS SCHWEISSTECHNIK

ROTROL-II V 7.00

06.09.01

[c:]

AUTOMATIC

STEP-START STARTLINE: TYP: Abort

ENDLINE:

2nd Page

******** PROGRAM STATUS ******** CARL CLOOS SCHWEISSTECHNIK WELD LIST: START LIST [direct]: END LIST [direct]: TACK LIST: SSPD [SIDE/HEIGHT]: CIRO: ROF: EXTSYNON: CHANGE: CPMAX: TCP: TOV

1 0 0 0 0 2 10 N N 33 0 -1

ROTROL-II V 7.00

06.09.01

[c:]

AUTOMATIC

STEP-START STARTLINE: TYP: Abort

ENDLINE:

******** PROGRAM STATUS ******** 0 0

-4500 -1

DEVOPS: DEVOPM: 3D-TRANS: MIRRORING: WORK- COORD: STV: PTPMAX: PTPAC: PTPSPD: POS-TOL: [CP/PTP]

DO YOU WANT TO MODIFY [Y], Abort [N], NEW PAGE [P], SAVE [ANY OTHER KEY]

3rd Page CARL CLOOS SCHWEISSTECHNIK ROTROL-II V 7.00

06.09.01

[c:]

AUTOMATIC

N N N 0 100 100 100 N

DOU YOU WANT TO MODIFY [Y], ABORT [N], NEW PAGE [P], SAVE [ANY OTHER KEY]

STEP-START STARTLINE: TYP: ABORT

ENDLINE:

******** PROGRAM STATUS ******** LINON: VELOCITY: WIRE FEED: VOLTAGE/FREQUENCY: HEIGHT SET POINT: OSCILLATING AMPLITUDE: BACKGROUND CURRENT: PULSTIME: PULSVOLTAGE: START LIST:

N N N N N N N N N 0

Leaving the change mode by means of ESC. By pushing the "E" key you will be returned the most recent PHG menu. All changes of the program state will be ignored.

DOU YOU WANT TO MODIFY [Y]; ABORT [E]; NEW PAGE [P]; SAVE [ANY OTHER KEY]

- Pushing the P key will open another page will more parameters, i.e. you will be returned from the last page to the first. Except for the functions Y, E or P, all other keys will return you, including all changes you have made, back to the last shown program step.

Page 10

Programming instructions ROTROL速 II

Bloc 6 - Standard

Program execution

CARL CLOOS SCHWEISSTECHNIK ROTROL-II V 7.00 06.09.01 [c:] AUTOMATIC L: 1 P: 1 + / - V: 50 1DR: 200 2 L:__U 3 H: 700 4AMP: 0 >> FREIGABETASTE PROGRAMM: GELOEST << ROTROL Z-INTERPRETER A1 Betriebsartwechsel, Abbruch [ESC,AUS] Line.No.

command

MainProg

1 VAR A 2 LIST 1=(4711,1,0,50,100,0,700,0,2,0,50,0 3 MAIN 4 $ (1) 5 GP (1,2) 6 GC (3,4,5) 7 ARC (5,6,7) 8 GC (9) 9 GP (10,11)

Subprog

A1 A1 A1 A1 A1 A1 A1 A1 A1

STEP_START WITHOUT SIMULATION STARTLINE: 5

If there are several parameters part of a GP or GC command, you have the opportunity with the F4 (STARTP = Start point) key to chose a data entry point within the Point or parameter lists. Acknowledge your inputs with the ENT key in order to return to the previous menu or you can execute the program with all its changes by pushing the F5 (Execute) key.

(UP,Dn,PgUp,PgDn), previous (ESC) F1:STARTLINE | F2:ENDLINE| F3:PROGSTATE | F4:STARTP | F5: EXECUTION

5 Overlapping Start 5.1 Termination of program during the weld process An undesirable weld result will occur if the weld process is to be continued at the point of an interruption. In order to prevent this from happening you have the opportunity to continue welding at a point of several millimeters before the interruption took place even if the robot has been moved away from the interruption position as it might be the case during a current tip change. The functions F2 (DIRECT) or F3 (INDIRECT) have been created for this purpose. a program continuation by means of all other functions will not overlap the weld seam or might even stop the program. Continuation of the program without overlapping

- START The robot will continue and move to the next point. - Operating mode change The program can be continued in a different operating mode - ESC The program will be interrupted at this point. - F1 - EST

F4 (STARTP = Start point)

START, change of op.mode, abort [ESC,OFF] EST DIRECT INDIRECT TEACH Line No. command 1 VAR A 2 LIST 1=(4711,1,0,50,100,0,700,0,2,0,50,0 3 MAIN 4 $ (1) 5 GP (1,2) 6 GC (3,4,5) 7 ARC (5,6,7) 8 GC (9) 9 GP (10,11)

MainProg A1 A1 A1 A1 A1 A1 A1 A1 A1

Subprog

actuel target point number: 1 K: -4500 4300 15677 0 900 900 R: 2538655 3516151 4194154 3007965 3468317 3197324

Start key, change op. mode or abort [ESC] ! PGM-MODE T1

The program can be continued in the EXE-STEP mode. - F4 - TEACH In the TEACH mode, the robot can be moved to any point from which it will be possible to return to the interruption point without colliding. Programming instructions ROTROL速 II V7.0X/S/12.03

Page 11

Program execution

Bloc 6 - Standard

Continuation of the program with overlapping Another menu is available following the "DIRECT" and "INDIRECT" functions. The overlapping can be defined within it. -

F2 - DIRECT

Menu Direct - F1 / F2 CP

PTP

OVERLAP SECTION: 10 mm SECTION EXEC.

Line No. command 2 LIST 1=(4711,1,0,50,100,0,700,0,2,0,50,0 3 MAIN 4 $ (1) 5 GP (1,2) 6 GC (3,4,5) 7 ARC (5,6,7) 8 GC (9) 9 GP (10,11) Actuel target point number: 5 K: -4500 4300 R: 2538655 3516151

MainProg A1 A1 A1 A1 A1 A1 A1 A1

15677 4194154

0 3007965

Subprog

900 3468317

You can choose the movement characteristics for the return to the interruption point by means of the CP/ PTP command. Because of safety concerns, the "CP" command has priority.

900 3197324

Overlap start: DIRECT Approach:CP App.section: 30 mm F1:CP | F2: PTP | F3: UEB.STRECKE | F5: AUSFUEHR | ESC:ZURUECK

- F3 (Overlap length)

The default overlap length is 10 mm. The overlap length will automatically be reduced to the proper size if one enters a length which is greater than the already welded seam or greater than the distance to the previous point. PGM-MODE T1

The next display will show you he actual overlap length once you have entered a value between 1 and 99 mm, and acknowledged it with the ENT key.

Illustration: Overlapping DIRECT

The "DIRECT" overlapping function will cause the robot to move directly to the point from which it is supposed to continue to weld.

Weld direction Interruption point Overlapping point

Page 12

Programming instructions ROTROL速 II

Bloc 6 - Standard -

Program execution

F3 - INDIRECT

Menu Indirect

OVERLAP SECTION: 10 mm SECTION EXEC.

Line No. command MainProg 2 LIST 1=(4711,1,0,50,100,0,700,0,2,0,50,0 A1 3 MAIN A1 4 $ (1) A1 5 GP (1,2) A1 6 GC (3,4,5) A1 7 ARC (5,6,7) A1 8 GC (9) A1 9 GP (10,11) A1 Actuel target point number: K: R:

-4500 2538655

4300 3516151

Subprog

PTP

5 15677 0 4194154 3007965

900 900 3468317 3197324

As in the DIRECT menu, in this menu you have all of the before mentioned functions available to you.

Overlap start: INDIRECT Annaeherung: CP Ueb.Strecke: 30 mm F1:CP | F2: PTP | F3: APPR.SECTION | F5: EXECUTION | ESC:RETURN PGM-MODE T1

Illustration: Overlapping INDIRECT

The "INDIRECT" overlapping function will cause the robot to move first to the interruption point and from there to the position from which the weld is supposed to be continued.

Weld direction Interruption point Overlapping point

- F5 EXECUTE The program will continue with all changes made.

Programming instructions ROTROL速 II V7.0X/S/12.03

Page 13

Program execution

Bloc 6 - Standard

Continuation of program after an E-Stop The overlap start function will allow you to continue the program after an E-stop occurred. This is also the case after a Stop command was initiated. The use of the menus is identical and has been described already.

F0331:EMERGENCY STOP: Power switched off

F2:DIRECT | F3: INDIRECT

Once the power has been turned on again and the START button has been pushed, the program will continue from the current robot position. The selection buttons F2 / F3 allow you to activate the functions for the overlap start mode. DIRECT- or INDIRECTStart activated.

Once a selection has been made, the program will continue.

F0331:EMERGENCY STOP: Power switched off

F2:INTERR.POINT

Page 14

When an EMERGENCY STOP is released during a spatial movement (GP command) it can be necessary in some situations to change the position of the robot mechanics manually in order to set the robot axes free and to acknowledge the E-STOP. To adjust the correct axis positions the function "Interruption point" can be selected via button "F2". The robot mechanics are moved to the "remembered" position before continuation of the user program.

Programming instructions ROTROL速 II

Bloc 6 - Standard

Program execution

6 File AUTOEXEC Following the booting of the controller, the system will automatically search the memory for a file called AUTOEXEC. This file, if found, will automatically be executed. In it, commands and functions can be entered individually. For example ;

- transferring weld parameters within serial welding equipment connections - Activating the arc monitoring

which will be available after editing in all other programs.

Program example:

MAIN WPSPAR (0;1;2,3,0) WPSPAR (0;35;4,1,20,50,210,25) WPSPAR (0;54;10) FUNCON ARCCON FUNCON ONLCON

with the shown program example, the WPSPAR command will initiate a basic setup of welding equipment as well as transfer parameters to the welding equipment. The individual parameters can be found in the chapter "Serial transfer of weld parameters" in Bloc 4.

END

The function "arc start control" and "arc monitoring" are active in all executed programs. The exception is with program which functions have been disabled by certain commands. Available commands in AUTOEXEC ARC, CIRDEF, CIRA, OSCDIR, CHANGE, CHOFF, CHON, CIR, CIRS, CIRO, COMM, CPMAX, CPSPD, CRC, DEACT, DECHANGE, DEVCL, DEVER, DEVOP, DEVOP, DCO, DRIVEA, DRIVER, GC, GP, MIRROFF, MIRRON, NOP, OSC, PACC, PAUSE, PDIS, PLEAV, PSPD, PTPAC, PTPMAX, PTPSPD, REFE, RESET, ROF, SET, SSPD, STCP, STORPOS, STORPOSA, STORPOSR, STOV, STV, TRAN, TROFF, TRON, DELETE, WAITM, WAITS, WAITI, WRITE, GETPOS, GETPOSA, GETPOSR, POSTOLR, POSTOLE, TOLACT, SEAMPAR, SEGPAR, GENNAME, EXTDEF, EXTCHAIN, EXTSYNON, EXTSYNOFF, SASTOPAT,USRFKT, RENAME, FUNCON, FUNCOFF, MANAX, ANAOUT, EXTORIOF, NEXTP, GUNCHAON , GUNCHAOF, NEWTCP, LISTACC, RPOINTS, ANAIN, SAVE, DEFMASTER, DEFSLAVE, CYLPOINT, SETDD, MPE, SDSTOP, CALCFT, GETTIME, SETTIME, MAXCRTVE, MAXCRTAC, EDCO, WPSPAR, USRMSG, WRERR, DRIVESTA, BKJOB, KILL GETVAR, SETVAR, IF (the instruction IF..THEN..ELSE.. has to be in the same instruction line) Programming instructions ROTROL速 II V7.0X/S/12.03

Page 15

Block 7 - Standard

Weld technic functions

1 Weld parameter lists .................................................................................................... 2 1.1 Definition of weld parameter lists ....................................................................... 3 1.2 Activation of weld parameter lists ($, $S, $E, $H)................................................ 4 1.3 Parameters of MIG/MAG- power sources ........................................................... 5 1.4 Start list ............................................................................................................. 12 1.5 End crater list .................................................................................................... 14 1.6 Spot weld list ..................................................................................................... 15 1.7 Tandem welding ................................................................................................ 17 1.7.1 Parameter and signal transfer .................................................................... 18 1.7.2 Limitations of tandem welding .................................................................... 18 1.7.3 Additional parameters in the weld parameter list ....................................... 19 1.7.4 Program example ...................................................................................... 20 1.8 Power supply MC3R ......................................................................................... 21 1.8.1 Parameter and signal transfer .................................................................... 22 1.8.2 Changed parameters of the MC3R: ........................................................... 22 1.8.3 Weld parameter changes ........................................................................... 23 2 Parameter of WIG- weld power supplies ................................................................ 30 2.1 Normal list ......................................................................................................... 30 2.2 Start list ............................................................................................................. 34 2.3 End crater list .................................................................................................... 35 2.4 Cold wire feed ................................................................................................... 36 2.5 PPAW ............................................................................................................... 37 2.5.1 Normal list .................................................................................................. 37 2.5.2 Start list ...................................................................................................... 37 2.5.3 End list ....................................................................................................... 38 2.6 Weld parameter changes ................................................................................. 39 3 Global list definitions ................................................................................................. 41 4 Digital program selection .......................................................................................... 42 5 Serial transfer of weld parameter lists ..................................................................... 43 5.1 Table for serial data transfer.............................................................................. 45 5.2 PHG (teach pendant) Menu for serial data transfer ........................................... 55 6 Free list access .......................................................................................................... 61

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 1

Index

Weld technic functions

Block 7 - Standard

Weld parameter lists As industrial robots not only have to move through space but also follow the contours of components, it is necessary to enter appropriate information into the controller in order to determine for example the speed along the parts contour. This information is called Parameter. Parameters are contained in parameter lists. These lists are used for example to produce an optimum weld on a particular component. These parameter lists are not just used for welding process but also in cutting, gluing, pasting, measuring etc. Since Cloos predominantly apply their industrial robots for welding, we talk about WELD PARAMETER LISTS. This term will also be used in the following chapters. In addition, terms like START LIST, END CRATER LIST and SPOT WELD LIST appear.

1 Weld parameter lists

TESTRUN.S RESTART VAR A LIST_1=(5411,3,0,85,210,300,700,0,2,0,100,100,240,0,0,0,0,0,0,120,0,0) MAIN PAUSE RESTART ST:PAUSE VAR A SET (213) LIST_1=(5411,3,0,85,210,300,700,0,2,0,100,100,240,0,0,0,0,0,0,120,0,0) $1 MAIN GP (1,2) PAUSE GC (3) SWITCH SETOUT,214 !Einschalten des zweiten ST:PAUSE !Wire SG2 1,2mm SET (213) !Type: Fillet weld / horizontal

TESTRUN.S

In the weld parameter list, all necessary information is summarized in order to weld a component optimally. You can define a maximum of 255 weld parameter lists within a single program.

In order to influence the quality of any weld seam, the system is capable of executing a variety of arc control functions - depending on the software and connected welding power sources.

Page 2

Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

Once the dialog field becomes visible after pushing the button, the data entry field for the definition of weld parameter lists becomes also available. The button functions are shown below: Display of current program run

RESTART VAR A LIST_1=(5411,3,0,85,210,300,700,0,2,0,100,100,240,0,0,0,0,0,0,120,0,0) MAIN

List entry menus

Option: Arc control Parameter linking

WPSPAR- parameter for serial control

Insertion of selected weld parameter lists

List entry menus

Arc control

see chapter "Parameter linking" and options in the programming section

WPSPAR - Parameter for serial control

1.1 Definition of weld parameter lists The definition of weld parameter lists is shown in the following weld parameter dialog field:

Weld parameter list number Selection of weld power source

List types

MAG-Normal Impuls mode U/I- Control I/I- Control

weld power source currently used

Parameter in use

Delaytime Speed Wire Speed Voltage Height Groove Offset Osc. Frequency Osc. Amplitude Digi. Progr Select Choke

= = = = = = = = = =

Weld process

0 2.0 20.0 0.0 700 0 0.00 0.0 0 50

[ms] [cm/min] [m/min] [Volt] [ ] [ ] [Hz] [mm] [ ] [%]

Selection of parameters for editing

Value input Standard setting

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 3

Display of current or newly defined weld paramter lists.

Weld technic functions

Block 7 - Standard

1.2 Activation of weld parameter lists ($, $S, $E, $H) The activation command for a weld parameter list is $_(..) and it can either be direct in one line (e.g.: $_(1)) or chained in a run command (e.g.: GC_(1,2,$_1,3,$_2,4) ) in the program text.

VAR A LIST_1=(5411,3,0,85,210,300,700,0,2,0,100,100,240,0,0,0,0,0,0,120,0,0) MAIN ST:PAUSE !Wire SG2 1,2mm SET (213) !Nahtform Kehlnaht/Horizontal LIST LIST LIST LIST LIST LIST LIST LIST

1=(5211,3,0,47,125,240,0,0,0,10,60,21,370,0,0,0,0,10,45,40,20,0) 2=(5211,3,0,47,125,240,0,0,0,10,60,21,370,0,0,0,0,10,45,40,20,0) 3=(5211,3,0,40,110,230,0,0,0,35,60,21,370,0,0,0,0,10,45,40,20,0) 4=(5211,3,0,55,115,240,0,0,0,15,60,21,370,0,0,0,0,10,45,40,20,0) 5=(5211,3,0,50,120,240,0,0,0,20,60,21,370,0,0,0,0,10,45,40,20,0) 6=(5211,3,0,50,105,230,0,0,0,25,60,21,370,0,0,0,0,10,45,40,20,0) 7=(5211,3,0,50,105,230,0,0,0,25,60,21,370,0,0,0,0,10,45,40,20,0) 8=(5311,3,0,50,115,240,3,0,0,25,60,21,370,0,0,0,0,10,45,40,20,0)

Before activating the weld parameter list, they would have to be defined in the definition part of the program text. In addition it is possible to define separate welding parameter lists at the start or end of the weld path in order to influence the weld process at the start or end of the path. These welding parameter lists are called start lists or end crater lists and have to be entered prior to the "normal" welding parameter list in the definition part of the program.

Declared weld paramter lists

In order to Activate the Start- / End crater list please proceed ass follows: 1.

the 16th position in the "normal" weld parameter list as Start list and in the 17th position in the "normal" weld parameter list as End crater list.

Enter the number of the weld parameter list , which is then automatically activated by the "normal weld parameter list". 2.

the activation in a separate command line with the commands: $S_(..) $E_(..)

S = Start list E = End crater list

The tack seam list for "tack seams" with a straight movement can only be can only be activated in a separate command line with the command

$H_(..)

H = Tack seam list

button. Yet before doing The insertion of these commands can be executed with the so one has to select the preferred weld parameter list from the display. The appropriate command line will be assembled ($_(..), $S_(..), $E_(..) i.e. $H_(..))and inserted into the current program line. The weld parameter list will be valid until a new weld parameter list has been activated, respectivley the weld list number "0" (z.B. $S_(0); $E_(0)) is given.

Page 4

Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

1.3 Parameter of MIG/MAG weld power sources Depending on the application of different weld power sources and peripherals, the parameters of the weld list menus for the following items -

weld power sources the execution welding process (MAG-Normal - U/I or I/I - controlled - ,Impulse mode) and the list type (normal weld parameter list, Start-,End- and tack seam list)

will be shown on the display. After input of these "basic settings", all other parameters for ever y application will be made available.

Example: List input menu of the Quinto in the MAG-Impulse mode U/I-control (Normal list) 1st page Delaytime Speed Wire Speed Pulse Frequency Height Groove Offset Osc. Frequency Osc. Amplitude Digi. Progr Select Background Current

MAG PULS U/I 0 [ms] 2.0 [cm/min] 20.0 [m/min] 0.0 [Hz] 700 [ ] 0 [ ] 0.00 [Hz ] 0.0 [mm] 0 [ ] 50 [ A ]

= = = = = = = = = =

Delaytime

2nd page

Puls Time Peak Voltage Ang. of Osc. current Osc. Start List No. End List No. Gas Preflow Ignition Feed Burn back time Gas postflow

= = = = = = = = = =

MAG PULS U/I 2.1 [ms] 37.0 [Volt] 0 [grd] 0 [ ] 0 [ ] 0 [ ] 1 [sec] 4.5 [m/min] 40 [ms] 0.5 [sec]

Burn back time

Standard setting

Illustration of a list input menu within the editor

LIST1 = (5211,3,0,47,135,270,0,0,0,8,60,21,370,0,0,0,0,10,45,40,20,0) LIST 2 = (5211,3,0,47,125,240,0,0,0,10,60,21,370,0,0,0,0,10,45,40,20,0) LIST 3 = (5211,3,0,40,110,230,0,0,0,35,60,21,370,0,0,0,0,10,45,40,20,0) LIST 4 = (5211,3,0,55,115,240,0,0,0,15,60,21,370,0,0,0,0,10,45,40,20,0) LIST 5 = (5211,3,0,50,120,240,0,0,0,20,60,21,370,0,0,0,0,10,45,40,20,0) LIST 6 = (5211,3,0,50,105,230,0,0,0,25,60,21,370,0,0,0,0,10,45,40,20,0) LIST 7 = (5211,3,0,50,105,230,0,0,0,25,60,21,370,0,0,0,0,10,45,40,20,0) LIST 8 = (5311,3,0,50,115,240,3,0,0,25,60,21,370,0,0,0,0,10,45,40,20,0) LIST 9 = (5211,3,0,50,110,240,0,0,0,20,60,21,370,0,0,0,0,10,45,40,20,0) LIST 10 = (5211,3,0,50,110,240,0,0,0,20,60,21,370,0,0,0,0,10,45,40,20,0) LIST 11 = (5211,3,0,50,110,240,0,0,0,20,60,21,370,0,0,0,0,10,45,40,20,0) LIST 12 = (5211,3,0,50,110,240,0,0,0,20,60,21,370,0,0,0,0,10,45,40,20,0)

Insert

Correction

Jump

Delete

Standard setting

The editor will show the list of parameters in sequence (1st position = 1st parameter; 2nd position = 2nd parameter and so on). Parameters which have several different inputs based on different weld modes will be inserted into the text .

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 5

Weld technic functions

Block 7 - Standard

1. Program number SQ Every weld power source has an SQ number assigned to it in order to differentiate it from other types power sources. SQ = Stromquelle = welding machine Weld power sources marked in the text with an * are capable of analog, serial and digital signal transfer. Serial connections have the added advantage of enabling the operator to change parameters via the list menu by way of the WPSPAR command. For this the following settings in the welding machine are necessary: Basic menu - the menu item operating mode must be set to „external“ and Configuration menu under robot serial (only for GLC 403 Quinto II) - the menu items robot serial „On“ machine no. „1-255“ take over data from robot list „On“ WPSPAR „On“

SQ-Numbersn

MIG-MAG-power sources

1111 2111 3111 4111 4211 4311 5111 5111 5211 5211 5311 5311 5411 5411 5611 5711 6111 6211 6511 8111

Page 6

403 PA-TS 603 PA-TS GLC 357 R GLC 357 R1 GLC 553 / 353 MC3R GLC 553 / 353 MC3R Tandem and/or double wire 503 QUINTO Profi* 353 QUINTO PROFI (350 Amp)* 553 QUINTO Profi Forte 353/553 QUINTO Profi V1.60* 553 QUINTO Profi SD (Tandem)* 853 QUINTO Forte Doppeldraht (Tandem) 553 Quinto (Digitalanwahl) Quinto Profi SD V1.60 (Tandem) Quinto II Quinto II (Tandem) 353 / 403 Robomag II 403 Robomag II (Double wire and/or tandem) 503 Robomag II 603 PA-TS Rapid-Melt (wire feed max. 35m/min)

Programming instructions ROTROL® II

Block 7 - Standard

Weld technic functions

The SQ- Numbers of the WIG-power sources will be mentioned in the WIGWeld parameter lists. (see chapter "Parameters of the WIG-power sources). for digital connections see chapter 5 "Digital program selection"

Status Result of "weld with/without pulse" with pulse = 3 without pulse = 1

Pause time The values shown here will not be activated unless a parameter list in connection with a weld path command had been activated. Unit = ms Range of valid values = 0..9999

Speed This parameter will enable you to adjust the path speed for a perfect weld. Unit = cm/min Range of valid values = 2..999

Wire advance Unit = m/min GLC 403 PA-TS GLC 603 PA-TS GLC 357 R GLC 357 R1 MANU-MAG 2

= = = = =

0..20 0..20 0..20 0..20 0..20

353 Quinto 503 Quinto 553 Quinto 403 Quinto II 603 Quinto II

= = = = =

353 Quinto 503 Quinto 553 Quinto 403 Quinto 603 Quinto

= 0..24 = 0..24 = 0..30 = 0..30 = 0..30

353 MC3 = 0..24 553 MC3 = 0..30

Voltage

Unit = V Value range at GLC 403 PA-TS GLC 603 PA-TS GLC 357 R GLC 357 R1 MANU-MAG 2

15..37 18..44 18..49 12..30 12..42

= 12..40 = 12..47 = 12..47 = 15..34 = 15..44

353 MC3 = 12..40 553 MC3 = 12..44,5

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 7

Weld technic functions -

Block 7 - Standard

Pulse frequency

Unit = Hz Range of valid values = 0..400

Height set value This parameter will allow you to define the wire distance during seam tracking (see also “arc sensor” in Block 9, -Options- ). Units = none Valid value range = 0..1000 (Were "0" is the smallest and "1000" the largest wire distance.)

Side to side offset Will define the torch offset in relation to the detected groove. Unit = 1/10 mm Valid value range = - 999 .. 999

Oscillation frequency

changeable from version V7.00.00.31 on

Unit =Hz Valid value range = 0..99 The oscillating frequency is infinitely adjustable from 0.1 to 5.56 Hz. Oscillating frequencies which have been entered by the command „ROF“ are overwritten (see also block 9, chapter 17.3 „Oscillating frequency“).

10. Oscillation amplitude This parameter allows you to adjust the width of the oscillation. Unit = mm Valid value range = 0..99,9

Page 8

Programming instructions ROTROL® II

Block 7 - Standard 11. -

Weld technic functions

*Choke

During welding without pulse, this parameter will influence the process dynamics to optimal conditions. Units = % Valid value range = 0 .. 100 -

Base current

With the pulse mode activated, this parameter changes the base current setting. Unit = Amp

12. -

Valid value range = dependent on welding machine Using a GLC 403 PA-TS = 0..400 Using a GLC 603 PA-TS = 0..600 Using a QUINTO = 0..500 Using a Quinto II = 0..400 / 500 Pulse time

This parameter allows you to adjust the pulse duration. Unit = msec Valid value range = 0..9,9 using QUINTO = 0..5 using Quinto II = 0,5..5 13. -

(base setting MAG PULSE U/I)

Pulse voltage

The pulse amplitude can be adjusted with this parameter. Unit = V The valid value range is dependant on the welding machine: Using a GLC 403 PA-TS Using a GLC 603 PA-TS Using a MANU-MAG2 Using a QUINTO

= = = =

(base setting MAG Pulse I/I)

*Pulse voltage

18..42 18..44 10..50 12..50

This parameter will influence the pulse voltage If the welding machine base setting is changed to "MAG Pulse I/I" Unit = Ampere Value range = 0.. 700

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 9

Weld technic functions

Block 7 - Standard

14. Oscillation angle This parameter changes the plane of the oscillation angle in relation to the wire. Unit = Degrees of angle Valid value range = -90..90 A "0" degree angle setting will cause it be perpendicular to the wire direction. 15. Actual oscillation Determines the behaviour of the oscillating plane (oscillating rotation) when the torch setting angle is altered during the welding path. Value = none Applicable range of values = 0..20 0

Irrespective of the torch orientation, the same oscillating plane is maintained as was determined at the beginning of the seam.

The oscillating plane is altered (actualised) during seam welding to maintain the relationship between oscillating plane and wire direction. The oscillating plane is always 900 in wire direction.

11..20 =

Oscillating and height direction are activated by OSCDIR (see chapter "Oscillation") If the value is smaller than 10, the standard behaviour, i.e. as with value "0", is used.

16. Start list This will activate a start list in which you can optimize the arc process. Unit = none Valid value range = 1..999 17. End crater list This will activate an end crater list, in which you can program an optimal weld seem finish. Unit = none Valid value range = 1..999 18. *Gas pre-flow This parameter will adjust the duration of time before the arc is allowed to ignite. Unit = Seconds Valid value range = 0..9.9 Page 10

Programming instructions ROTROL速 II

Block 7 - Standard 19. -

Weld technic functions

*Ignition feed

This parameter influences the wire feed during arc ignition. Unit = m/min Valid value range = 0..25 -

*Arc length

This parameter will change the length of the arc, if the base setting for "MAG Pulse I/I - control" has been set. Unit = % Valid value range = -99..99

20. *Burnback time This parameter influences the time that the voltage stays on, after the wire feed has stopped at the end of the seem, thus shortening the welding wire for the next arc ignition. Unit = % Valid value range = 0..250 21. *Gas post flow This parameter influences the duration of time that the torch will remain above the end of the seam, ejecting gas after the arc has been turned off. Unit = Seconds Valid value range = 0..9.9

22. Digital Prog-Selection This parameter activates data sets (jobs) which were stored in the "Job memory" of the Quinto or MC3R. Selection can be made serially or via hardware. UNIT = none Valid value range:

Quinto Quinto II

1..255 1..20000

Depending of the design of the welding machine up to 20,000 data sets can be activated.

Parameters which are marked “*“ can only be used if a serial connection to the welding machine is in place.

Programming instructions ROTROL® II

V7.0X/S/12.03

Page 11

Weld technic functions

Block 7 - Standard

1.4 Start list The start list can optimize the beginning of a weld seam through the modification of a pause duration or by specifying the start location of a weld path. If you have entered a specific pause duration in Parameter 3 of the start list, the robot will wait for pecisely that amount of time, above the start point of the weld path. Once this amount of time has elapsed, the robot will switch to the weld parameter list and start moving down the weld path using all parameters from within the weld list. Should you wish to overlap the weld at the beginning of a path, you would need to enter a value in Parameter 17 of the start list first. This value will ensure that the robot does not ignite the arc until it has moved through this distance. This distance will then be welded in the reverse direction, utilizing the weld list parameters. Once it has reached the beginning of the weld path, it will reverse direction once again, switching to the weld parameter list and welding to the end of the programmed path. You can also optimize the begiining of a weld seam by combining the Pause duration with the Start path length. For this, you will have all other parameters of the start list available to you. Input matrix for a start list Example for Impulse mode settings

Delaytime Speed Wire speed Pulse Frequency Height Groove Offset Osc. Frequency Osc. Amplitude Digi Progr Select Background Current

= = = = = = = = = =

0 2.0 20.0 0.0 700 0 0.00 0.0 0 50

[ms] [cm/min] [m/min] [Hertz] [ ] [ ] [Hz ] [mm] [ ] [A]

Pulse Frequency Background Current Pulse time Peak Voltage Ang. of Osc. current Osc. Crater Fill Lenght Burn back time Gas Preflow Ignition Feed

= = = = = = = = =

50 2.2 34.0 0 0 10 30 0.5 3.5

[A] [ms] [Volt] [grd] [ ] [mm ] [ms] [sec] [m/min]

Crater Fill Lenght

The maximum start path length is 100 mm.

Page 12

Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

Example for settings without impulse

Delaytime Speed Wire Speed Voltage Height Groove Offset Osc. Frequency Osc. Amplitude Digit. Progr. Select Choke

= = = = = = = = = =

0 2.0 20.0 0.0 700 0 0.00 0.0 0 50

[ms] [cm/min] [m/min] [Volt] [ ] [ ] [Hz ] [mm] [ ] [%]

Voltage

Osc. Amplitude Digit Progr. Select Choke Ang. of Osc. current Osc. Crater Fill Lenght Burn back time Gas Preflow Ignition Feed

= = = = = = = = =

0.0 0 50 0 0 0 30 0.5 3.5

[mm] [ ] [%] [grd] [ ] [mm ] [ms] [sec] [m/min]

Crater Fill Lenght

If these parameters have been entered correctly, the programmtext might look like the one shown to the right, were the start list is linked with the weld parameter list.

RESTART VAR A LISTS 1 = (5211,3,0,43,40,200,700,0,2,0,50,100,240,0,0,0,0,5,35,30,5,0) LISTE 1 = (5211,1,0,30,62,340,700,0,2,0,50,100,240,0,0,0,0,5,35,30,5,0) LIST_1=(5411,3,0,85,210,300,700,0,2,0,100,100,240,0,1,1,0,0,0,120,0,0) MAIN ST:PAUSE !Draht SG2 1,2mm SET (213) !Nahtform Kehlnaht/Horizontal $ (1) !Gas: 92% Ar / 8% CO2 $S (1) GP (1,2) !Drahtabstand: 18mm GC (3) SWITCH SETOUT,214 !Einschalten des zweiten

RESTART VAR A LISTS 1 = (5211,3,0,43,40,200,700,0,2,0,50,100,240,0,0,0,0,5,35,30,5,0) LISTE 1 = (5211,1,0,30,62,340,700,0,2,0,50,100,240,0,0,0,0,5,35,30,5,0) LIST_1=(5411,3,0,85,210,300,700,0,2,0,100,100,240,0,1,1,0,0,0,120,0,0) MAIN ST:PAUSE !Draht SG2 1,2mm SET (213) !Nahtform Kehlnaht/Horizontal $ (1) !Gas: 92% Ar / 8% CO2 GP (1,2) !Drahtabstand: 18mm GC (3) SWITCH SETOUT,214 !Einschalten des zweiten GC (4,5) !Schweißdrahtes

call for a multi linked Start list

Should the start list be activated in an isolated condition, the program text to the left shows how it will appear.

call for a isolated Start List

Programming instructions ROTROL® II

V7.0X/S/12.03

Page 13

Weld technic functions

Block 7 - Standard

1.5 End crater list A problem in welding is the creation of a crater at the end of a welded path. This crater is comon but it needs to be filled in order to ensure the strength and integrety of the weld. End crater lists are available to you in order to fill these craters in terms of time and length. Once you have entered a end crater time value in Parameter 16 = Crater Fill Time of the end crater list, the robot will wait, with the arc turned on, at the end of the weld path, filling the crater, using the parameter of the weld list. This will ensure strength and integrety of the weld. If you like to enter a distance instead of a time value, Parameter 17 = End Crater Section of the end crater list will allow you to do so. In this case, the robot will reverse direction at the end of the weld path, filling the crater and thus ensuring the quality and entegrety of the weld. At times it might be nessasary to combine and utilize both end crater list parameters in order to fill a larger end crater, which means that after the robot has completed the distance as entered in Parameter 17 = End Crater Section, it will now pause, utilizing the crater fill time from Parameter 16 = Crater Fill Time. When starting the end crater list, you can enter an additional time via parameter 1 = Waiting time. The robot waits with burning arc and then covers the end crater distance Of course, you can utilize all the other parameters within the end crater list in order to maximize the quality of your end crater fill. Input matrix for a end crater list Example with impulse mode

Parameter "1" Parameter "16" Parameter "17"

Delaytime Speed Wire Speed Pils Frequency Height Groove Offset Osc. Frequency Osc. Amplitude Digi. Progr Select Background Current

= = = = = = = = = =

0 2.0 20.0 0.0 700 0 0.00 0.0 0 50

[ms] [cm/min] [m/min] [Hertz] [ ] [ ] [Hz ] [mm] [ ] [A]

Delaytime

Background Current Pulse time Peak Voltage Ang. of Osc. current Osc. Crater Fill Time End Crater Section Burnback time Gas Postflow

= = = = = = = = =

50 2.2 33.0 0 0 0 0.0 30 0.5

[A] [ms] [Volt] [grd] [ ] [ms] [mm] [ms] [ms]

Crater Fill Time

The maximum end crater fill pause time is 9999 ms. The maximum end crater fill path length is 99,9 mm.

Page 14

Programming instructions ROTROL速 II

Block 7 - Standard Example without impulse mode

Delay time Speed Wire speed Voltage Height Groove Offset Osc. Frequency Osc. Amplitude Digit. Prog-selection Choke

= = = = = = = = = =

Delay time

0 2.0 20.0 0.0 700 0 0.00 0.0 0 50

Weld technic functions

[ms] [cm/min] [m/min] [Volt] [ ] [ ] [Hz ] [mm] [ ] [%]

Osc. Amplitude Digit Prog-selection Choke Ang. of Osc current Osc. Crater Fill Time End Crater section Burnback Time Post gas

= = = = = = = = =

0.0 0 50 0 0 0 0.0 30 0.5

[mm] [ ] [%] [grd] [ ] [ms] [mm] [ms] [sec]

Crater Fill Time

Linked start- and end crater lists have to appear in the declaration section of the proper weld parameter list. If you activate a linked weld parameter list in connection with a start and end crater list, then the direct call command will cause the robot to work with these parameters only. You cannot activate the start- and end crater lists from wihtin a GCcommand.

1.6 Tack weld lists At times it is nessasary to tack weld components before welding them together. These tack welds are composed of several short seams along the path of the weld. In order to avoid programming the spacing and lengths of these short welds, you can chose to access tack weld lists. These lists will allow you to space the weld tacks evenly by entering the parameters for the appropriate tack lengths, the weld speed and empty spacing in between the tacks. At the end of the tack weld seam you can even utilize a end crater list if you like. The above mentioned "speeds" and "empty spaces" are entered into Parameter 16 and 17. In Parameter 18 of the tack weld list, the length of the tacks are entered. Except for Parameter 19, you can use all other parameters in order to optimize your tack weld process. Parameter 19 will allow you to chose the end crater list in order to fill the end crater of the tacks. If you have entered an end list into a tack weld list, then distance shown in the endlist will be ignored.

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 15

Weld technic functions Input matrix for a tack weld list

Block 7 - Standard

Example with Impulse mode The maximum speed between the tacks is 1000 cm/min

Delaytime Speed Wire Speed Pulse Frequency Height Groove Offset Osc. Frequency Osc.Amplitude Digi Progr Select Background Current

= = = = = = = = = =

0 2.0 20.0 0.0 700 0 0.00 0.0 0 50

[ms] [cm/min] [m/min] [Hz] [ ] [ ] [Hz ] [mm] [ ] [A] Pulstime Peak Voltage Ang. of Osc. current Osc. Gap speed Gap lenght Tack lenght End List No. Burnback time Gas Postflow

Delaytime

= = = = = = = = = =

0.0 0.0 0 0 0 0.0 0.5 35 30 0.5

[ms] [Volt] [grd] [ ] [cm/min] [mm] [mm] [ ] [ms] [sec]

Gap speed

The maximum values for the spaces between the tacks and tack weld lengths are 999,9 mm.

You cannot activate tack weld lists from within a GC-command. The highest list number is: Start list End list Tack weld list Standard list

999 999 999 9999

Tack weld lists can only be activated as a separate entity withn the text of the program. If you want to link a End crater list and a tack weld list, the end crater list needs to be placed above tack weld list in the declaration of the program. Restrictions: It is not possible to activate a "tack seam list" include a GC- Command If an end crater list (LISTE) is called up within a tack seam list (LISTH) the parameters „Endcrater distance“ and „End waiting time“ are not activated which is dependent on the system. Waiting times when using a tack seam list: Waiting time at the start of the weld path: Waiting time (Param. 3) of tack seam list (LISTH) Waiting time at the end of weld path: Waiting time (Param. 3) of tack seam list (LISTE) Page 16

Programming instructions ROTROL® II

Block 7 - Standard

Weld technic functions

1.7 Tandem welding The TANDEM-weld procedure drastically increases the amount of welding wire used and thus increase the welding speed. At the same time it will increase production output and result in a much higher weld seam quality. The Tandem weld process is mostly applied in connection with the serial controllable welding power source Quinto but it can also be applied with the analog controllable welding power source MC3R. The functionality is the same in both cases. Different weld seam contours need the flexibilty offered by a Tandem weld system.

The following comands will allow you to chose between individual application options during the weld process.

Application options

Commands

Results

Tandem*

SWITCH_TANDEM

- welding will be executed with both wires. Data will transferred to weld power sources 1 and 2

Tandem

SWITCH_TANDEM1

- Welding will be executed with wire 1 Data will be transferred to weld power source 1

Tandem

SWITCH_TANDEM2

- Welding wil be executed with wire 2 Data will be transferred to weld power source 2

Single wire

SWITCH_SINGLE

- Welding will be executed after switching torches (Torch change system) with separate single wire torch. Data will be transferred to weld power source 1

During the Tandem operating mode (SWITCH_TANDEM) both weld power sources can be configurd seperately with the WPSPAR_(..) command.

If the procedure welding "Tandem with one wire" has been selected, the power source which is not needed should not be turned off. Enter the proper power source number in the parameter "Equipment Nr. robot".

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 17

Weld technic functions

Block 7 - Standard

1.7.1 Parameter and signal transfer The a/m described commands (SWITCH_TANDEM..) execute the serial transfer of signals and parameters of the robot controller to the welding power sources being connected via the coupling and connecting module (KVM box). But due to safety reasons a release for each welding power source is necessary for the signal transfer (e.g. arc on) which is made by means of digital outputs. Output 213 activates the first power source, output 214 activates the second power source. In addition, the guide wire for the seam tracking system (see Options - Chapter: Arc Sensor) can be determined by output 215. inactive output 215 active output 215

Measured values of power source 1 are applied. Measured values of power source 2 are applied.

The guide wire must run ahead in welding direction because otherwise wrong or incorrect measured values will be evaluated. The direction of both welding wires must be parallel to the weld seam. The angle of attack depends on the process and may vary.

The coupling and connection module is not necessary when using the welding machines GLC 403 (Quinto II) because they are directly connected to each other. Adjust the release of the welding machines and the guiding wire for the seam tracking system via the command WPSPAR (chapter 5 „Process configuration“ with number 80) resp. in the configuration menu of the welding machines.

1.7.2 Limitations of Tandem welding Out-of-position weldings such as vertical-up welds, vertical-down welds >45 degress, too narrow V-seams < 40 degrees and sheet thicknesses below 1.5 mm cannot be executed.

See also chapter "Serial transmission of weld parameters" in block 6.

Page 18

Programming instructions ROTROL® II

Block 7 - Standard

Weld technic functions

1.7.3 Additional parameters in the weld parameter list - Welding without impulse 12. -

Wire feed 2

Value = m/min For the applicable range of values please refer to parameter "Wire feed". 13. -

Voltage 2

Value= V For the applicable range of values please refer to parameter "Voltage". - Welding with impulse Wire feed 2

12. -

Value = m/min For the applicable range of values please refer to parameter "Wire feed". 13. -

Pulse frequency 2

Value= Hz For the applicable range of values please refer to parameter "Pulse frequency".

In this case, the parameters impulse time and impulse voltage will not be transmitted by the weld parameter list. The command WPSPAR can change these parameters.

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 19

Weld technic functions

Block 7 - Standard

1.7.4 Program example RESTART ! LIST FOR TANDEM (BOTH WELDING MACHINES) DIGITAL PROGRAM SELECTION TO 10, ! THIS MEANS QUINTO LIST 10 IS ACTIVATED ! LIST 1 = (5311,3,0,100,145,200,480,10,0,10,80,85,150,0,0,0,0,0,35,30,0,10) ! LIST FOR SIGNLE WIRE DIGITAL PROGRAM SELECTION TO 20, ! THIS MEANS QUINTO LIST 20 IS ACTIVATED ! LIST 2 = (5211,3,0,90,145,200,480,10,0,10,80,85,150,0,0,0,0,0,35,30,0,20) MAIN SET (213,214) SWITCH TANDEM

! SWITCH MACHINE TO TANDEM (PRESET BY CONFIG)

!************ NOW ALL DATA TO WELDING MACHINE 1, QUINTO – PROGRAM NO.: 10 ************ WPSPAR (0;0;1) ! ALL FOLLOWING WPSPAR COMMANDS ONLY REFER TO ! WELDING MACHINE 1 WPSPAR (10;4;1) ! WELDING MACHINE 1 TO: PROCEDURE -> MAG PULSE WPSPAR (10;1;0,3,4) ! WELDING MACHINE 1 TO: MATERIAL -> STEEL ! WIRE -> 1,2 MM ! GAS -> 92%AR, 8%CO2 WPSPAR (10;35;2) ! WELDING MACHINE 1 TO: MAG PULSE -> PULSE EDGE STEEPNESS 2 WPSPAR (10;22;370,21)! IN CASE OF TANDEM IT IS NOT POSSIBLE TO SET PULSE TIME AND PULSE ! HEIGHT IN THE ROTROL LIST. THEREFORE BOTH PARAMETERS MUST BE ! TRANSMITTED VIA WPSPAR ! !************ NOW ALL DATA TO WELDING MACHINE 2, QUINTO – PROGRAM NO.: 10 ************ WPSPAR (0;0;2) ! ALL FOLLOWING WPSPAR COMMANDS ONLY REFER TO ! WELDING MACHINE 2

! same setting as with welding power source 1 ! THE WELDING MACHINES HAVE GOT THEIR PARAMETERS WHICH ARE FILED IN THE NON! VOLATILE MEMORY OF THE QUINTO GP (1,2) GC (3)

!1. SEAM WITH TANDEM TORCH AND BOTH WIRES ! THE LIST PARAMETERS ARE TRANSFERRED TO BOTH ! WELDING MACHINES

SWITCH TANDEM1

!2. SEAM WITH TANDEM TORCH AND ONLY 1. WIRE ! INFORM THE ROTROL: ARC AND ERROR MESSAGE ! ONLY WELDING MACHINE 1

$ (1) GP (4,5) GC (6)

SWITCH TANDEM2

$ (1) GP (7,8) GC (9)

Page 20

! THE LIST PARAMETERS ARE TRANSFERRED TO 1. ! WELDING MACHINE !3. SEAM WITH TANDEM TORCH AND ONLY 1. WIRE ! INFORM THE ROTROL: ARC AND ERROR MESSAGE ! ONLY WELDING MACHINE 2

! THE LIST PARAMETERS ARE TRANSFERRED TO 2. ! WELDING MACHINE

Programming instructions ROTROL® II

Block 7 - Standard SWITCH TANDEM

$ (1) GP (16,17) GC (18)

Weld technic functions !4.SEAM WITH TANDEM TORCH AND BOTH WIRES ! SWITCH TO TANDEM

! THE LIST PARAMETERS ARE TRANSFERRED TO BOTH ! WELDING MACHINES

CALL BRE2 SWITCH SINGLE WPSPAR (20;35;3)

$ (2) GP (30,31) GC (32)

!5. SEAM WITH TORCH CHANGE AND SINGLE TORCH ! CHANGE TO SINGLE TORCH (CHANGING SYSTEM) ! SWITCH TO SINGLE WIRE TORCH ! WELDING MACHINE TO: MAG PULSE -> PULSE EDGE STEEPNESS 3 ! TARGET INDICATION (WPSPAR 0;0;1) IS NOT NECESSARY AFTER ! COMMAND SWITCH SINGLE ! ACTIVATE LIST FOR SINGLE WIRE TORCH !

CALL BRE1 SWITCH TANDEM

! THE LIST PARAMETERS ARE TRANSFERRED TO THE ! WELDING MACHINE ! CHANGE TO TANDEM TORCH

END

1.8 MC3R Welding power source When using a type MC3R welding machine the welding capacity is set via the parameter wire speed. Because of the factory setting (wire diameter, material, shielding gas etc.) the welding voltage is automatically adapted. Parameter arc length (voltage precise adjustment) enables to set the arc softer or harder in order to improve the welding result. With regard to the different cable lengths it is also required to react on possible capacitance losses in the cables (capacitance resistance). Parameter pulse adaptation allows to modify the pulse shape in the range of zero to one hundred per center in order to largely compensate the losses. The adaptation for the different lengths of connection cable assemblies is divided as follows: Pulse adaptation 0% 50 % 100 %

Lengths of connection cable assemblies 1 meters 5 meters > 10 meters

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 21

Weld technic functions

Block 7 - Standard

1.8.1 Parameter and signal trqansfer The parameters of a weld parameter list are transferred analogously. Signals (arc on) are controlled by digital inputs and outputs. A serial control is not provided for the MC3R. Another control possibility of the MC3R is the optional "Digital program selection" with which up to fifty parameter sets (jobs) can be selected. A combination of digital and analogous control completes the functionality of the MC3R at the robot controller.

1.8.2 Changed parameters of the MC3R: - with impulse 5.

Wire feed

Value = m/min Applicable range of values= 6.

Arc length

Value = none Applicable range of values = -100..+100 11. -

Pulse adaptation

Value =% Applicable range of values =

0..100

Additional parameters of the MC3R Tandem - with impulse 12. -

Wire feed 2

Value = m/min 13. -

Arc length 2

Value = % Applicable range of values = -100 .. +100

Page 22

Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

1.8.3 Weld parameter changes Teach pendant display when MIG/MAG welding without impulse active parameter list

EXE/P1 +/-V:_43

L: 1DR:118

2U:270

5 3H:820

P: 12 4AMP:_23

8 GC (..)

After pressing the movement and number key AXIS6 :

EXE/P1 1DL:_40

2SO:__0

L: 5 P: 3PF:__0 4PT:_22

12 5PU:330

8GC (..)

4AMP:Osc. Amplitude 3H:

Height (only for active arc sensor)

4PT: (unused) 3PF: Osc. Frequency

2U: Voltage 1DR: Wire speed +/-V: Speed

5PU: (unused)

2SO: Groove offset 1DL: Choke

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 23

Weld technic functions

Block 7 - Standard

Teach pendant display when MIG/MAG welding with impulse (U/I control)

EXE/P1 +/-V:_55

L: 1DR:139

2F:201

5 3H:652

P: 12 4AMP:_18

8 GC (..) After pressing the movement and number key AXIS6 :

EXE/P1 1IG:_50

L: 2SO:__0

3PF:__2

5 4PT:_20

P: 12 5PU:360

8GC (..)

4AMP: Oscillating amplitude

5PU: Impulse voltage

3H: Height set value (only for active arc sensor)

4PT: Impulse time

2F: Impulse frequency

3PF: Oscillating frequency

1DR: Wire feed +/-V: Welding speed

Page 24

Programming instructions ROTROL速 II

2SO: Groove offset 1IG: Background current

Block 7 - Standard

Weld technic functions

Teach pendant display when MIG/MAG welding with impulse (I/I control) EXE/P1 +/-V:_55

L: 1DR:139

2F:201

5 3H:652

P: 12 4AMP:_18

8 GC (..)

After pressing the movement and number key AXIS6 : 5PI:

3H: Height set value (only for active arc sensor)

4PT: Impulse time

2F: Impulse frequency

3PF: Oscillating frequency

1DR: Wire feed +/-V: Welding speed

EXE/P1 1IG:_50

2L:__0

Impulse current

L: 5 3PF:__2 4PT:_20

2L:

Arc length

1IG:

Background current

P: 12 5PI:360

8GC (..)

After pressing the movement and number key AXIS6 :

EXE/P1 1SO:_50

8GC (..)

1SO: Groove offset

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 25

4AMP: Oscillating amplitude

Weld technic functions

Block 7 - Standard

Teach pendant display when MIG/MAG welding without impulse Application: (Double wire resp. Tandem welding)

EXE/P1 +/-V:_53

L: 1DR:_75

2U:_21

5 P: 12 3DR2:_72 4U2:_28

8 GC (..) After pressing the movement and number key AXIS6 :

EXE/P1 1DL:__0

2SO:__0

L: 5 3PF:__0 4H:_0

P: 12 5AMP:0

8GC (..)

4U2: Voltage 2

5AMP: Oscillating amplitude

3DR2:Wire feed 2

4H:

2U:

Page 26

Voltage 1

Height set value (only for active arc sensor)

3PF: Oscillating frequency

1DR: Wire feed 1

2SO: Groove offset

+/-V: Welding speed

1DL: Choke

Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

Teach pendant display when MIG/MAG welding with impulse (U/I control) Application: (Double wire resp. Tandem welding)

EXE/P1 +/-V:_53

1DR:_75

2F:210

L: 5 3DR2:_72

P: 12 4F2:280

8 GC (..)

EXE/P1 1IG:_90

L: 2SO:__0

3PF:__0

5 4H:_700

P: 12 5AMP:_0

8GC (..)

4F2: Impulse frequency 2

5AMP: Oscillating amplitude

3DR2: Wire feed 2

4H:

2F:

3PF: Oscillating frequency

Impulse frequency 1

Height set value (only for active arc sensor)

1DR: Wire feed 1

2SO: Groove offset

+/-V: Welding speed

1IG: Constant current

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 27

After pressing the movement and number key AXIS6 :

Weld technic functions

Block 7 - Standard

Teach pendant display when MIG/MAG welding without impulse (welding machine type MC3R) active parameter list

EXE/P1 +/-V:_43

L: 1DR:118

2L:270

5 3H:820

P: 12 4AMP:_23

8 GC (..)

After pressing the movement and number key AXIS6 :

EXE/P1 1DL:100

2SO:__0

8 GC (..)

4AMP:Oscillating Amplitude 3H:

Height set value (only for active arc sensor)

2L: Arc lenght

Page 28

1DR: wire feed

2SO: Groove Offset

+/-V: Welding speed

1DL: Choke

Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

Teach pendant display when MIG/MAG welding with impulse (welding machine type MC3R) active parameter list

EXE/P1 +/-V:_43

L: 1DR:118

2L:270

5 3H:820

P: 12 4AMP:_23

8 GC (..)

After pressing the movement and number key AXIS6 :

EXE/P1 1PA:100

2SO:__0

8 GC (..)

4AMP:Oscillating Amplitude 3H:

Height set value (only for active arc sensor)

2L: Arc lenght 1DR: Wire feed

2SO: Groove Offset

+/-V: Welding speed

1PA: Impulse adaptation

It is possible, and even recommended for short weld seams, to change the parameters with release key disengaged. After changing the parameters and activating the release key, the robot continues the program run with these new parameters.

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 29

Weld technic functions

Block 7 - Standard

2 Parameters of WIG-weld power supplies In completion to the weld parameter lists for the MIG/MAG welding, the software of the controller ROTROL II includes weld parameter lists which meet the particular conditions of the TIG welding process. Handling of the TIG weld parameter lists is the same as for weld parameter lists of MIG/ MAG welding. When TIG welding, START and END CRATER LISTS have to be used. The three tables below show the list input menus and the meanig of the individual, different input values for -

Normal list, Start list and End crater list.

2.1.1 Normal list 1st page Delaytime Speed Wire Speed Pulse Frequency Background current Main Current Ratio Osc. Frequency Osc. Amplitude Height

= = = = = = = = = =

0 2.0 20.0 0.0 50 70 0 0.00 0.0 700

[ms] [cm/min] [cm/min] [Hertz] [A] [A] [%] [Hz] [mm] [ ]

2nd page

Osc. Ampiltude Height Groove Offset Ang. of Osc. current Osc. Start List No. End List No. Gas Postflow Hot wire current

Delaytime

= = = = = = = = =

0.0 700 0 0 0 0 0 0.5 30

[mm] [ ] [ ] [grd] [ ] [ ] [ ] [sec.] [A ]

Hot wire current

The meaning of the single parameters are as below: 1.

Program NO.SQ

(SQ = power source = welding machine)

TIG-welding machine

Program NO. SQ

GL 200 T GL 250 I-T GLW250 I-T GLW350 I-T GLW150I-T GL 250 I-H bzw. GLW 250 I-H GL 300 I-H bzw. GLW 300 I-H

= = = = = = =

Page 30

7111 7211 7311 7411 7511 7611 7711

Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

GL450I-H-P-R PPAW 250 A PPAW 300 A 2.

= = =

7811 9111 9211

Status Result from "WELDING WITH/WITHOUT COLD WIRE" or hot wire without cold wire = 1 with cold wire = 9 hot wire current = 11 This parameter automatically changes when values are entered in the parameters cold wire or hot wire current (shown on the editor only). Delay time (Waiting time) Becomes effective when recalling the list and reaching the start of a path in the program Value = ms Applicable range of values = 0..9999

Speed This parameter is used to adjust the seam speed in order to achieve an optimum weld. Value = cm/min Applicable range of values = 2..500

Wire feed Value = m/min Applicable range of values = 0..500

Pulse frequency Indicates the pulse frequency between main current and basic current. When entering value 0, the basic current is only shown. Value = Hz Appicable range of values = 0..50

Height set value Defines the wire distance the robot has to adhere to when seam tracking (see Programming Instructions - Options -, Block 9 “Arc sensor”. Value = none Appicable range of values = 0..1000 ("0" being the smallest and "1000" the largest wire distance.)

Programming instructions ROTROL® II

V7.0X/S/12.03

Page 31

Weld technic functions 8.

Block 7 - Standard

Groove offset (side offset) Defines the side tolerances of the torch to the real found seam in connection with a laser sensor. Unit = 1/10 mm valid value range = - 999 .. 999

Oscillating Frequency

changeable from version V7.00.00.31

Unit = Hz valid value range = 0..999 The oscillating frequency is infinitely adjustable from 0.1 to 5.56 Hz. Oscillating frequencies which have been entered by the command „ROF“ are overwritten (see also block 9, chapter 17.3 „Oscillating frequency“). 10. Oscillating amplitude This parameter is for adjusting the width of the oscillation movement. Unit = mm valid value range = 0..99,9 11. Constant CURRENT Unit = Ampere valid value range for GL 250 I-H or GLW 250 I-H GL 300 I-H or GLW 300 I-H GL 450 I-H-P-R

= = =

0..250 0..300 0..450

12. Ratio (Pulse duty factor) Indicates the wire feed speed ratio during main current and base current phase of the arc. Unit = % valid value range for = 30..70 13. Main current Unit = Ampere valid value range for GL 250 I-H bzw. GLW 250 I-H GL 300 I-H bzw. GLW 300 I-H GL 450 I-H-P-R

= = =

0..250 0..300 0..450

14. Angle of Oscillation The plane to be oscillated by the robot is to be turned by a certain angle. Unit = Degree valid value range = -90..90 The value "0" means perpendicular to the wire.

Page 32

Programming instructions ROTROL® II

Block 7 - Standard

Weld technic functions

15. Actual Oscillation Determines the behaviour of the oscillating plane (oscillating rotation) when the torch setting angle is altered during the welding path.

Irrespective of the torch orientation, the same oscillating plane is maintained as was determined at the beginning of the seam.

The oscillating plane is altered (actualised) during seam welding to maintain the relationship between oscillating plance and wire direction. The oscillating plane is always 900 in wire direction.

11..20

Oscillating and height direction are activated by OSCDIR (see chapter "Oscillation") If the vaue is smaller than 10, the standard behaviour, i.e. as with value "0", is used.

16. Start list A start list is activated, with which the ignition process is optimized. Unit = none valid value range = 1..999 17. End crater list An end crater list is activated for an optimum welding setting for a path end. Unit = none valid value range = 1..999 20. Hot wire current Optimises the melting of cold wire. Unit = ampere valid value range = 0..160 21. Gas postflow The robot stops at the end of the seam when the arc is switched off, until the given time has elapsed. Unit = seconds valid value range = 0..9.9

Note: Positions which are not mentioned are not used in the normal list.

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 33

Unit = none valid value range = 0..20

Weld technic functions

Block 7 - Standard

2.2 Start list 1.Page

Delay Main Current Speed Wire Speed Pulse Frequency Background Current Main Current Ratio Osc. Frequency Osc. Amplitude Height

= = = = = = = = = =

0.2 50 20.0 0.0 50 70 0 0.00 0.0 700

[ms] [cm/min] [cm/min] [Hertz] [A] [A] [%] [Hz] [mm] [ ]

2. Page

Delay Main Current

Osc. Frequency Osc. Amplitude Height Groove Offset Ang. of Osc. current Osc. Gas Preflow Puls on Cold wire on

= = = = = = = = =

0 0.0 700 0 0 0 0.5 3.5 3.0

Cold wire on

Parameters of Start list:

Delayed main current Delayed switching on the main current after arc ignition Unit - seconds valid value range = 0.0..9.9

18. Gas preflow Arc only ignites at the end of the given time. Unit - seconds valid value range = 0..9.9 19.

Pulsing on Delays pulsing between main and base current. Unit - seconds valid value range = 0.0..9.9

20.

Cold wire on Cold wire is fed when the time has expired. Unit - seconds valid value range = 0.0..9.9

Page 34

Programming instructions ROTROL速 II

[Hz] [mm] [ ] [ ] [grd] [ ] [sec.] [sec] [sec]

Block 7 - Standard

Weld technic functions

2.3 End crater list 1.Page

Puls on Speed Wire Speed Pulse Frequency Background Current Main Current Ratio Osc. Frequency Osc. Amplitude Height

= = = = = = = = = =

0.2 50.0 20.0 31 50 100 0 0.00 0.0 700

[sec] [cm/min] [cm/min] [Hertz] [A] [A] [%] [Hz] [mm] [ ]

2.Page

Puls on

Osc. Amplitude Height Groove Offset Ang. of Osc. current Osc. Crater Fill Time End Crater Section Wire back Decrease time

= = = = = = = = =

0.0 700 0 0 0 0 0.0 3.5 3.0

[mm] [ ] [ ] [grd] [ ] [ms] [mm] [sec] [sec]

Decrease time

Parameters of End crater list: 3.

Pulsing on Delayed main current switching off before the arc extinguishes. Unit - seconds valid value range = 0..9.9

19. Wire retraction The wire is retracted with a speed of 50 cm/min. Unit - seconds valid value range = 0.0..9.9 20. Lowering Time The arc is switched off when the set time has expired. Unit - seconds valid value range = 0.0..9.9

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 35

Weld technic functions

Block 7 - Standard

2.4 Cold wire feed With the function " WIRE PULSING " it is possible: to have the wire pulsing in a percentage ratio between main current and base current (according to the parameter Pulse duty factor), using the command FUNCON_WIGWIRE,1 or to switch the wire feed off during the base current, using the command FUNCON_WIGWIRE,2 The commands have to be entered in the relevant program run part. When TIG welding without cold wire feed the status must be "1" (Parameter 2 of the weld parameter list) and when welding with cold wire feed the value must be "9" gesetzt sein. This is done automatically with the input of a value (> 0) in the parameter "Wire feed".

Program example: Welding with cold wire in the base current phase 0 RESTART 1 LISTS_1=(7711,9,10,2,70,100,300,0,2,0,150,50,170,0,0,0,0,10,10,1,0,0) 2 LISTE_1=(7711,9,5,2,70,100,300,0,2,0,80,50,100,0,0,0,0,0,1,5,0,0) 3 LIST_1=(7711,9,0,20,110,100,300,0,2,0,140,50,160,0,0,1,1,0,35,30,20,0) 4 5 MAIN 6 $_(1) 7 FUNCON_WIGWIRE,1 8 GP_(1,2) 9 GC_(3) 10 GP_(4,1) 11 END 12 | Program example: Welding without cold wire in the base current phase 0 RESTART 1 LISTS_1=(7711,9,10,2,70,100,300,0,2,0,150,50,170,0,0,0,0,10,10,1,0,0) 2 LISTE_1=(7711,9,5,2,70,100,300,0,2,0,80,50,100,0,0,0,0,0,1,5,0,0) 3 LIST_1=(7711,9,0,20,110,100,300,0,2,0,140,50,160,0,0,1,1,0,35,30,20,0) 4 5 MAIN 6 $_(1) 7 FUNCON_WIGWIRE,2 8 GP_(1,2) 9 GC_(3) 10 GP_(4,1) 11 END 12 |

Page 36

Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

2.5 PPAW The PPAW process (Powder-Plasma-Arc-Welding) enables the welding speed to be increased by two to five times, compared with the conventional TIG welding process. Instead of cold wire a powder is used (grain size between 40µ and 100µ ). The robot movement is not limited because it is not necessary to position the welding torch in a certain angle. 2.5.1 Normal list 1.Page

= = = = = = = = = =

2 50 20.0 31.0 50 100 0 0.00 0.0 700

[ms] [cm/min] [g/min] [Hertz] [A] [A] [%] [Hz] [mm] [ ]

2.Page

Delaytime Speed Powder quantity Pulse Frequency Background Current Main Current Ratio Osc. Frequency Osc. Amplitude Height

Osc. Frequency Osc. Amplitude Height Groove Offset Ang. of Osc. current Osc. Start List No. End List No. Gas Postflow

Delaytime

= = = = = = = = =

0.00 0.0 700 0 0 0 1 1 0.5

[Hz] [mm] [ ] [ ] [grd] [ ] [ ] [ ] [sec]

Gas Postflow

Normal List Parameter: 5.

Powder quantity Value = g/min Applicable range of values =

0.0..34.0 g/min

2.5.2 Start list 1.Page

Puls On Speed Powder quantity Pulse Frequency Background Current Main Current Ratio Osc. Frequency Osc. Amplitude Height

= = = = = = = = = =

Puls On

0.2 50 20.0 31.0 50 100 0 0.00 0.0 700

[sec.] [cm/min] [g/min] [Hertz] [A] [A] [%] [Hz] [mm] [ ]

2.Page

Osc. Frequency Osc. Amplitude Height Groove Offset Ang. of Osc. current Osc. Gas Preflow Puls on Powder forward

= = = = = = = = =

0.00 0.0 700 0 0 0 0.5 3.5 3.0

[Hz] [mm] [ ] [ ] [grd] [ ] [sec.] [sec.] [sec.]

Powder forward

Parameters of start list: Programming instructions ROTROL® II

V7.0X/S/12.03

Page 37

Weld technic functions

Block 7 - Standard

Delayed Main Current Delayed start of main current after ignition of arc Value = s Applicable range of values = 0.0..9.9 s

19.

Pulse ON Delayed change-over to normal list Value = s Applicable range of values = 0.0..9.9 s

20.

Powder forward Delayed start of powder supply Value = s Applicable range of values =

0.0..9.9 s

2.5.3 End list

1.Page

Puls on Speed Powder quantity Puls Frequency Background Current Main Current Ratio Osc. Frequency Osc. Amplitude Height

= = = = = = = = = =

0.2 50 20.0 31.0 50 100 0 0.00 0.0 700

2.Page

[sec.] [cm/min] [g/min] [Hertz] [A] [A] [%] [Hz] [mm] [ ]

Osc. Amplitude Height Groove Offset Ang. of Osc. current Osc. Crater Fill Time End Crater Section Powder back Decrease Time

Puls on

= = = = = = = = =

0.0 700 0 0 0 1 0.1 3.5 3.0

Decrease Time

Parameters of the end list: 5.

Pulse ON Main current is switched off Value = s Applicable range of values =

0.0..9.9 s

19.

Powder Postflow Delayed powder off Value = s Applicable range of values = 0.0..9.9 s

20.

Reducing Time Delayed arc off Value = s Applicable range of values = 0.0..9.9 s

Page 38

Programming instructions ROTROL速 II

[mm] [ ] [ ] [grd] [ ] [ms] [mm] [sec.] [sec.]

Block 7 - Standard

Weld technic functions

2.6 Weld parameter changes Teach pendant display when TIG welding

EXE/P1 +/-V:_53

1DR:_075

L: 5 2L:_21 3IH:_72

P: 12 4IW:_28

8 GC (..) After pressing the movement and number key AXIS6 :

2SO:__0

L: 5 3PF:__0

P: 12 4AM:_22 5F:330

EXE/P1 1H:__0 8GC (..)

4IW: Hot wire current

5F:

3IH: Main current

4AM:Oscillating amplitude

2IG: Constant current

3PF: Oscillating Frequency

1DR: Wire feed

2SO: Groove offset (only for laser sensor option)

+/-V: Welding Speed

1H: Height set value

Programming instructions ROTROL速 II

Impulse frequency

V7.0X/S/12.03

Page 39

Weld technic functions

Block 7 - Standard

Teach pendant display when TIG welding (PPAW application) EXE/P1 +/-V:_53

L: 1PU:_75

2IG:_21

5 3IH:_72

P: 12 4IW:_28

8 GC (..) After pressing the movement and number key AXIS6 : EXE/P1 1H:__0

2SO:__0

L: 5 3PF:__0

P: 12 4AM:_22 5F:33

8GC (..)

4IW: Hot wire current 3IH: Main current

5F:

Impulse frequency

4AM: Oscillating amplitude

2IG: Constant current

3PF: Oscillating frequency

1PU: Powder quantity

2SO: Groove offset (only for laser sensor option)

+/-V: Welding speed

1H:

Height set value

Weld parameters are modified in operating modes EXE or EST, as with MIG/MAG welding. If the welding process is interrupted (STOP, EMERGENCY OFF etc.) the start list is carried out again when welding is continued. Tack seam lists cannot be carried out.

Page 40

Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

3 Global list definition

The command FUNCON_LISTSRC

The command is entered in the program sequence part, the weld parameter lists of which contains the parameters to be transmitted. This could be the program named LISTSRC (see program example: LISTSRC in this block). After starting the program this function is activated and remains active until the command FUNCOFF_LISTSRC is given for deactivation. The deactivation command FUNCOFF_LISTSRC must only be given once.

Parameters in the weld parameter list which have the same identification number as those in the program to be defined (LISTSRC) will be overwritten with those of program LISTSRC when starting the user program. All other weld parameter lists in the user program remain unchanged. The transmission of parameters does not depend on the user program name and is repeated after each Start.

Modifications in the weld parameter lists which have been carried out during the sequence are overwritten after a new start.

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 41

enables the use of constant weld parameter settings in all user programs. It is used for offline programming or when exactly constant weld parameters are required in different programs.

Weld technic functions

Block 7 - Standard

4 Digital program selection The weld parameters can be programmed at the QUINTO as well as at the MC3R welding machine and are stored in data records. The number of the data records to be programmed is for the welding machine Welding machine

Number of data records

Quinto Profi Quinto Profi SD GLC 403 (Quinto II) MC3R

63 255 20.000 50

They do not only contain the parameters for the welding process but also the secondary parameters (wire diameter, material, gas etc.) activating the preassigned characteristics of the welding machine. The digital program selection enables the activation of these "adapted" data records, e.g. in case of automatic torch changing systems, and thus an optimum welding of different materials. The 22nd place corresponds to the parameter "Digital program selection" in the list input menu. The set value activates the corresponding data record of the welding machine.

List 1=(5211,1,0,50,200,0,700,0,0,0,50,0,0,0,0,0,0,5,335,30,5,10) MAIN END

List 1=(5211,1,0,50,200,0,700,0,0,0,50,0,0,0,0,0,0,5,335,30,5,10)

Page 42

Programming instructions ROTROL速 II

Digital program selection

Block 7 - Standard

Weld technic functions

5 Serial transfer of weld parameter lists With the serial coupling of the welding power source to the robot control considerably more information can be exchanged than in the case of an analogue/digital coupling. All values given in the welding parameter list can be transferred to the welding power source and be altered during the program run. These parameters which come from the list input menu are sufficient to fulfil many of the welding tasks, but are not adequate for all tasks. With the command WPSPAR

Weld Power Source PARameter

the parameters of the welding power source can also be altered. The parameters particularly concerned are as follows: material, wire diameter, gas, spatterfree ignition, characteristic curve, power limit, pulse edge steepness, AluPlus parameters and monitoring parameters

The values to be changed are indicated by a code number in the command WPSPAR . Please refer to the following table for the code numbers. The WPSPAR command must be called up before the weld seam. These values are basic settings and it is therefore recommended that modifications are carried out at seam start or in the AUTOEXEC file.

The WPSPAR command is composed as follows:

Example: GLC 403 (Quinto_II) WPSPAR_(0;1;1,4,0,4,0) 3rd to 5th value (parameter values for material, gas and variant) 2nd value (parameter value of the following basic number "Wire diameter" value 4 =1.2 mm Ă&#x2DC;) 1st value (parameter value of the indicated basic number "Process" value 1 = MSG Pulse U/I) Basic number (first parameter to be changed) Data set number of the welding power source (Quinto I = 0..255 data sets; Quinto II = 20.000 data sets) When switching on the welding power source the data set which was active at last is automatically loaded in the temporary main memory (data set number 0). Because of the indication of the data set number 0 in the command WPSPAR_(0;..) the respective parameter values in the main memory are overwritten by the new values. They are valid until switching off the welding power source because this deletes the temporary memory. Programming instructions ROTROLÂŽ II

V7.0X/S/12.03

Page 43

Weld technic functions

Block 7 - Standard

The temporary data set "0" loses the current settings when switching off the welding power source. The basic number indicates the parameter from which it shall be changed. In the above mentioned example the basic setting "Process - basic number 1 -" is selected as start parameter and set to "one = MSG Pulse U/I" (value 1). Then the values for the following parameters (wire diameter, material etc.) ca be set. This is only possible in case of continuous basic numbers. In case of a non-continuing basic number another command WPSPAR has to be entered with the corresponding basic number.

The transfer of the basic settings to the welding power source GLC 403 (Quinto II) must always be made as complete block (basic number 1-5). Pay attention to the order of the basic number in the following summary for the welding power source Quinto I !! Example: WPSPAR_(10;1;1,4,0,0,0) Data set number of the welding power source The basic settings are programmed in data set 10. The data set is changed to the setting: Process: Wire diameter: Material: Gas: Variant:

MSG Pulse U/I 1.2 mm Steel 82/18 0

When different configuration, monitoring and secondary parameters are used, they should be filed in the different data sets. The welding power source

and the

Quinto SD offers 255 GLC403/603 offers 255

different data sets. These defined parameters are activated by the weld list parameter "Digital program selection". Please pay attention that this parameter includes the respective data set of the welding power source. However, only the secondary parameters of the respective data set are activated with this application because the weld list parameters (main parameters) of the robot controller are used in principle.

Page 44

Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

5.1 Table for serial data transmission between welding power source and robot

GLC 353/553 (Quinto I)

Please note: The WPSPAR command with the code number „0“ is an internal control command of the Rotrol controller and defines to which of the two welding machines the data of the robot controller are transferred. Only valid for GLC 403/603 Quinto II: The code numbers 1 to 5 must be comprised in one WPSPAR command. Otherwise it is possible that error messages on the welding machine Quinto II occur due to temporary influences. From code number „70“ on changes must be effected by means of separate WPSPAR commands

GLC 403/603 (Quinto II)

Basic settings Selection of power source in tandem mode Code No. 0

Code No. 0

Value

1 Data are transferred to the welding power source with machine no. 1.

2 Data are transferred to the welding power source with machine no. 2.

Procedure Code No. 4

Code No. 1

Value 0 1 2 3 4 5 6 7 8 9 10

MSG-Normal MSG-Puls U/I

MSG-Normal MSG-Puls U/I MSG-Puls I/I MSG-Löten Normal MSG-Löten Puls U/I MSG-Löten Puls I/I unused unused Band Normal Band Puls U/I Band Puls I/I

Programming instructions ROTROL® II

V7.0X/S/12.03

Page 45

Weld technic functions GLC 353/553 (Quinto I)

Block 7 - Standard GLC 403/603 (Quinto II)

Wire diameter Code No. 2 Value 0 1 2 3 4 5 6 7 8 20 21 22 23 24

Code No. 2 0,8 0,9 1,0 1,2 1,4 1,6 2,0 2,4

mm mm mm mm mm mm mm mm

0,6 mm 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm 2,0 mm 2,4 mm 3,75 * 0,5 4,00 * 0,5 4,00 * 0,6 4,50 * 0,5 4,50 * 0,6

mm mm mm mm mm

Material Code No. 1

Code No. 3

Value 0 1 2 3 4

Steel CrNi Aluminium

Steel CrNi AlSi AlMg CuSi

Gas Code No. 3

Code No. 4

Value Ar [%] O2 [%] CO2 [%] He [%] H2 [%] 0 ............ 99 ......... 1 1 ............ 97 ......... 3 2 ............ 98 ......... 2 3 ............ 98 ........................ 2 4 ............ 92 ........................ 8 5 ............ 90 ...................... 10 6 ............ 82 ...................... 18 7 ............ 90 ......... 5 ........... 5 8 .......... 100 9 ..................................... 100 10 .......... 98 ................................................. 2 11 .......... 94 ................................................. 6 12 .......... 30 ................................... 70 13 .......... 50 ................................... 50 14 .......... 69 ......... 1 ...................... 30 15 ..................................................................

Page 46

Ar [%] O2 [%] CO2 [%] He [%] H2 [%] 82 90 98 92 100 98 94 30 50 99 97 98 69

...................... 18 ........ 5 ............ 5 ........ 2 ........................ 8 .................... 100 ................................................. 2 ................................................. 6 .................................. 70 .................................. 50 ........ 1 ........ 3 ........................ 2 ........ 1 ...................... 30 ................................................... ...................................................

Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

GLC 353/553 (Quinto I)

GLC 403/603 (Quinto II)

Variant Code No. --

Code No. 5

Value ---

0..9

Preparatory and postprocessing auxiliary parameters

Code No. 10

Value

0 to 99

0,0 s to 9,9 s

0 to 99

Gas Preflow

0,0 to 9,9 s

Gas Postflow Code No. 11

Code No. 11

Value

0 to 99

0,0 s to 9,9 s

0 to 99

0,0 to 9,9 s

Wire advance Code No. 12

Code No. 12

Value

0 to 240

0,0 m/min to 24,0 m/min

5 to 100

0,5 m/min to 10,0 m/min

Spatterfree ignition Code No. 13

Code No. 13

Value

0 1

OFF ON

0 1

OFF ON

Burnback Code No. 14

Code No. 14

Value

0 to 100

0% to 100%

0 to 100

0% to 100%

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 47

Weld technic functions

Block 7 - Standard

GLC 353/553 (Quinto I)

GLC 403/603 (Quinto II)

Range (retraction) Code No. 15

Code No. 15

Value

0 to 100

0 ms to 100 ms

0 to 100

0 mm to 100 mm

Main parameters Wire feed Code No. 20

Code No. 20

Value

0 to 300

0,0 m/min to 30,0 m/min

5 to 400

0,5 m/min to 40,0 m/min

Voltage / Frequency/Pulscurent Code No. 21

Code No. 21

Value

100 to 700 20 to 400 0 to 500

10,0 V to 70,0 V 20 Hz to 400 Hz 0 A to 500 A

80 to 700 20 to 400 5 to 600

8,0 V to 70,0V 20 Hz to 400 Hz 5 A to 600 A

Pulse height Code No. 22

Code No. 22

Value 150 to 700

15,0 V to 70,0 V

150 to 700

15,0 V to 70,0 V

Pulse width Code No. 23

Code No. 23

Value 5 to 50

0,5 ms to 5,0 ms

5 to 50

0,5ms to 5,0 ms

Choke / Constant current Code No. 24

Code No. 24

Value 0 to 100 5 to 500

Page 48

0 % to 100 % 5 A to 500 A

0 to 100 6 to 600

Programming instructions ROTROL速 II

0% to 100% 5 A to 600 A

Block 7 - Standard

Weld technic functions

GLC 353/553 (Quinto I)

GLC 403/603 (Quinto II)

Arc length Code No. 25

Code No. 25

Value

0% to 100% (only for extension to MAG PULSI/I )

0% to 100%

Der True Synergie Modus ist nur im Handschweißbetrieb sinnvoll einsetzbar. Das Schweißgerät arbeitet wie die MC3 / MC4 auf einer vorgegebenen Kennlinie und wird nur über den Parameter Drahtvorschub geregelt. Wire feed Code No. 27 Value 5 to 400

0,5 to 40 m/min

Arc length Code No.28 Value -100 to 100 Impulse adaption Code No.29 Value -50 to 50 Auxiliary parameters MAG-Normal: Characteristic curve Code No. 30

Code No. 30

Value

0 1 2 3

0 V/100 A 3 V/100 A 5 V/100 A 6 V/100 A

0 to 60

0v/100 A to 6,0 V / 100 A

Power limit Code No. 31

Code No. 31

Value

0 to 100

0 % to 100 %

50 to 200

5,0 KW to 20,0 KW

Programming instructions ROTROL® II

V7.0X/S/12.03

Page 49

TSM =True SynergieModus (nur bei GLC 403/603)

Weld technic functions

Block 7 - Standard

GLC 353/553 (Quinto I)

GLC 403/603 (Quinto II)

MAG-Pulse: Pulse edge steepness Code No. 35

Code No. 35

Value

1 to 4

0 to 9

AluPlus ON / OFF Code No. 36

Code No. 36

Value

0 1

without AluPlus with AluPlus

0 1

without AluPlus with AluPlus

AluPlus frequency Code No. 37

Code No. 37

Value

5 to 100

0,5 Hz to 10,0 Hz

1 to 100

0,1 Hz to 10,0 Hz

AluPlus width repetition rate Code No. 38

Code No. 38

Value

20 to 80

20 % to 80 %

20 to 80

20% to 80%

AluPlus Pulse height Code No. 39

Code No. 39

Value

150 to 700

15,0 V to 70,0 V

150 to 700 5 to 600

15,0 V to 70,0 V 5 A to 600 A (I/I control)

AluPlus Pulse width Code No. 40

Code No. 40

Value

5 to 50

0,5 ms to 5,0 ms

5 to 50

0,5ms to 5,0 ms

AluPlus constant current Code No. --

Code No. 41

Value

Value 5 to 600

Page 50

Programming instructions ROTROL速 II

5 A to 600 A

Block 7 - Standard

Weld technic functions GLC 353/553 (Quinto I)

Monitoring parameters Configuration Code No. 50

0 64 192

0 256 768

0 1024 3072

0 16384 49152

Monitoring of all parameters

Arc-break

Welding time

0 4096 12288

0 21845 65635

Add the values from the above table in order to determine the parameter value to be transmitted. With the command WPSPAR the parameter value determined is transmitted to the power source and the suitable configuration is set. When the SD monitoring system recognized an arc fault, this fault is shown on the robot control screen (message) or the path travel is stopped (interruption) and a message is given. This depends on the configuration (message or interruption). Condition:

The function "FUNCON_SDSTOPCP" (see bloc 8) must be active.

Determination of the parameter value to be transmitted. Monitoring parameter Weld current Weld voltage / Pulse frequency Wire feed Wire storage Gas flow Reserve/Porosity Welding time Arc-break

Reaction

Parameter value

Interruption

Interruption Interruption Message Message Message Off Off Total:

12 48 64 256 1024 0 0 1407

The parameter value to be transferred by the command WPSPAR is 1407. WPSPAR_(0;50;1407)

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 51

0 16 48

Reserve / Porosity

0 4 12

Gas flow

Welding voltage/ Impulse frequency

0 1 3

Wire storage

Weld current

OFF MESSAGE INTERRUPTION

Wire feed

Monitoring parameter

SD monitoring is configurated on "OFF", "MESSAGE or "ABORT" .

Weld technic functions

Block 7 - Standard GLC 353/553 (Quinto I)

Set and limit values Start delay Code No. 51

Code No. 58

Value

1 to 99

0,1s to 9,9s

0 to 99

0 V to 9,9 V

Error time Code No. 52

Code No. 59

Value

1 to 99

0,1s to 9,9s

0 to 250

0,0 l/min to 25,0 l/min

Set value wire Code No. 53

Code No. 60

Value

0 to 300

0,0 m/min to 30,0m/min

0 to 99

0,0 l/min to 9,9 l/min

Limit value wire Code No. 54

Code No. 61

Value

0 to 99

0,0 m/min to 9,9 m/min

0 to 1000

0,0 V to 10,0 V

Set value current Code No. 55

Code No. 62

Value

0 to 300

0,0 A to 500 A

0 to 100

0,0 V to 10,0 V

Limit value current Code No. 56

Code No. 63

Value

0 to 99

0 A to 99 A

0 to 32400

0,0 s to 3240,0 s

Set value voltage Code No. 57

Code No. 64

Value

0 to 700 Page 52

0,0 V to 70,0 V

0 to 250

Programming instructions ROTROL速 II

0,0 s to 25,0 s

Block 7 - Standard

Weld technic functions

GLC 353/553 (Quinto I)

GLC 403/603 (Quinto II)

Commands Wire retract Code No. 70

Code No. 70

Wert

Value

-400 to 400 -400 mm to +400 mm

-500 to 500 -500 mm to +500 mm Das rangieren des Drahtes wird mit fester Drahtgeschwindigkeit ausgef端hrt. 0 - 49 mm = 2,0 m/min 50 -100 mm = 4,0 m/min 200 - 500 mm = 7,0 m/min

Code No. 71

Value

Reset

Mailfunction

Process configuration of the welding power sources in the operation mode Tandem Code No. --

Code No. 80

Value

Value 0 OFF No Tandem operation, the welding power source no. 1 is approached. 1 Tandem - seam tracking of Master Both welding power sources are approached. 2 Tandem - seam tracking of Slave Both welding power sources are approached. 3 Single wire - Master Only the welding power source no. 1 is approached. 4 Single wire - Slave Only the welding power source no. 2 is approached.

Only active in the Quinto II configuration menu with the Tandem operating mode "External".

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 53

Weld technic functions

Block 7 - Standard GLC 403/603 (Quinto II)

Impulse synchronisation Code No. 81 Value 0 1 2 3

Asynchronous Master Slave synchronous Slave asynchronous

Only active in the Quinto II configuration menu with Only active in the Quinto II configuration menuwith the Tandem operating mode "External".

Switch-over wire drive unit Code No. 82 Value 1 2 3 4

Wire drive unit 1 Wire drive unit 2 Wire drive unit 3 Wire drive unit 4

Switch-over wire must be activated in the config menu and the requested wire drive unit for PAW must have been recognised.

Change component and seam Code No. 90 Value 1 to 32767

Set component counter Sets the component counter to the indicated value.

Code No. 91 Value 0 to 32767

Set seam counter Sets the seam counter to the indicated value.

Code No. 92 Value -32768 to 32767

Shift the component counter Adds the indicated value to the component counter. A figure lower than 1 is not allowed.

Code No. 93 Value -32768 to 32767

Page 54

Shift the seam counter Adds the indicated value to the seam counter. A figure lower than 0 is not allowed.

Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

5.2 PHG – Menu for serial data transfer between power source and robot

Call up the menu for WPSPAR – parameters

WPSPAR –parameters for serial drive

Call up the WPSPAR – data sets Data set Number (1 - 255)

"TOGGLE" - keys "Forward" / "Backward"

Insert WPSPAR parameters

Create new data set

Programming instructions ROTROL® II

delete data set

V7.0X/S/12.03

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Weld technic functions

Block 7 - Standard

WPSPAR â&#x20AC;&#x201C; Data set with adequate parameters

Activate or deactivate data set

Activate all data sets

Deactivate all data sets

Characteristic Number Value input of identification parameters

Aktivated parameter

Deaktivated Parameter

More WPSPAR - characteristic numbers

Page 56

Programming instructions ROTROLÂŽ II

Block 7 - Standard Note:

Weld technic functions

The command WPSPAR cannot be interpolated. A change during the contour path causes the arc to be switched off for a moment. The switching during the contour path is made by the commands: SWITCH_SINGLE SWITCH_TANDEM SWITCH_TANDEM1 SWITCH_TANDEM2 SWITCH_TANDEM0 - serielles Ausschalten des Lichtbogens

see chapter 1.7 Tandem welding

Additional functions of serial interfaces in connection with the commands FUNCON and FUNCOFF are:

FUNCON_WIREON

The welding wire is transported forwards with the speed of the weld parameter list which has been active last.

FUNCON_WIREBACK

The welding wire is drawn back with the speed of the weld parameter list which has been active last.

FUNCON_GAS

The solenoid valve for shielding gas in the wire drive unit is opened and the shielding gas flows through the cable assembly.

FUNCON_BLAST

The solenoid valve for compressed air in the wire drive unit is opened. Impurities in the welding torch are removed (e.g. loose weld spatters).

FUNCON_WATERSHT

When the Quinto SD monitoring system recognizes a water shortage in the water circulation, a STOP signal is transmitted to the robot control. The program run must be interrupted completely by turning the operating mode selector switch to "OFF". By activating this function if need be, in connection with the functions "FUNCON_ARCCON" bzw. "FUNCON_ONLCON", the signal Arc Fault appears. A program interruption is avoided, the operation can be continued by pressing the push button "START".

Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 57

Weld technic functions

Block 7 - Standard

FUNCON_SDSTOPCP,x,y The reasons for arc faults can better be determined and shown if a type QUINTO SD welding machine with serial interface is used instead of a Quinto Profi. When the function SDSTOPCP in the sequence part of the robot program is activated, the robot reacts to faults which are not covered by the function "FUNCON ONLCON" (see "Block 8 Arc monitoring") - see error messages in this block. The robot is stopped immediately. By indicating an output number (x) in the welding machine, this function is switched on if an error occurs. The output can be switched on depending on the configuration (abort or message). If zero is entered in the second parameter (y) the output is switched on with configuration "Abort". If one is entered it is switched on with the configuration "Message".

SDSTOP_(nr)

If the robot is only to stop after the weld seam, the command SDSTOP is entered in the corresponding command line of the sequence program. If an output number is entered behind the command, this output is switched on in the case of an error. Enter Zero, if you do not want an output to be switched on.

FUNCON_WPSRESET

Errors which occur during welding and are signaled can be reset during program run.

Explicitly, the above mentioned functions can be switched off with the command FUNCOFF.

Error messages: 1.

F1800: "Communication error to the welding machine!" Cause:

. 2.

Welding machine is switched off, connection is interrupted, interface on the PC-IF- (robot) or serial interface A19 (QUINTO) defective.

F1801: "No communication to the welding machine. Simulation operation!" Cause:

Page 58

If the error F1800 occurs, the program run can be continued by pressing the START key. In this case the above message appears, in order to inform the user about the simulation operation.

Programming instructions ROTROL速 II

Block 7 - Standard 3.

Weld technic functions

F1802: "Version of welding machine is incompatible!" Cause:

The operating system of the robot controller is incompatible with the software in the welding machine.

Measure: Configuration in the robot controller or update of the software version in the welding machine.

F1804: "Welding machine: parameter out of range!" Cause:

Wrong input in the command WPSPAR of the robot run program.

Measure:

Correction of the input.

F1807: "System error welding machine:under voltage"

F1808: "System error welding machine:over voltage"

F1809: "System error welding machine: temperature/transformer/rectifier/cascade"

F1810: "System error welding machine:temperature pump/fan"

F1811: "System error welding machine:water shortage" The error messages F1807 until F1811 are errors, which can appear in the interior of the Quinto welding machine. The robot controller is informed about the error status and the errors are indicated on the monitor.

Messages:

11. M/F1812: "SD - Error: current" 12. M/F1813: "SD - Error: voltage" 13. M/F1814: "SD - Error: wire speed" 14. M/F1815: "SD - Error: gas" 15. M/F1816: "SD - Error: wire supply" 16. M/F1817: "SD - Error: reserve" 17. M/F1818: "SD - Error: arc-break" 18. M/F1819: "SD - Error: porosity" Programming instructions ROTROL速 II

V7.0X/S/12.03

Page 59

Weld technic functions

Block 7 - Standard

Messages with the designation M/F... are messages which are sent from a Quinto SD welding machine to the robot controller if the welding data monitoring is switched on. If one parameter falls out of the set tolerance, the corresponding message is indicated on the monitor of the robot controller.

The serial communication with the welding machine can be switched off with the command FUNCOFF_WPS and can be switched on again with the command FUNCON_WPS Switching off the serial communication is required when the welding machine is to be operated with analogue outputs or digital program selection at the robot control.

Page 60

Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

6 Free list access The function LISTACC =

LIST ACCess

makes a free access to the welding parameter list during program run possible. With the help of variables individual parameters of a welding parameter list (hereafter called "list" ) can be changed. Execution In the following the command LISTACC is built up in individual steps.

1. Parameter LISTACC_(2; Input here a value (between 0 and 3) which determines the kind of list access that you intend to have The valid values and there meaning are: 0 1 2 3

Reading of a list parameter Writing of a list parameter Copying of a complete list Copying of a complete list with the possibility of modifying a parameter in the copy during copying

2. Parameter LISTACC_(3;5, Source list Input as source list the number of the list you intend to access.

3. Parameter LISTACC_(3;5,0, List type Meaning of the valid values for the list type: 0 1 2 3

Normal list (LIST) Start list (LISTS) End list (LISTE) Tack list (Heftnahtliste) (LISTH)

Programming instructions ROTROL速 II

V7.0X/S/12.03

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Weld technic functions

Block 7 - Standard

4. Parameters LISTACC_(3;5,0,4; Parameter numbers Please refer to the table concerning the valid values Table:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Parameter number for the different types

0 Normal list

1 Start list

2 End list

3 Tack list

Status Waiting time Speed Wire feed Voltage/frequ. Height Side offset ROF Osc. amplitude Choke/base current Pulse time Pulse voltage Ang.of osc. Actual osc. Start list End list Gas preflow Ignition feed Burnback time Gas postflow Free

Status Waiting time Speed Wire feed Voltage/frequ. Height Side offset ROF Osc. amplitude Choke/base current Pulse time Pulse voltage Ang.of osc. Actual osc. -------------------Start section --------------------------------------Burnback time Gaspostflow Free

Status Waiting time Speed Wire feed Voltage/frequ. Height Side offset ROF Osc. amplitude Choke/base current Pulse time Pulse voltage Ang. of osc. Actual osc. End waiting time End section --------------------------------------Burnback time Gas postflow Free

Status Waiting time Speed Wire feed Voltage/frequ. Height Side offset ROF Osc.amplitude Choke/base current Pulse time Pulse voltage Ang. of osc. Actual osc. Gap speed Gap section Tack seam length End list Burnback time -------------------Free

When using different welding technologies and welding power sources, the designations of the above mentioned parameters change. Please refer to the current weld parameter list (Chapter 6.1 -6.2.1). Please take into account that the parameter "PROGRAMMNR.SQ" is not included in the above chart, so that the LISTACC-Parameter number is shiftet by "one" compared with the current weld parameter list number.

Example: : Weld parameter list number 1..22

LIST_1=(5311,1,0,27,56,230,0,0,2,0,0,22,330,0,0,0,0,0,0,120,0,0) LISTACC-Parameter no.1..21

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Programming instructions ROTROL速 II

Block 7 - Standard

Weld technic functions

5. Parameter LISTACC_(3;5,0,4;PARAIST; In this variable the current value of the indicated parameter is input. 6. Parameter LISTACC_(3;5,0,4;PARAIST;95; Set value Input the value, which the indicated parameter should have. In the example the wire feed (Parameter No. = 4) is set to the value 9,5 m/min (95).

7. Parameter LISTACC_(3;5,0,4;PARAIST;95;7) Target - List Input the number of the list in which you want to copy. Since this value is only of importance to the two functions 2 and 3 LISTACC (copy or copy with modification) it must not be applied for the functions 0 and 1 (read or write parameter )

Examples 1. Reading parameters After the program run the actual welding speed is to be displayed on a screen message.

VAR_PARAIST LIST_1=(5311,1,0,27,56,230,0,0,2,0,0,22,330,0,0,0,0,0,0,120,0,0) MAIN XX:_PAUSE GP_(1,2,3) $_(1) GC_(4) LISTACC_(0;1,0,3;PARAIST;0) WRITE_(‘MOMENTANE GESCHWINDIGKEIT IST: ‘,PARAIST) GP_(5,1) JUMP_XX END |

Programming instructions ROTROL® II

V7.0X/S/12.03

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Weld technic functions

Block 7 - Standard

2. Writing of parameters Due to varying air gap the operator should enter the value for the parameter "oscillating amplitude" via keypad before the program run.

VAR_PARAIST,PARASOLL LIST_1=(5311,1,0,67,56,230,0,0,2,30,0,22,330,0,0,0,0,0,0,120,0,0) MAIN XX: WREAD_(‘BITTE PENDELAMPLITUDE IN 1/10 MM EINGEBEN ‘,PARASOLL) LISTACC_(1;1,0,9;PARAIST;PARASOLL) GP_(1,2,3) $_(1) GC_(4) GP_(5,1) JUMP_XX END |

Copying a list

All seam parameters of a seam are to be transferred to another seam on the component, even after modification.

VAR_PARAIST LIST_1=(5311,1,0,44,55,231,0,0,2,30,0,22,330,0,0,0,0,0,0,120,0,0) LIST_2=(5311,1,0,44,55,231,0,0,2,30,0,22,330,0,0,0,0,0,0,120,0,0) MAIN XX:_PAUSE GP_(1,2,3) $_(1) GC_(4) LISTACC_(2;1,0,3;PARAIST;0;2) GP_(5,6,7) $_(2) GC_(8) GP_(9,1) JUMP_XX END |

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Programming instructions ROTROL® II

Block 8 - Standard

Arc monitoring

Index Arc monitoring................................................................................................................. 2

3 Final monitoring ........................................................................................................... 8 3.1 Extension arc monitoring ..................................................................................... 9 3.2 Status information from the power source ......................................................... 10 4 Causes for malfunctions ........................................................................................... 11 5 Heat input.................................................................................................................... 12

Programming Manual ROTROL速 II

Page 1

2 Monitoring during the welding process.................................................................... 5 2.1 ONLCON ............................................................................................................ 5 2.2 Monitoring function SDSTOPCP - SDSTOP ....................................................... 6 FUNCON_SDSTOPCP,x,y ................................................................................... 6 SDSTOP_(nr) ....................................................................................................... 7 2.3 Recognition of porous weld seams ..................................................................... 7

1 Ignition monitoring....................................................................................................... 3 1.1 Ignition monitoring ARCCON .............................................................................. 3 1.2 Ignition routine ARCIGNIT .................................................................................... 4

Arc monitoring

Block 8 - Standard

Arc monitoring Arc monitoring The arc monitoring is used for controlling an uninterrupted program execution in the normal robot welding operation. The computer controls the welding process via the arc control and reacts in the case of an error according to program instructions. Acorresponding message of the error cause (e.g. wire low) appears on the display. The arc control is divided into 1. Ignition monitoring 2. Monitoring the welding process 3. Final monitoring To select the individual monitoring functions, go to the menu via the dialogue box of the weld parameter lists.

IF T1S1NAHT = 1 THEN BEGIN SUCHPOS := 111 CALL SUCHEN WRITE (‘L1080BT 1 SEITE 1 NAHTNUMMER’,T1S1NAHT) !WURZEL

LIST LIST LIST LIST LIST LIST LIST LIST LIST LIST LIST

1 =(5211,3,0,47,135,270,0,0,0,8,60,21,370,0,0,0,0,10,45,40,20,0) 2 =(5211,3,0,47,125,240,0,0,0,10,60,21,370,0,0,0,0,10,45,40,20,0) 3 =(5211,3,0,40,110,230,0,0,0,35,60,21,370,0,0,0,0,10,45,40,20,0) 4 =(5211,3,0,55,115,240,0,0,0,15,60,21,370,0,0,0,0,10,45,40,20,0) 5 =(5211,3,0,50,120,240,0,0,0,20,60,21,370,0,0,0,0,10,45,40,20,0) 6 =(5211,3,0,50,105,230,0,0,0,25,60,21,370,0,0,0,0,10,45,40,20,0) 7 =(5211,3,0,50,105,230,0,0,0,25,60,21,370,0,0,0,0,10,45,40,20,0) 8 =(5311,3,0,50,115,240,3,0,0,25,60,21,370,0,0,0,0,10,45,40,20,0) 9 =(5211,3,0,50,110,240,0,0,0,20,60,21,370,0,0,0,0,10,45,40,20,0) 10 =(5211,3,0,50,110,240,0,0,0,20,60,21,370,0,0,0,0,10,45,40,20,0) 11 =(5211,3,0,50,110,240,0,0,0,20,60,21,370,0,0,0,0,10,45,40,20,0)

Actuate the button "FUNCON" before activating a monitoring function (except "SDSTOP") and then select the requested function. The selected monitoring function is entered into user program after the input of all required parameters (e.g. FUNCON_ARCCON).

Insert / Monitoring FUNCON ARCCON FUNCON ONLCON IF T1S1NAHT = 1 THEN BEGIN SUCHPOS := 111 CALL SUCHEN

Monitoring

Funcon On Function

Funcoff Off Function

Define output for arc monitoring

The functions are switched off by selecting the button "FUNCOFF" and the respective monitoring function (e.g. FUNCOFF_ARCCON). Additional parameters which are attached to the corresponding function have also influence on the delay and answer times of the control functions. Digital outputs can be defined freely and are switched as soon as an arc error occurs. Page 2

Programming Manual ROTROL® II

Block 8 - Standard 1

Arc monitoring

Ignition monitoring

1.1 Ignition monitoring ARCCON Arc monitoring of the ignition process is activated by the command FUNCON_ARCCON. Command for switching on ignition monitoring FUNCON_ARCCON,2000 Adjustment in milliseconds Control Arc On Function

It is only necessary to execute the "FUNCON_ARCCON" command once and the arc monitoring is activated with every start of the seam. When reaching the start of the seam, the signal “current yes” has to appear within 1.5 s (standard value if no other value has been entered) or within the given ignition time. Otherwise the robot stops and indicates a malfunction in the arc. The following message appears on the display: GLC-ERROR: ARC Press START KEY or switch to ADJUSTMENT T1

Command for switching off the ignition monitoring FUNCOFF_ARCCON

Program example LIST 1 = (5211,3,0,47,135,270,0,0,0,8,60,21,370,0,0,0,0,10,45,40,20,0) MAIN ST: PAUSE FUNCON ARCCON $ (1) GP (1,2) GC (3) GP (4,1) FUNCOFF ARCCON JUMP ST END

Programming Manual ROTROL® II

Ignition time- > CON -> ARC -> ON -> FUNC ->

Page 3

Arc monitoring

Block 8 - Standard

1.2 Ignition routine ARCIGNIT It often happens that the arc has to be ignited on the so-called "slag" of a previous welding path. This situation always causes ignition problems which only result in stopping the robot - using the command FUNCON_ARCCON. The "slag" must be manually removed before the arc can be ignited and the robot can continue the program run.

The function

FUNCON_ARCIGNIT,...,..,..,.. IGNITION ARC ON FUNC

-> -> -> ->

Ignition Arc On Function

allows to restart the ignition process at a defined point of the welding path in the case that an ignition was not successful. The parameters behind the command are separated by a comma (,) as follows ...,distance, ignition attempts, overwelding, weld parameter list The parameter "distance" defines the distance where a further ignition attempt is to take place. The parameter "Ignition attempts" informs the system how often this process is to be repeated. It can be continued until the end of the seam. The third parameter "Overwelding " determines whether the robot continues its run from the ignition position or whether it returns to the previous point (probably the start of the path) with ignited arc in order to overweld the first part of the seam. Enter the value "1" to activate the overwelding process or "0" for a continuation from the ignition position. When overwelding is activated, the weld parameter list indicated in the fourth parameter is used for the return and then it is switched back to the last valid weld parameter list.

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Programming Manual ROTROL速 II

Block 8 - Standard

Arc monitoring

Program example FUNCON_ARCIGNIT,distance, ignition attempts, overwelding, weld parameter list FUNCON_ARCIGNIT,100,2,1,5 100,

repeated ignition attempt at a distance of 10 mm from the starting point of path.

100,2

two ignition attempts are carried out

100,2,0 1

start from ignition point robot returns to the previous point for overwelding

100,2,1,5

weld parameter list used when returning.

2 Monitoring during the welding process

During the welding process the parameters wire, gas and current are controlled. The program run is stopped if a parameter is missing or if the weld current fluctuations are too severe. The operator is given a message on the cause of the malfunction (e.g. lack of wire) on the display. After elimination of the fault (e.g. change of the wire coil) the program run is continued from the interruption position (also see chapter "Overlapping start" in block 6). The additional indication of an output number behind the command ONLCON,.., activates the output when an error occurs. An additional indicating lamp, for the general fault, can be activated. If a delay time is indicated in the second parameter, the monitoring will only be activated after expiry of this period. Switch on the arc monitoring by the command FUNCON_ONLCON,10,500,500 Error time in ms Delay time in ms (reaction only after time expiry) Number of the digital output for general error message Online control

and switch it off by FUNCOFF_ONLCON.

Programming Manual ROTROL速 II

Page 5

2.1 ONLCON

Arc monitoring

Block 8 - Standard

The monitoring of the two parameters wire and gas can also be switched off individually by the following commands:

FUNCOFF_ONLCON,1

Gas monitoring

FUNCOFF_ONLCON,2

Wire monitoring

FUNCOFF_ONLCON,1,2

Gas and wire monitoring

After having pushed the button "FUNCOFF_ONLCON" a dialogue box appears with the question "Do you wish to enter more parameters?". If you answer "Yes", the monitoring will be individually deactivated by entering the corresponding number

Do you want to enter additional Parameters? Switch Off (1=GAS; 2=WIRE)

1 = Gas monitoring 2 = Wire monitoring 1+2 = Gas and wire monitoring.

2.2 Monitoring function SDSTOPCP - SDSTOP FUNCON_SDSTOPCP,x,y

When using a welding machine of the series Quinto SD with serial interface the causes for arc errors can be detected and indicated more detailed as with the Quinto Profi. When the function SDSTOPCP is activated in the robot program run the robot reacts to errors which are not covered by the function "FUNCON ONLCON" and stops immediately. By indicating an output number (x) the output is switched on when an error occurs. The output can be switched on in the welding machine depending on the configuration (abortion or display). By setting a zero in the second parameter (y) the output is switched on in case of configuration "Abortion". By setting a one, it is switched on in case of configuration "Display".

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Programming Manual ROTROL速 II

Block 8 - Standard

Arc monitoring

SDSTOP_(nr) When the robot must stop behind the weld seam the command SDSTOP is entered in the corresponding command line of the user program. By indicating an output number behind the command the output is switched on in case of an error. If the output shall not be switched on, enter a Zero.

2.3 Recognition of porous weld seams A recognition of porous weld seams with the function "FUNCON_ONLCON" is not possible because of the information "gas yes" or "gas no". This function ensures that the robot only stops when there is really no more gas available.

The command FUNCON_POROSITY,2500

activates an arc controlling function. If the arc becomes unsteady e. g. due to draught, it is recognised and the robot stops.

Please consider the optional conditions of the welding machine (Quinto with SD monitoring).

Programming Manual ROTROL速 II

Page 7

delay time in ms

Arc monitoring

Block 8 - Standard

3 Final monitoring By means of the two commands FUNCON_ENDCON and FUNCOFF_ENDCON the arc control for the seam end is switched on or off. After FUNCON_ENDCON,1 - the robot waits (max. five seconds) at the seam end until the arc has extinguished, FUNCON_ENDCON,2

the robot waits (max. five seconds) at the seam end until the powersource announcer program-end,

FUNCON_ENDCON,3

the robot waits (without a time limit) at the seam end until the arc has extinguished,

FUNCON_ENDCON,4

the robot waits (without a time limit) at the seam end until the powersource announcer program-end.

In case that the function FUNCON_ENDCON is not used, the command FUNCON_WAITEND,1000 Waiting time in milliseconds causes the robot to respect the entered waiting time on each end of the welding path. With this waiting time you reach a more defined burn back time of the wire and thus a perfect free end of wire. By means of the command FUNCOFF_WAITEND the function is switched off.

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Programming Manual ROTROL速 II

Block 8 - Standard

Arc monitoring

3.1 Extension arc monitoring Insert / Monitoring

After switching on the arc monitoring you have the additional possibility to allocate a digital output to each of the three error causes (wire, gas and current). Thus a visual or acoustic signal transmitter could be actuated indicating the error.

FUNCON ARCCON FUNCON ONLCON IF T1S1NAHT = 1 THEN BEGIN SUCHPOS := 111 CALL SUCHEN

Monitoring

Define output for arc monitoring

FUNCON_ARCERR,Nr.

Gas:

FUNCON_GASERR,Nr.

Wire:

FUNCON_WIREERR,Nr.

Current:

Switching on the extension

The indicated output is switched on after the arc error occured and is only switched off with continuation or abortion of the program run (after elimination of the error cause). Please note that the number of the digital output can be defined separately for the three error causes. Please see the current digital output layout in the circuit diagrams of the controller.

Programming Manual ROTROL速 II

Page 9

Arc monitoring

Block 8 - Standard

3.2 Status information from the power source

Use the command:

GETSTAT_(VAR)

to transfer a ROTROL internal variable for further processing to a CAROLA- Variable

The BOOL- Function (see Option: Block 8, page 5) and the mask parameters the individual messages can be filtered.

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Arc monitoring

Meaning of the individual bits and the corresponding decimal mask (additionally also the Hex value): Bit

Meaning

Mask

Reserved Reserved Reserved Reserved Reserved

1 2 4 8 16

000001H 000002H 000004H 000008H 000010H

6 7 8 9 10 11 12 13 14 15 1 6

SD – Failure : SD – Failure : SD – Failure : SD – Failure : SD – Failure : SD – Failure : SD – Failure : SD – Failure : SD – Failure : SD – Failure :

32 64 128 256 512 1024 2048 4096 8192 16384

000020H 000040H 000080H 000100H 000200H 000400H 000800H 001000H 002000H 004000H

Reserved

32768

008000H

17 18 19 20 21 22 23 24

Current yes (Current monitoring) Wire yes (wire monitoring) Gas yes (Gas monitoring) Arc existing End of welding program Collective fault SD- Abbortion Recognition SD- Abbortion Porosity supercision

65536 131072 262144 524288 1048576 2097152 4194304 8388608

010000H 020000H 040000H 080000H 100000H 200000H 400000H 800000H

Current Voltage Wire speed Gas Wire storage Reserve Arc break Porosity Weld time error Motor current counter

1 2 3 4 5

----------------------------------------------------------------------------------------------------------------------------------------

4 Causes for malfunction A malfunction means that the arc does not work correctly. Causes for malfunctions could be: - Lack of gas - "Sticking in the nozzle" - Lack of wire - Wire feed problems (missing or bad wire feed) - Not enough cooling water in the welding machine (perhaps no ventilation) - Welding machine (GLC) damaged - Earth problems (missing earth connection) - Failure in the cable assembly Programming Manual ROTROL® II

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Arc monitoring

Block 8 - Standard

5 Heat input When the heat input is too high it is possible that the material structure of high-alloy steel can be changed or destroyed. These changings lead to hot cracks which can cause the steel to break when loaded. Therefore, the heat input must be exactly observed when welding this kind of steel. It is indicated in KJ/cm for each kind of steel. The heat input is calculated with the formula Heat input

U*I*60 V

Es =

U = Voltage (Volt) I = Weld amperage (Ampere) V = Speed

By means of the command FUNCON_ HEATINP

the current heat input is shown on the display of the robot controller.

Robot controller display of the heat input

CARL CLOOS SCHWEISSTECHNIK ROTROL-II V 7.00 L: 1 P: 1 + / - V: 50 1DR: 200 2 L:__U 3 H: 700 4AMP: 0 >> FREIGABETASTE GELOEST << ROTROL Z-INTERPRETER PROGRAMM: A1 Betriebsartwechsel, Abbruch [ESC,AUS] LineNr.

Command

[c:]

HP-Name

1 VAR A 2 LIST 1=(4711,1,0,50,100,0,700,0,2,0,50,0 3 MAIN 4 FUNCON HEATINP 5 $ (1) 6 GP (1,2) 7 GC (3,4,5) 8 ARC (5,6,7) 9 GC (9) 10 GP (10,11)

(UP,Dn,PgUp,PgDn), continue (ENT), return (ESC)

AUTOMATIK

Up-Name

A1 A1 A1 A1 A1 A1 A1 A1 A1 A1

| F5: Execute

CARL CLOOS SCHWEISSTECHNIK ROTROL-II

ROTROL Z-INTERPRETER

7.00

PROGRAMM:

[c:]

AUTOMATIK

8 GC (2,3,4)

target point number:

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Programming Manual ROTROL速 II

E=19800

[J/ cm]

Block 9 - Standard

Program functions

Index Program functions ........................................................................................................ 3 1 Summary of the program functions ....................................................................... 3/4 2 Linkage operations .................................................................................................... 5 2.2 Jump command ................................................................................................. 6 2.3 Linkages to digital inputs ................................................................................... 8 2.4 Linkages to variables ......................................................................................... 9 2.5 Alternative instruction after next instruction ......................................................... 9 2.6 Program examples .......................................................................................... 10 2.7 Other applications ............................................................................................ 11

4 Online parallel shift ................................................................................................... 18 4.1 Cartesian shift of spatial points ........................................................................ 18 4.2 Online transformation and imaging ................................................................... 19 5 Digital inputs and outputs ....................................................................................... 20 5.1 Switching of digital outputs via program command ........................................... 20 5.2 Interpolated switching on and off of digital outputs ............................................ 21 5.3 Binary coded interrogation of digital inputs/outputs ........................................... 22 5.4 Binary coded switching on of digital inputs ....................................................... 23 5.5 Digital input/output menu .................................................................................. 24 5.6 Digital outputs with reserved functions .............................................................. 25 6 External axes ............................................................................................................ 26 7 Changing the TCP and TOV during program run .................................................. 26 7.1 Change of the TCP value ................................................................................. 26 7.2 Temporary change of the TOV value ................................................................ 27 7.4 Read existing TCP values ................................................................................ 28 7.5 Online transformation due to a determined TCP deviation ................................ 28 8 Keypad simulation ................................................................................................... 29 9 Processing point information ................................................................................. 29 10 Program interruption .............................................................................................. 29 11 Wait commands ...................................................................................................... 29 Programming Manual ROTROL速 II v7.0x/S/12.03

Page 1

3 Subroutines .............................................................................................................. 12 3.1 Summary ......................................................................................................... 12 3.2 Handling and commands ................................................................................. 13 3.3 Program example ............................................................................................ 14 3.4 Enlarged subroutine technology ....................................................................... 16 3.4.1 Commands in comparison ........................................................................ 16 3.4.2 Program example ..................................................................................... 16 3.5 Additional functions .......................................................................................... 17 3.5.1 Copying points from external programs ..................................................... 17 3.5.2 Definition of variables ............................................................................... 17

Program functions

Block 9 - Standard

12 Read and write run times ....................................................................................... 31 12.1 Read in a time ............................................................................................... 31 12.2 Write a time ................................................................................................... 33 12.3 Read and write a time in the parallel task ....................................................... 33 13 Multi-layer technology ............................................................................................ 34 14 CEBS Production Data Acquisition ...................................................................... 34 14.1 Parallel task .................................................................................................. 34 14.2 Production Data Acquisition .......................................................................... 34 14.3 Program creation and linkage ........................................................................ 34 14.3.1 Start programs from the main memory .................................................... 35 14.3.2 Reload and start programs from disk, hard disk or PC ............................ 36 14.3.3 Creation of program names for the automatic reload of programs ........... 37 14.3.4 Delete programs ..................................................................................... 38 14.3.5 Save programs ....................................................................................... 38 15 Messages and entry of variable values ................................................................ 39 15.1 General .......................................................................................................... 39 15.2 Command WRITE .......................................................................................... 39 15.3 Command GOTOXY ...................................................................................... 40 15.4 Command READ and WREAD...................................................................... 40 16 Oscillation ............................................................................................................... 41 16.1 General view .................................................................................................. 41 16.2 Oscillating amplitude (oscillating width) .......................................................... 41 16.3 Oscillating frequency ...................................................................................... 43 16.4 Oscillating direction ....................................................................................... 44 16.5 Current oscillation .......................................................................................... 45 16.6 Oscillating orientation to be defined ............................................................... 45 16.7 Oscillating form .............................................................................................. 46 16.8 Axis oscillation ............................................................................................... 47 16.9 Manual axis oscillation ................................................................................... 47 16.10 Oscillating synchronous signals .................................................................... 48 17 Operational mode MASTER-SLAVE ...................................................................... 48 18 Subroutine call........................................................................................................ 48 19 Error messages and procedure call in case of errors ......................................... 49 19.1 Summary ....................................................................................................... 49 19.2 Extended error message output ..................................................................... 49 19.3 ONERROR .................................................................................................... 50 19.4 Switching of digital outputs in case of error messages ................................... 52 20 Online point shift in the workpiece coordinate system ....................................... 52

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Program functions

Program functions Program functions The realisation of complex and comfortable program runs requires a lot more functions and commands as described in the mode PROG. This includes among others functions and commands that are able to create, relocate and copy points during the program execution, to acquire program run times or welding times and to allow linkages of several programs.

1 Summary of the program functions GABELWEL.S RESTART EXTERNAL PROC REI FROM MASTER VAR INP LISTS 2 = (5211,1,0,40,80,0,700,0,0,0,100,22,330,0,0,0,10,0,35,30,0,0) LISTE 3 = (5211,1,0,40,80,0,700,0,0,0,100,22,330,0,0,10,10,0,35,30,0,0) LIST 1 = (5211,1,0,222,0,0,700,0,0,0,100,22,330,0,0,0,0,0,35,30,0,0) LIST 100 = (5211,0,0,178,0,0,700,0,0,0,100,22,330,0,0,0,0,0,35,30,0,0) MAIN DECHANGE PTPMAX (40)

GABELWEL.S

SET (5) GP (100) ! STARTPKT.SUCHBEWEGUNG WHEN IN(1 ) DURING GC ( 102) THEN JUMP L001 RESET ( 2) PAUSE ! SENSORSIGNAL NICHT GEKOMMEN

Button Function / Command

Page

Linkage operations (interrogation of digital inputs and variables) ........................ 5 Counting loop, jump command Define subroutines and variables ...................................................................... 12 Parallel shift, transformation and imaging .......................................................... 19 Switching digital outputs ................................................................................... 20 Define, position and parameterise external axes .............................................. 26

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Program functions

Block 9 - Standard

Button Function / Command

Page

TCP/TOV change during program execution .................................................... 26 Keyboard simulation ........................................................................................ 29 Online TCP transformation Store, read, copy points during program execution ........................................... 29 Command: PAUSE .......................................................................................... 29 Acquisition of program run and welding times Waiting times ................................................................................................... 29 Multi-layer technology ....................................................................................... 34 Parallel task, overlay and run ............................................................................ 34 News (WRITE,READ,WREAD,GOTOXY) ........................................................ 39 Oscillation and weaving patterns ...................................................................... 41 Operational mode Master-Slave ....................................................................... 48 Call subroutines ............................................................................................... 48 Show freely definable messages in EMERGENCY-OFF situations Function: Onerror ............................................................................................. 49 Activation of a defined coordinate system ........................................................ 52

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Program functions

2 Linkage operations 2.1 Summary After selection of the dialogue box for the linkage of programs and program runs the following possibilities appear: ELSE..: Alternative instruction after THEN (IF_IN(xx)_THEN_JUMP_AA_ELSE_JUMP..) Availability: only after preceding IF-instruction. Insert / Variablenbearb. RESTART MAIN START: IF IN(11) THEN JUMP ABLAUF WRITE ('KEIN TEIL EINGELEGT. BITTE PRUEFEN !)

FOR..: Definition of counting loop

Read in and set variables see variable processing

A:=..: Add / select variables

BOOL..: Arithmetic linkage operation

IF..: Interrogation of digital input signals and variable values

Label: Define jump target JUMP..:Jump command

RESTART MAIN START: IF IN(11) THEN JUMP ABLAUF WRITE ('KEIN TEIL EINGELEGT. BITTE PRUEFEN !)

Selection window with selected functions and instructions

When the functions "IF, FOR or BOOL" are selected, a number of selected instructions appears in the selection window of the dialogue box and can be chosen via the

arrow keys "UP DOWN ". The transfer to the preview bar is made with the button "Select". Only after the creation of a complete command line the entry into the user program can be made by means of the instruction "Insert". The button "ELSE" is only available after the input of a complete IF instruction in the user program. This allows the programmation of an alternative instruction after the next instruction in the user program. The jump instruction (JUMP) and jump target (LABEL) are input via the simulated alphanumeric keypad in the run. ( IN NOT IN VAR/ZAHL

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Program functions

Block 9 - Standard

2.2 Jump command Normally, the program is executed line by line. However, in some cases, it may be required to 'jump' to another line in the program. This is possible using a Jump label or Jump command. These commands are often used in conjunction with inquiries. These inquiries can refer to the signal state of the digital inputs or are used with variables. At least two positions must be defined for a jump within a program.

The first position is the jump target (jump label). This target is identified by a name and a colon ":". It is possible to define several jump labels within a program, however, these jump labels must have different names (8 digits maximum). Example: START: The second position to be defined is the jump position. This is the position in the program from where the jump is executed. It is possible to jump from several positions within a program to a jump target with the same name. Example

JUMP_START

Restrictions 1.

Define Label only once (another jump target is given another name)

Label names should be different to variable names and CAROLA commands

It is not allowed to jump from a sub-routine into the main program

It is not allowed to jump from a counting loop or a BEGIN/END instruction

8 digits maximum may be used.

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Program functions

Program example In this example, the welding sequence of the two seams was modified. START: SEAM1: SEAM2:

identifies the program start identifies the performance of the 1st seam identifies the performance of the 2nd seam

Sprung.S

Programming Manual ROTROL速 II v7.0x/S/12.03

RESTART LIST 1=(5211,3,500,259,160,290,0,0,2,30,67,40,330,0,0,0,0,0,0,12) LIST 2=(5211,3,430,228,132,180,0,0,2,28,67,40,330,0,0,0,0,0,0,12) MAIN START: PAUSE JUMP NAHT2 NAHT1: $ (2) GP (1..3) GC (4,5) GP (6,7,1) JUMP START NAHT2: $ (1) GP (7..9) GC (10,11) GP (12,2) JUMP NAHT1 END

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Program functions

Block 9 - Standard

2.3 Linkages to digital inputs The digital inputs are used for the communication between the robot controller and the peripheral equipment, which is specially designed for the user's requirements. These linkage tasks include signals for the position interrogation of tools and clamping elements or the inquiry of the start preselection buttons on the different working stations. During program execution, the inputs are interrogated by means of commands and the connected commands influence the program execution. ABFRAGE.S RESTART MAIN START: IF IN(11) THEN JUMP ABLAUF WRITE ('KEIN TEIL EINGELEGT. BITTE PRUEFEN !)

It is often required to continue the program run depending on the "conditions" of the peripheral equipments.

IN(11) THEN AND OR

ABFRAGE.S RESTART MAIN START: IF IN(11) THEN JUMP ABLAUF WRITE ('KEIN TEIL EINGELEGT. BITTE PRUEFEN !) IN(11) THEN BEGIN JUMP PAUSE RUN

next instructions

The following commands are made available by the operating system: IF_IN(12)_THEN_JUMP_START IF_NOT_IN(5)_THEN_PAUSE. These commands are composed of two parts: 1. Condition IF_IN(12)

Inquiry of signal state 1 on input 12

IF_NOT_IN(5)

Inquiry of signal state 0 on input 5

IF_NOT_IN(6)_AND_IN(7)

Inquiry of signal state 0 on input 6 and signal state 1 on input 7

IF_NOT_IN(6)_OR_IN(7)

Inquiry of signal state 0 on input 6 or signal state 1 o input 7

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Program functions

2. Next instruction The instruction to be executed follows after THEN if the condition is true. In the example given a PAUSE follows.

THEN_PAUSE

2.4 Linkages to variables BAUTEIL8:=0 !INITIALISIERUNG SCHWEISSWERTEALLER STATIONEN IF BAUTEIL = 0 THEN T1WERT1: =1 ELSE T1WERT1: =0 IF BAUTEIL = 0 THEN T1WERT2: =1 ELSE T1WERT2: =0

BAUTEIL 1 * / + < >= <>

By means of variables, simple arithmetic operations can be installed in a program. With the IF command, limited jumps can be effected which depend on the value of one or several variables. As with digital inputs, linkage operations can be made by means of variables.

IF_COMPONENT1_=_0_THEN_T1VALUE1:=_1_ELSE_T1VALUE1_:=_0 Alternative instruction Next instruction Condition

see block 10 "Variable processing" 2.5 Alternative instruction after next instruction In the case that the program execution should not be continued in the next line if the condition in the instruction is not met, an alternative instruction can be given, e.g. XX:_IF_NOT_IN(7)_THEN_JUMP_AC_ELSE_JUMP_BC. If input 7 is not "1", the program will continue at AC. If input 7 is "1", the program will jump to BC. Standard interrogation loop WW:_IF_NOT_IN(5)_THEN_JUMP_WW In this line, continuation of the program is made dependent on the signal state of input 5. Please also see the chapter "Wait commands" in block 9.

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Example:

Program functions

Block 9 - Standard

2.6 Program examples Program example 1 Within a selection program with the program name “MENU” three keys are interrogated. These keys are situated directly at the three working stations of the installation. By means of these keys, the release is given to the respective station. The inputs are as follows: Input 14 = is station 1 = is program "STATION1" Input 15 = is station 2 = is program "STATION2" Input 16 = is station 3 = is program "STATION3" Selection program example MENU MENUE.S

RESTART MAIN START: IF IN(14) THEN RUN STATION1 IF IN(15) THEN RUN STATION2 IF IN(16) THEN RUN STATION3 JUMP START END

Using the RUN command, another program in the working memory is started. The name followed by the RUN command indicates the relevant program (see multi program technology).

Program example 2 The workpiece clamping device of a robot installation has a switch installed which is activated by the workpiece, thereby checking that a workpiece is present before welding. In the following example, this switch is connected at input 11. After the interrogation IF_IN(11) the program jumps to RUN only if input 11 has the signal state "1" and thus a workpiece is clamped. SIGNALE.S

RESTART MAIN START: IF IN(11) THEN JUMP ABLAUF WRITE ('NO PART INSERTED, PLEASE CHECK IT!') PAUSE WRITE ('') JUMP START ABLAUF: GP (1..3) $ (2) .. END

Page 10

If the condition is not met, a text which is defined in the WRITE command is shown on the display. In the next line there is the command PAUSE. As soon as the operator has inserted a part, he must activate the START key on the operation panel. Then the screen text is deleted and the program continues by jumping back to the start line.

Programming Manual ROTROL® II

Block 9 - Standard

Program functions

Program example 3 The next instruction described in the previous explanations and examples only comprised one command. But it may be necessary that a next instruction must consist of a number of commands. For this reason, the two commands begin of a next instruction and end of a next instruction

BEGIN END

are integrated in the operating system to define a package (list) of commands, for linkage with a condition.

TEST.S

RESTART MAIN IF NOT IN(11) THEN BEGIN WRITE ('WRONG PART INSERTED!') PAUSE WRITE ('') END WRITE ('PROGRAM IS RUNNING') GP (1..3) $ (2) .. END

2.7 Other applications Counting loop definition (see chapter "Variable processing") Variable definition (see chapter "Variable processing") Arithmetic linkage operations (see special documentation "Parallel task")

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Program functions

Block 9 - Standard

3 Subroutines By means of subroutines, the programming time and the required storage capacity in the robot controller can be reduced. Furthermore, complicated program structures can be arranged more clearly. The principle of the subroutine technology is also applied for the parameter lists. In a certain range of the program a procedure is declared and given a name. This is done in the declaration part, i.e. before the MAIN command. During program execution the procedure is called by a command, executed and then execution is continued in the next line of the program. Subroutines can be nested, e.g. a procedure can be called during another procedure. It is however important that the called procedure is declared before the procedure where the call is made. It is possible to save more programming time by calling up a procedure that has been declared in one program in one or several programs

3.1 Summary

Define procedures for the use in external programs

Making available external procedures in the current program

RESTART PUBLIC PROC SYN EXTDEF (1;0;700,701,702) EXTCHAIN (1) ENDP SYN

Copying points of external programs

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Define and call up internal procedures

Define variables

Programming Manual ROTROL速 II

Define and call up subroutines and simultanously use variables

Block 9 - Standard

Program functions

3.2 Handling and commands Internal procedures are created and called up in the section "PROC" of the dialogue box. Procedures which have been declared for internal use are only available in the user program where they were defined. This means that they cannot be used in another program. They are used if the program text can be shortened by repeating text paragraphs and thus arranged clearer. Start of procedure (PROC_....) is created in the declaration part of the program. At the same time the procedure is given a name via keypad. The name should describe the content. End of procedure (ENDP) This command causes a jump back to the place where the procedure was called.

RETURN Quit of procedure before having worked out the procedure totally. The commands PROC, ENDP and RETURN are in the declaration part. Call of procedure(CALL_....) At this line of the program the procedure with the name XXX is executed. The command CALL is located in the operational part of the program. Procedures which shall be used in external programs must be defined as "Public". Normally they are used to control functions in the peripheral equipment and are named "MASTER" in the main program. Included are among others the cleaning of the gas shroud and the synchronous movement of external axes because these functions are used in most of the user programs. To define an external procedure, push the button "Public" which remains active until you push it again. When creating a procedure (see above) it is automatically defined as "Public".

PUBLIC_PROC_REI Enables this procedure to be called up from another program.

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Program functions

Block 9 - Standard

If a user program needs an externally defined procedure, it is necessary to inform the controller in which main program it is defined. The controller asks for the name of the procedure after pushing the buttons "Extern" and "DEF". The name is entered via the simulated keyboard. EXTERNAL_PROC_REI_FROM_MASTER This command is located in the program part before MAIN instead of the procedure declaration. This command indicates the following: - that it refers to an externally declared procedure

EXTERNAL_PROC

- the name of the procedure

REI FROM_MASTER

- the program in which the procedure is declared

3.3 Program examples Example 1 Before the robot moves the figure from the workpiece, it should search the right position by means of a touch sensor.

LIST1=(5411,3,500,259,160,290,0,0,2,30,87,40,330,0,0,0,0,0,0,12) LIST100=(5411,0,0,20) PROC SUCH GP (100) $ (100) SET (1) GP (101) WHEN IN (1) DURING GC (103) THEN JUMP L001 RESET (1) PAUSE DECHANGE L001: RESET (1) DECHANGE CHANGE (102) ENDP MAIN START: PAUSE GP (1..2) CALL SUCH $ (1) GP (3) GC (4..6) GP (7..9) CIRO (0) CIR (9,10,11,60) GP (12,1) DECHANGE JUMPSTART END

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Program example 2 This example shows a subroutine which moves the robot to the mechanical cleaning system. Since this procedure is required in several programs, it is declared as PUBLIC_PROC in the program with the name MASTER. Part 1

Extract from the declaration part of the program MASTER MASTER.S RESTART PUBLIC PROC REIN REI1: IF IN(4) THEN JUMP REI2 WRITE ('MESSER DER REINIGUNG NICHT IN ORDNUNG') PAUSE WRITE ('') JUMP REI1 REI2: GP (1..3) SET (4) WAITI (NOT IN(4)) WAITI (IN(4)) RESET (4) SET (212) GP (2,1) RESET (212) ENDP

Part 2 This program example shows a welding program with a declaration part where the procedure REI is made available from the program MASTER. It is inserted into the run by the CALL command. Several subroutines can be taken over simultaneously in one takeover line. Example: EXTERNAL_PROC_REI,SYNC_FROM_MASTER. UNTERPROG.S RESTART LIST 1=(5411,3,500,259,160,290,0,0,2,30,87,40,330,0,0,0 EXTERNAL PROC REIN FROM MASTER MAIN START: PAUSE $ (1) GP (1..3) GC (4..6) GP (7..9) CIRO (0) CIR (9,10,11,60) GP (12,1) CALL REIN JUMP START END

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PUBLIC PROC SYNC

Program functions

Block 9 - Standard

3.4 Enlarged subroutine technology The enlarged subroutine technology allows the simultaneous use of variables and subroutines (see chapter 2). This is also useful for the parallel shift with a sensor. The handling and creation of subroutines is made in the same way as the creation of normal subroutine described above.

3.4.1 Commands in comparison normal application PROC_SEARCH ENDP RETURN EXTERNAL_PROC.. CALL_SEARCH

Function Start of procedure End of procedure premature end of procedure external procedure procedure call

Application using variables DEFSUBF_SEARCH_(STP) ENDSUBF RETSUBFUNC EXTERNAL_DEFSUBF.. SUBFUNC_SEARCH(9503)

Value of the variable STP

3.4.2 Program example UNTERPROG.S RESTART VAR STP,SPD,STA,POL VAR X,Y,Z,AL,BE,GA,E1,E2,E3,E4 LIST 1 = (5111,1,0,217,0,0,700,0,2,0,100,22,330,0,0,0,0,0,35,30,0,0) LIST 9999 = (5111,0,0,20,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0,0) DEFSUBF SEARCH (STP) $ (9999) SET ( 1) GP (STP) ! START PUNKT SUCHBEWEGUNG WHEN IN(1 ) DURING GC (STP+2) THEN JUMP L001 RESET ( 1) PAUSE ! SENSOR SIGNAL NICHT GEKOMMEN DECHANGE L001:RESET ( 1) DECHANGE CHANGE (STP+1) GP (STP) ENDSUBF PROC TOPCAD L002: GP (9501,9502) SUBFUNC SEARCH(9503) GP (9506) SUBFUNC SEARCH(9507) GP (9510) SUBFUNC SEARCH(9511) GP (9514)

To be continued... Page 16

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...continued: UNTERPROG.S DECHANGE GETPOSR (9520;SPD,POL,STA;1;X,Y,Z,AL,BE,GA;E1,E2) IF X > 100 THEN JUMP TORCHCHK IF Y > 100 THEN JUMP TORCHCHK IF Z > 100 THEN JUMP TORCHCHK STORPOS (9520,100,1,0) !ZEILE NACH ERSTEM DURCHLAUF LOESCHEN STORPOS (9521,100,1,0) NEWTCP (9520,9521,2) GP ,9501) JUMP L003 TORCHCHK: PAUSE ! DIFFERENZ > 10.0 MM >>>> SCHWEISSPISTOLE PRUEFEN<<<< JUMP L002 L003: ENDP TOPCAD

MAIN CALL TOPCAD $ (1) GP (1,2) GUNCHAON (2) GP (3) GC (4,5,6) GP (7) GUNCHAOFF GP (8,9) END

3.5 Additional functions 3.5.1 Copying points from external programs Individual points are copied from external programs. (see chapter "Copy/Create points during program run")

3.5.2 Define variables Necessary variables can be declared via an alphanumeric keypad. The entry is made in the declaration part of the program run (see chapter "Variable processing")

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Program functions

Block 9 - Standard

4 Online parallel shift 4.1 Cartesian shift of spatial points If there are repetitive welds to be made on a part, it is possible to program the points of the repeating cycles only once.

Parallel

Transformation

All other positions are calculated or approached within the cartesian coordinates of the robot, based on the section already programmed.

Spiegelung

VERSCHIE.S LIST 1 = (5211,1,0,48,124,260,700,0,0,16,50,0,0,0,0,0,0,5,35,30,5,0) MAIN DECHANGE GP (1..4)

As this kind of shifting only uses the calculation of one point for all other sections, the program sections (original and copy) can only be shifted parallely to each other. The workpieces can be arranged at different heights but they must also be arranged parallel to each other.

Command: Activation of shift, No. = point number

CHANGE_(No.) CHANGE_(No.,No.)

VERSCHIE.S RESTART LIST 1 = (5211,1,0,48,124,260,700,0,0,16,50,0,0,0,0,0,0,5,35,30,5,0) MAIN DECHANGE GP (1..4) $ (1) GC (5) ARC (5,6,7) GC (8) GP (9..14) !GP (9..13) CHANGE (4) GC (5) ARC (5,6,7) GC (8) GP (9,10) DECHANGE GP (1) END

Using the command CHANGE_(No.) the control calculates a shift vector between the present robot position and the point indicated. This vector is now added to all the following points. All points are ap-

!ALTERNATIV !CHANGE (4,14) !GP (4) !GC (5)

proached, shifted by the calculated vector, until the shift is deleted (DECHANGE).

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Program functions

CHOFF = Turn off shift All the following points are approached with their initial position. CHON = Reactivate the shift vector Using the command CHON the last shift vector is reactivated. The next points are again approached, shifted by the vector. DECH = Delete the shift vector All the following points are approached with their initial position. In order to effect a new shift, a new vector must be created using the command CHANGE_(No.).

Point corrections can only be carried out at the source, except for the shift vector point.

4.2 Online Transformation and Imaging

Transformation

Mirroring

Please see the option chapter "Transformation of points" regarding transformation and imaging.

Parallel

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5 Digital Inputs and Outputs In the standard version, 16 digital inputs and 16 outputs are provided (see block 2 chapter "Digital inputs/outputs"). They serve to control the functions in the peripheral equipment which have to be linked to the program run. "Digital" means that signals from or to the peripheral equipment can have two states only ("ON" or "OFF"). The input signals can be interrogated in the program. The use of conditional jumps allows to control or modify the program run according to the existing input signals. Digital outputs are available for the transmission of signals to the peripheral equipment. They can be set or reset during the program run. Besides, the controller disposes of digital outputs with reserved functions by which systeminternal functions (e.g. arc on/off) can be switched.

MAIN SET (1..3) WAITM (500) RESET (1..3)

Switching of digital outputs via program command

Output

In.-output

Function outputs with reserved functions

Switch

Arc

Pulse

Gas

blow

Wire 1

Wire 2

Digital input/output tester (see block 2 "Digital in/outputs")

5.1 Switching of digital outputs via program command The following commands allow to control functions which are connected to the digital outputs dependent on the program run. There are two commands in the operating system:

SET_(12)

Setting or switching on of one or several outputs

RESET_(12) Reset or switching off of one or several outputs

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Program functions The output numbers are entered via the appearing numerical keypad. If more than one output shall be set, answer the question "Do you wish to set an output range?" that appears after confirmation of the first output number with "YES". Enter the last output number. An output range is entered with two dots(..), individual outputs are entered with a comma (,) in the program run separately. Example: SET_(1..3)

In this example, outputs 1 to 3 are switched on. 5.2 Interpolated switching on and off of digital outputs The command SWITCH_SETOUT,No. Number of digital output

is used to switch on a digital output during path movement without affecting the appearance or quality of the weld seam. The command

SWITCH_RESOUT,No. Number of digital output.

is used for switching off. Interpolated switching on / off of digital outputs is applicable for the Tandem welding procedure. The second welding wire, for example, can be switched on or off during path welding without delaying the welding speed and switching off the arc for a short time. Example: RESTART LIST 1=(5411,3,0,85,210,300,700,0,2,0,100,240,0,0,0 MAIN ST: PAUSE SET (213) GP (1,2) GC (3) SWITCH SETOUT,214 GC (4,5) RESET (213,214) GP (6,7) JUMP ST END

!Wire SG 2 1,2mm !Gas: 92% Ar / 8% CO2 !Wiredistanz: 18 mm !second Wire on

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5.3 Binary coded interrogation of digital in-/ and outputs 5.3.1 Binary coded interrogation of digital outputs The command GETOUT_(OUT,9,8) Number of outputs to be read First output to be read Variable (is given a decimal value)

16 0

15 0 64

Output number Scwitching state ( = BCD-Code)

128

is used to interrogate the signal states of max. 32 digital outputs being connected in series. The signal states of the indicated outputs (see chapter 5.4) are looked at in the binary system and the variable OUT mentioned in the example is given a decimal value. 14 1

13 0

12 1

11 0

10 1

9 0

Decimal value = 42

Decimal significance of the bits

The BCD-Code which was read-out by the external controller can now be checked in combination with the command INWORD. For this purpose, the external controller has to re-transfer the BCD-Code back to the inputs of the robot controller. The decimal variable value in the command INWORD must then be the same as in the command GETOUT.

5.3.2 Binary-coded interrogation of digital inputs If digital inputs are used to determine program names (see chapter "Generate program names for automatic reloading of programs), the command INWORD_(EING,9,8) Number of inputs to be read First input to be read Variable (is given a decimal value) is used to interrogate a group of inputs. The variable EING mentioned in the example is given a decimal value which is based on signal states existing on the inputs. In the above mentioned example eight inputs are interrogated. The first input to be interrogated is number 9.

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32 1

16 0

8 0

4 0

2 1

1 0

Input 14

Input 13

Input 12

Input 11

Input 10

Input 9

Input 15

128 64 0 1 Input 16

Example: the decimal value of 98 is created

Programming Manual ROTROL速 II

decimal value Signal state at input

Block 9 - Standard

Program functions

Program example: SIGNALE.S

RESTART VAR_EING MAIN INWORD_(EING,9,8) GENNAME_(‘PR’,EING,’A’) OVERLAY_E,PRGXXXXX END

! Read in the inputs and create the decimal value ! Generate the program name ! Load the program

5.4 Binary coded switching on of digital outputs The command OUTWORD_(14,9,8)

switches on an output group from a decimal numerical value by means of binary codes. This binary output combination can be processed in other controllers. In the above example eight outputs are switched on. The first output to be switched on is number 9. The given decimal value fourteen induces that outputs 10, 11 and 12 are switched on.

8 1

4 1

2 1

1 0

Output 11

Output 10

Output 9

16 0

Output 12

32 0

Output 13

Output 15

Output 16

128 64 0 0

Output 14

An addition of the different decimal values results in 14.

decimal value Signal state at output

The command "SWITCH_OUTBYTE" is nearly the same as the above described command OUTWORD. However, it is interpolational, i.e. it is possible to connect outputs during welding. GC_(3,4) SWITCH_OUTBYTE_(14,9,8) GC_(5..7) Restriction: Maximum eight outputs can be connected in series. Programming Manual ROTROL® II v7.0x/S/12.03

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Number of outputs to be switched First output to be switched Decimal numerical value

Program functions 5.5 Digital in/output menu

Block 9 - Standard

Digital in/outputs are also necessary for the control of peripheral equipments. The user disposes of up to 64 inputs and outputs for this purpose.

Danger

ATTENTION!! Make sure that no dangerous movement of the peripheral equipment is initiated when digital outputs are switched on/off manually. Tools and workpieces may become loose and can fall down.

Set/reset digital outputs Inquire digital inputs

OUT IN

Select the range of numbers with the arrow keys. 1 65 193 209

- 64 - 80 - 208 - 216

I/O freely available for the user Option for MANAX/QUINTO digital Internal system I/O Internal I/O for GLC control

An output is switched on/off directly by the SET/ RESET. The requested output is entered via a numerical keypad. When switching several outputs, the numbers are separated by commas or the last input/ output numbers are entered via the button "range of point numbers" . A set output and an existing input signal will be shown yellow.

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Program functions

To link the computer with the controller, digital outputs are also required for a change of signals. These signals are controlled by the operating system.

Ausgang.S

INSERT/SET-RESET GC (5,6) SWITCH SETOUT,214 GC (7) Output

In.-Output

Switch

Arc

Pulse

Gas

blow

Wire 1

Wire 2

In special cases it might be necessary for the programmer to switch on or off these outputs via the user program. The output numbers from 209 onwards are reserved in the operational system for these special functions.

Arc ON/OFF Pulses ON/OFF Shielding gas ON/OFF Torch blowing-through ON/OFF Switch on wire 1 Switch on wire 2 Change seam tracking direction

output number output number output number output number output number output number output number

209 210 211 212 213 (for tandem only) 214 (for tandem only) 215 (for tandem only)

The function outputs "Arc ON/OFF" and "Pulse ON/OFF" are normally switched by the parameter "State" in the weld parameter list. The commands SET and RESET switch the other function outputs at the respective place in the user program. The use of a certain method depends on the program requirements and the experience of the programmer.

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The following output signals are useful for the programmer:

Program functions

Block 9 - Standard

6 Define, positioning und parameterisation of external axes see chapter "External Axes"

7 Changing the TCP and TOV during program run The use of automatic torch changing systems requires the adaptation of the TCP and TOV during the program run. The controller offers the following possibilities:

TOOL.S

INSERT/TCP-BEARBEITUNG MAIN STCP (10,-5,4905) GP (1..3) Ă&#x201E;ndern

- Temporary change of the TCP and TOV, - Change of the system TCP and TOV,

System

- TCP online transformation (option) due to a determined TCP deviation.

Online Transformation

7.1 Change of the TCP value Calculations of circle and part circle movements, movements of the manual axes of the robot (change of the setting angles alpha, beta, gamma) as well as synchronous movement with external axes require an exact determination of the TCP value for all welding torches in a user program. Enter the TCP values for X, Y and Z via the appearing numerical keypad.

(...,<TCP-value in Z-direction>) STCP (0,0,

The command

4900

Attention

STCP_(value,value,value)

overwrites the System-TCP (TCP.-Nr. 0).

A travel of the robot axes over the angles alpha, beta and gamma in the mode TEACH causes the wire tip to drift away.

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Program example: The example shows that the TCP of the used welding torch is determined by the command "STCP". It is valid until the end of the program or until it is overwritten by another command "STCP".

RESTART LIST 1=(5411,0,0,120,....) MAIN STCP (3,0,496) $ (1) GP (1..3) GC (4..6) GP (7..9) CIRO (0) CIR (9,10,11,60) GP (12,1) END

7.2 Temporary change of the TOV value Because the torch angles can be as different as the TCP values, the command

STOV_(value,value,value) Z direction Y direction X direction can determine the new directional relation of the used welding torch for this program run. The input of the ratios is the same as for the TCP. 7.3 Change of the system TCP The command STCP does not change the settings of the system TCP. Only the program including the command STCP is processed with the values indicated in the program. It is possible to change the system TCP or one of the other five TCP during the program run by means of the command SETTCP_(0,TCPX,TCPY,TCPZ) TCP value for the direction Z TCP value for the direction Y TCP value for the direction X TCP number. Please note that a change in the system TCP results in a change to the travel behaviour in operating mode TEACH.

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7.4 Read existing TCP values TCP values which have been already determined and entered in the TCP mask can be read in during the program run with the command GETTCP_(0,TCPX,TCPY,TCPZ) and used for the program run if necessary. Program example: Read in of the system TCP 3 LESENTCP.S VAR TCPZ,TCPY,TCPX LIST 1=(5411,0,0,120,....) MAIN GETTCP (3,TCPX,TCPY,TCPZ) WRITE ('TCPWERTE SIND:' ,TCPX,TCPY,TCPZ) STCP (TCPX,TCPY,TCPZ) START: PAUSE $ (1) GP (1..3) GC (4..6) GP (7..9) CIR (9,10,11,60)

The example shows that the system TCP 3 is read by the command "GETTCP". The values are filed in the variables "TCPX, TCPY and TCPZ" and shown on the touch screen by the command "WRITE". The command "STCP" adjusts the travelling behaviour of the robot rmechanics in this program run according to the welding torch geometry.

7.5 Online transformation due to a determined TCP deviation NEWTCP

(Determine new TCP during program run)

GUNCHAON

(Activate TCP online transformation)

GUNCHAOFF

(Deactivate TCP online transformation)

Please find a detailed description of the commands in part 2 of the programming manual options, chapter "Transformation of points".

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8 Keypad simulation The keybad simulation makes it easy to enter commands with longer syntax. The button "RETURN" transmits the command line to the program and allows to enter more command lines. The command lines are entered above the current program line.

WRITE ('BITTE DIE STARTTASTE DRUECKEN')

(Please see also block 2 chapter "Terminal simulation")

9 Processing point information see block 9 " Copying and creation of points"

PAUSE By pushing this button the command "PAUSE" is entered in the program run which will be stopped at this point. Only a new START command continues the program run. Depending on the selected operational mode a START command can be input by pushing the button "START" on the PHG (teach pendant) or the control panel and also from the peripheral controllers. 11 Wait commands Some times it is necessary to let the computer wait before processing the next command or to let it wait for the signal change of an input. The respective commands are: PROG:ABFRAGE PROC REI GP (1..4) SET (4)

WAITS

WAITS ( Waitend

WAITM

Wait

The letters "M or S" define the two units Millisecond and Second. VAR/ZAHL (

selection

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10 Program interruption

Program functions

Block 9 - Standard

The letter "I" says that it shall be waited for the signal change of an input, e.g.

WAITI_(IN(4)) WAITI_(NOT_IN(4)) WAITI_(IN(4)_AND_IN(6)) WAITI_(NOT_IN(4))_OR_(NOT_IN(6))

Waits for the "ON-Signal" at input 4 Waits for the "OFF-Signal" at input 4 Waits for the "ON-Signal" at input 4 and input 6 Waits for an "OFF-Signal" at input 4 or input 6

The following example of the command "WAITI" explains how to input the wait commands: After selection of the button "WAITI" the dialogue box shows the interrogation conditions of how the signal state of a digital input must be to be able to continue the program run. Via an "AND" resp. "OR" linkage it is possible to interrogate the signal states of several inputs. Mark the desired condition with the arrow keys. After confirmation by the button "Selection" you enter the number of the respective input. A variable can be used instead of the input number by pushing the button "VAR".

PROG:ABFRAGE PROC REI GP (1..4) SET (4)

WAITI ( Waitend

IN NOT IN

Selection

Dialogue Button to take box over the selection

Then chose a linkage method and repeat the a/m procedure in order to enter other input numbers or finish your input by setting the closing bracket ")". The input which is displayed in the preview bar will be entered into the program run.

PROG:ABFRAGE

PROC REI GP (1..4) SET (4) WAITI ( Waitend

Wait

IN NOT IN

PROG:ABFRAGE selectionPROC

REI GP (1..4) SET (4)

WAITI ((NOT IN(4) AND (NOT IN(6)) Waitend

Wait

AND OR )

selection

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Wait

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NOP The command NOP = (No Operation) is the shortest possible delay time. It corresponds to a cycle of the processor.

7.3 Programmlaufzeit

12 Read and write run times 12.1 Read in a time With the GETTIME command you have the possibility to interrogate three different times (Timer), -

absolute time with date program run time welding time

(Timer 00) (Timer 10) (Timer 20)

and to file the result in one or several variables. Example:

Read in the absolute time with date

GETTIME_(00;SECOND, MINUTE; HOUR, DAY, MONTH; YEAR) Variables where the different units are filed. Defines the Timer

It is not necessary to indicate all parameters. For example only the first three variables are necessary in order to ask for the time. The handling of the two timers for the program run and welding time only differs from the first parameter which determines the timer. Example:

Read in the welding time

GETTIME_(20;MSEC,SECOND,MINUTE,HOUR,DAY) Contrary to the Timer 00 it is not possible to ask for the month and the year. The value for the 1st variable is given in milli seconds. With the two timers 10 and 20 it is not necessary to indicate all parameters. If you only enter one parameter, the total time is stored in the unit "millisecond" in this variable. Example:

Interrogation of the welding time with one variable

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As result for a welding time of e.g. three hours, the value "10.800.000" is input in the variable "Time". This value is calculated as follows: 3 hours = 180 minutes = 10800 seconds = 10800000 Milli seconds The following example shows that the subroutine program for torch cleaning is to be started after a welding time of 25 minutes.

RESTART EXTERNAL PROC REI FROM MASTER LIST 1 =(5411,3,500,259,160,290,0,0,30,87,40,330,0,0,0,0,0,0,12) VAR MSEK,SEK,MIN MAIN START:PAUSE $ (1) !ARBEITSPROGRAMM GETTIME (20;MSEK,SEK,MIN) IF MIN > 24 THEN CALL REI

!im Unterprogramm REI wird der !Timer wieder auf "0" gesetzt; !siehe "Schreiben einer Zeit")

JUMP START END

The same program run with only one variable:

RESTART EXTERNAL PROC REI FROM MASTER LIST 1 =(5411,3,500,259,160,290,0,0,30,87,40,330,0,0,0,0,0,0,12) VAR ZEIT MAIN START:PAUSE $ (1) !ARBEITSPROGRAMM GETTIME (20;ZEIT) IF ZEIT > 1500000 THEN CALL REI JUMP START END

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12.2 Write a time Since the welding time is to be asked once again for example after the cleaning process, it is necessary to set the corresponding timer to "zero". Contrary to the command GETTIME, with which the absolute time can be asked, only the command (Write a time)

SETTIME

allows it to influence the two timers for program run and welding time. Example:

Reset the welding time

RESTART PUBLIC PROC REI SETTIME (20;0) REI1: IF IN (4) THEN JUMP REI2 WRITE ('FEHLER') JUMP REI1 REI2: GP (1..3) SET (4) WAITS (1) RESET (4) WAITI (IN(4)) SET (212) GP (2,1) RESET (212) ENDP

In the above example the Timer 20 (welding time) is set to "0" (zero). But it is also possible to input another value in the command SETTIME which defines the total time in the unit "millisecond".

MAIN END

Example:

Writing a program run time of 15 minutes SETTIME_(10;900000) 15 min = 900 s = 900.000 ms

Program run and welding times are not reset by switching off the main switch. The program run time is not continued with STOP, EMERGENCY STOP, PAUSE and dead man switch released. The absolute time can be set in the operating mode SERVICE (see service manual).

12.3 Read and write a time in the parallel task Please find the description of GETTIME and SETTIME in the special documentation "Parallel task".

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Program functions

Block 9 - Standard

13 Multi-layer technology Please find the description of the multi-layer technology in block1 of the programming manual -Options-.

14 CEBS Production Data Acquisition

Start and stop of a parallel task

Production Data Acquisition

Program creation and linkage

14.1 Parallel task Please see the corresponding special documentation regarding the "Paralell task".

14.2 Production Data Acquisition Please see the corresponding special documentation regarding the "Production Data Acquisition" (Not available at the moment - as of 12.11.01)

14.3 Program creation and linkage Automatic start and reload of programs Due to the fact that several programs can be in the main memory at the same time, it is useful to start one program with another program. You can achieve a maximum amount of security and labour saving by using this function, for example in conjunction with digital inputs, because the start of an unwanted program by the operator is avoided. Page 34

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The function Automatic program execution is divided into two sectors: 14.3.1 Start of programs from the main memory The command RUN_Program name start the programs. Program example The programs Tube, Beam and Frame are programmed on three fixed working stations and shall be executed in any order after actuation of a start preselection (digital input). To do this, another program has to be created which controls the selection. Normally the name MENU is used for this program because of its statement about the program task. ROHR

RESTART MAIN START: IF IN (1) THEN RUN ROHR IF IN (2) THEN RUN RAHMEN IF IN (3) THEN RUN BEAM JUMP START END

RESTART EXTERNAL PROC REI FROM MASTER LIST 1=(5411,1,0,44,56,230,0,0,0,2,30......) MAIN Ablaufprogramm CALL REI RUN MENUE

END

MASTER RESTART PUBLIC PROC REI BEGIN IF IN(4) THEN JUMP L01 WRITE ('MESSER NICHT IN GRUNDSTELLUNG') END L01:GP (1,2,3) GC (4) SET (4) WAITI (NOT IN(4)) WAITI (IN(4)) RESET (4) GC (5) GP (6,1) ENDP REI PUBLIC PROC SYNC EXTDEF (1;1;700,701,702) EXTDEF (2;0;800,801,802,803,804) EXTDEF (3;0;900,901,902,903,904) EXTCHAIN (1,3,2) EXTSYNON ENDP SYNC MAIN

MENUE

RAHMEN RESTART EXTERNAL PROC REI FROM MASTER LIST 1=(5411,1,0,44,56,230,0,0,0,2,30......) MAIN Ablaufprogramm CALL REI RUN MENUE

END

BEAM RESTART EXTERNAL PROC REI,SYNC FROM MASTER LIST 1=(5411,1,0,44,56,230,0,0,0,2,30......) MAIN CALL SYNC Ablaufprogramm CALL REI RUN MENUE

END

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Program functions 14.3.2

Block 9 - Standard

Reload and start of programs from disk, hard disk or PC The capacity of the main memory is often not sufficient enough to file all programs at the same time. But the command

OVERLAY_Name gives you the possibility to automatically reload and start programs from disk, hard disk or PC during the program run. Because it might be necessary to delete a program before reloading another program you are allowed to set more parameters in the command OVERLAY.

OVERLAY_D,Load name,Delete name,SRC The SouRCe code (program text) is also loaded It is not necessary for the program run. Without this information only Z code and points are loaded. Name of the program to be deleted. Without this information no program is deleted. Name of the program to be reloaded. Disk drive identification letter

Program example MENUE MAIN START: IF IN(11) THEN OVERLAY E,PRG1,PRG2,SRC IF IN(12) THEN OVERLAY D,PRG2,PRG1 JUMP START END

PRG1 LIST 1=(....) MAIN GP (1,2) $ (1) GC (3..6) GP (7,8,1) RUN MENUE END

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The add-on SRC is reserved for SourceCode. Therefore, please do not use SRC as program name. The program is deleted before reloading regardless whether reloading was effected successfully or not.

PRG2 LIST 1=(....) MAIN GP (1,2) $ (1) GC (3..6) GP (7,8,1) RUN MENUE END

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Program functions

14.3.3 Creation of program names for the automatic reloading of programs A great number of programs to be reloaded would be beyond the scope of the program MENU. With the command GENNAME

generate name

you have the possibility of using a variable as part of the program name. The program to be reloaded can be determined by inputting a number (max. 4 digits). Basis for GENNAME is the command OVERLAY. However, the real program name is not input as a program to be reloaded, but the reserved name PRGXXXXX. If the control gets the command OVERLAY_E,PRGXXXXX, before having defined a program name with GENNAME, this program will be loaded. In the following example the programs XY0001AB to XY9999AB are to be reloaded and started.

GENNAME_('XY',NUMM,'AB') Variable, the value of which determines the number in the program name.

The program name can be made up of any combination of letters and a variable. Put the letters in quotation marks and separate the letters and variable with a comma.

Program example When inputting for example 7345 for NUMM, the program XY7345A on disk drive (E) is reloaded and started. A program from an external PC with Carola-EDI is reloaded with the identification letter E1: Please ensure that the program names produced by GENNAME do not exceed a total length of eight digits. VAR NUMM MAIN WREAD (NUMM) GENNAME (‘XY’,NUMM,’A’) OVERLAY E,PRGXXXXX END

That means that in addition to the four digits which are reserved for the variable value four further characters can be input.

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The following syntax defines the program name:

Program functions

Block 9 - Standard

14.3.4 Delete programs A program can be deleted during the program run with the command DELETE_Name If the command is DELETE_PRGXXXXX a program, the name of which was determined by GENNAME, is deleted.

14.3.5 Save programs In a similar way as described above, a program can be saved with the command SAVE_Name or SAVE_E,PRGXXXXX

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15 Messages and entry of variable values 15.1 General The output of text messages during the program run makes it easier for the operator to recognise current processes in the robot system as e.g.

WRITE ('REINIGUNGSSTATION WIRD ANGEFAHREN') CALL REI WRITE ('')

- Travel to the cleaning station - Interrogation of digital inputs - current robot position at the workpiece - and more and to specifically affect the program run, if needed, or to enter parameters via keypad which are necessary for the run.

The WRITE command enables self defined texts and variable values to be obtained during a program run. This can be done on the screen (teach pendant PHG), a printer or via a communication interface. With the command WRITE_('..text to be output..') the text is shown on the display. A new command overwrites the text or it is deleted with the command WRITE_(''). It is also possible to obtain the variable values or a combination of text and variable values.

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15.2 Command WRITE

Program functions

Block 9 - Standard

Examples WRITE_(A,B,C) WRITE_('THE_VALUES_OF_VARIABLES_ARE',A,B,C) WRITE_('QUANTITY=',A_'REST=',B) For a printout please use the command WRITE_('LST:','THE_VALUES_OF_VARIABLES_ARE',A,B,C) WRITE_('LST:','QUANTITY=',A_'REST=',B) For an output via communication interface please use the command WRITE_('E:','THE_VALUES_OF_VARIABLES_ARE',A,B,C) WRITE_('E:','QUANTITY=',A_'REST=',B)

15.3 Command GOTOXY The command GOTOXY_(_,_) line number / Y direction position in X direction positions on the screen the texts which are output e. g. by the commands WRITE and WREAD. The position indication refers to the first character of the text to be output and must be carried out before the commands WRITE or WREAD. The normal text output by these commands is carried out in line nine from the left edge of the screen. In X direction max. seventy-nine characters and in Y direction max. twenty-four characters can be displayed. The left corner at the top of the screen has the position values 0,0. If text is output on screen lines reserved for the operating system, the operating system overwrites it when an error appears (e. g. EMERGENCY OFF) with the corresponding messages.

15.4 Commands READ and WREAD Please read chapter "1.2 Commands for the variables" in Block 10.

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16 Oscillation As the weld seam conditions can vary due to tolerances, different air gaps etc., it is often not sufficient to weld simple straight passes. In order to meet these conditions, it is possible to weld a weaving seam instead of a simple straight seam. Oscillation means, the robot traverses the welding path with an oscillating movement. This oscillation movement is a sinusoidal movement and is at 90° to the direction of the path as well as at 90° to the wire direction in its basic position. Different parameters are required to oscillate with the robot. They are described in detail in the following paragraphs.

16.1 General view Oscillating amplitude Pre-defined weaving patterns Define weaving pattern

PENDELFI.S INSERT/PENDELFORM RESTART LIST 1=(5411,1,0,48,124,260,700,0,0,16,50,0,0,0,0,0,0) MAIN Pre-defined weaving patterns

Linear oscillating movement Sinusoidal oscillating movement

Determine oscillating orientation

Shifting the outputs of the synchronous oscillating signals

Activate/deactivate manual axis oscillation

oscillating frequency Activate/deactivate axis oscillation

16.2 Oscillating amplitude (oscillating width) In order to comply with the request for oscillation, the oscillating movement has to be assigned a value. This value is given in a welding parameter list and is called oscillating amplitude.

z.b. ROF ( 2 ) Pendelfrequenz z.b. ROF (10 )

The oscillating amplitude is 10th in the parameter list and is input in "mm". The maximum oscillating amplitude is 99,9 mm. When using a parameter list in which the oscillating amplitude is larger than "0", the robot starts weaving in the next path movement.

Pendelamplitude = Pendelbreite

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Program functions

Block 9 - Standard

The oscillating amplitude can be changed during the welding process by means of the teach pendant (PHG). Example: LIST 1 = (1111,3,0,50,150,259,70,0,2,34,99,22,330,0,0,0,0,0,0,0,0) Value on10th position of the parameter list oscillating amplitude 34 = 3,4 mm

In the above example, a value of 34 is given as the oscillating amplitude. This corresponds to an oscillating amplitude of 3,4 mm. The oscillating amplitude is either entered directly into the welding parameter list or set during path movement by means of the teach pendant (PHG). The value previously set is automatically transmitted to the parameter list and stored. Program example:

RESTART LIST 1= (5411,1,0,50,200,0,700,0,0,14,50,0,0,0,0,0,0,50 MAIN $ (1) GP (1,2) GC (3..6) GP (7,8,1)

oscillating amplitude 14 = 1,4 mm

RUNMENUE END

L: 1 P: 1 + / - V: 50 1DR: 200 2 L:__U 3 H: 700 4AMP: 14 >> DEADMAN SWITCH NOT PRESSED << Change operation mode, abort [ESC,OFF] Line.Nr

Command

MainProg

1 VAR A 2 LIST 1=(4711,1,0,50,100,0,700,0,2,0,50,0 3 MAIN 4 $ (1) 5 GP (1,2) 6 GC (3,4,5) 7 ARC (5,6,7) 8 GC (9) 9 GP (10,11) actual target point number: K: R:

-4500 2538655

4300 3516151

1 15677 4194154

0 3007965

900 3468317

Press release key, change operating mode or abort with ESC

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SubProg

A1 A1 A1 A1 A1 A1 A1 A1 A1

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Program functions

16.3 Oscillating frequency A robot welds a weaving seam with a certain number of weaving motions per second. This is called "Oscillating frequency" The value of the oscillating frequency is determined with the command: ROF ==> Reduce Oscillating Frequency Example ROF_(3). When using the ROF the following table is used for the reduction of the oscillating frequency: Hz Hz Hz Hz Hz Hz Hz Hz Hz Hz

ROF_(12) ==> 2,08 Hz : : ROF_(15) ==> 1,67 Hz : :

ROF_(1) ==> 25,00 ROF_(2) ==> 12,50 ROF_(3) ==> 8,33 ROF_(4) ==> 6,25 ROF_(5) ==> 5,00 ROF_(6) ==> 4,17 ROF_(7) ==> 3,57 ROF_(8) ==> 3,13 ROF_(9) ==> 2,78 Standard- ==> ROF_(10) ==> 2,50 setting ROF_(11) ==> 2,27

The ROF values given in the table depend on the axes and refer to a 6 axes robot. If the ROF command is used in a program run, its value remains valid until another value is input or the program is ended. If the ROF command is not used in a program, the computer automatically uses the ROF_(10) frequency factor (standard setting). Program example: Please note:

RESTART LIST 1= (5411,1,0,50,200,0,700,0,0,14,50,0,0,0,0,0,0,50 MAIN PAUSE $ (1) ROF (6) GP (1,2) GC (3..6) GP (7,8,1) RUNMENUE END

!FrequenzĂ¤nderung auf 2,78 Hz

The nineth parameter of the weld parameter list "OSCILLATING FREQUENCY" is active from software version V700.31A on. The changing of the oscillating frequence in the weld parameter list has priority over a change via the command "ROF" (see chapter "Weld parameter lists" in block 7).

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Program functions

Block 9 - Standard

16.4 Oscillating direction During oscillation, the oscillating motion is 90° to the travel direction; with the exception of "longitudinal seam oscillation". The oscillating movement is also 90° in relation to the wire direction. This value, however, can be changed. The oscillating plane is changed in the parameter list under the designation “Angle of Oscillation”. The value for “Angle of Oscillation” must be at the 14th position in the parameter list and is input as a degree. LIST 1 = (1111,3,0,50,150,259,70,0,2,16,99,22,330,0,0,0,0,0,0,0,0) value at 14th position in the parameter list Ang. of Oscillation Alteration of oscillating direction

When the "Angle of Oscillation" is indicated in degrees, the oscillating plane is then turned to the wire direction by the value indicated. If the Angle of Oscillation is given as 0, then the oscillating plane is 90° to the wire direction. A value of 45° is input for "Angle of oscillation", i.e. the oscillating plane is to be turned 45° in the positive direction.

" The angle of oscillation depends on TOV.

Chart: Oscillating direction in relation to wire direction

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16.5 Current oscillation In principle, a specified oscillating direction refers to the first point of the path. It is maintained until the next point of the weld path even if the welding torch changes its orientation while traversing the path. It is, however, possible to actualize the oscillating direction when changing the position of the welding torch in the welding path, i.e. to adjust it to the present position of the wire direction. This is shown in the 15th position of the parameter list. LIST 1 = (5411,3,0,50,150,259,70,0,2,16,99,22,330,0,0,0,0,0,0,0,0) Value at 15th position in the parameter list Present osc. direction 0 ==> Oscillating direction constant 1 ==> Actualize oscillating direction 11- 20 ==> using defined oscillating direction

In addition to the two values "0" and "1" for the "actual oscillation", you have the possibility of activating an oscillating orientation which is defined with the command OSCDIR = OSCillation DIRection. Possible values for the parameter "actual oscillation" are here "11..20", whereby the value "11" activates a weaving orientation with number "1"; value "12" activates the oscillation orientation with number "2" etc. For the command "OSCDIR" two points with the same torch position are programmed. The direction from the first point to the second represents a weld seam for which an oscillating orientation is determined and used on the real weld seam.This mainly occurs by changing the component position with the aid of external axes during welding. The whole syntax of the command OSCDIR is: OSCDIR_(101,102,3) Index, Number of the oscillating orientation 2. point 1. point The determination of the oscillating orientation is not necessary in case of synchronised axes.

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16.6 Defined oscillating orientation

Program functions

Block 9 - Standard

Program example:

RESTART LIST 1 = (5211,3,0,48,92,236,700,0,261,13,60,23,363,0,14,0,0,5,35,30,5,1) MAIN PAUSE OSCDIR (200,201,4) $ (1) GP (1,2,3) Weld list parameter GC (3..5) GP (6) "CURRENT OSCILLATION" END

16.7 Oscillating form Command:

OSC_FORM Name of the oscillating form

The two oscillating forms "SIN" and "LIN" are already integrated in the controller.

SIN -

"Normal" sine oscillating form

LIN -

Linear oscillating form (torch oscillates in seam direction forward and backward)

Without input OSC_SIN is given.

As an option, weaving patterns can be freely defined. They are needed for example to weld vertical-up seams. Please read the chapter "Freely programmable weaving patterns" in the programming and service manual - part "option".

The form of the weaving pattern created via button

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16.8 Axis weave (oscillation) The oscillating movement of only one axis is called axis weave. Since in the case of "normal" oscillation the oscillating movement is produced by several axes, this can lead to collisions with components which are hardly accessible. Due to axis weave, the oscillating movement is only produced by one axis and is therefore easy to survey. Switch on command: FUNCON_AWEAV,5 Axis number AWEAV = Axis WEAVE FUNCON = FUNCtion ON In this example the oscillation is carried out only with axis 5. The parameter axis number is optional. Without indication axis 4 is given. The list parameter "oscillating stroke" (without axis weave with the unit 1/10 mm) has now the value 1/10 degrees in the axis which is concerned (indicated). FUNCOFF_AWEAV

Due to the conversion of the unit in the parameter "oscillating stroke" from 1/10 mm into 1/10 degrees, extremely big movements can arise at the torch, especially in the case of axis oscillation with the base axes (1 - 3). Before starting the program, reduce the "oscillating stroke" in the welding parameter list.

16.9 Manual axis weave (oscillation) (WRISTOSC) Special isolated cases make it necessary to execute an oscillating movement only with the manual axes (axes 4, 5 and 6). It may be that due to problems with the calculation of the kinematic spatial position and depending on the oscillating amplitude delaying movements appear in the robot controller.

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Switch off command:

Program functions

Block 9 - Standard

16.10 Oscillating synchronous signals (SYNCOSC) The measuring of the weld current in case of the option arc sensor is made synchronously to the oscillating movement of the robot. The oscillating synchronous signals (outputs) are switched when achieving the maximum oscillating movement. They are determined for every system but can be freely selected if required - e.g. special system configuration.

17 Operational mode MASTER-SLAVE The operational mode MASTER_SLAVE allows two independent robots to move on a freely programmable external axis (see chapter "External axes").

18 Subroutine call The button opens the following dialogue box from which you can call the procedures being necessary for the program run. Select the requested procedure via the arrow keys and confirm it. This enters CALL_Procedure name Bitte Prozedur wĂ¤hlen... CALL SYNC REIN

in the current program line of your user program. (See chapter 3 "Subroutine technology" in this block).

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19 Error messages and procedure call in case of errors 19.1 Summary Beside the general error messages in case of EMERGENCY-OFF the dialogue box "ERRORS" enables you to define and visualise your own error messages in case that an EMERGENCY-OFF situation was recognised in the peripheral equipment with the aid of optional hardware. This essentially simplifies a recognition of the error reason. ABFRAGE.S

INSERT/ERRORS

RESTART USRMSG (1,’NOTAUS AN WARTUNGSTUER 1 -BITTE TUER PRUEFEN-’,13,0) USRMSG (2,’NOTAUS AN WARTUNGSTUER 2 -BITTE TUER PRUEFEN-’,14,0) MAIN WRERR (1,1) ST:

Define the procedures which have to be processed in case of an arc error so that movements to possible maintenance positions can be made in order to quickly eliminate the reason for the error.

19.2 Extended error message output By means of the command USRMSG_(1,'.... text to be defined freely.... ',5,0) State of digital input Number of digital input Error message displayed on the screen after EMERGENCY-STOP Number of the USRMSG declaration a freely definable error message can be displayed on the screen during an EMERGENCYSTOP situation. The command is entered in the declaration area of a program, i.e. before the MAIN command line. Up to twenty different error messages can be defined. The error message output depends on the state of the given digital inputs (signal state 0 or 1). In the case of an EMERGENCY-STOP the relevant error message is displayed if these inputs are the same as the state indicated in the declaration.

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Program functions

Block 9 - Standard

In the above mentioned example the text is only indicated if the digital input 5 has a 0signal. The error messages are also entered into the error memory of the controller and can be displayed after a program run using the command ERRORS (see block 4, "Error messages"). Irrespective of a digital input these error messages can also be displayed during a program run (and during other programs) with the command WRERR_(1)

WRite ERRor

Number of error message to be displayed

19.3 ONERROR If an error is found in the welding process by the active arc monitoring system, it is possible to interrupt the welding process with the command ONERROR_CALL_ERROR subroutine name subroutine call ONERROR command

and to have a previously defined sub program depleted. In the following example (example 1) the freely defined subroutine ERROR is called up when an arc fault occurs. With the STORPOS command a point is stored at the place of interruption, and this point can be approached later in order to continue the program run. With the command ERRLEVEL_(ERRV) the given variable (ERRV) is allocated a value which results from error indicated by the arc monitoring (see table below). Error table:

Error cause IGNITION ARC GAS WIRE POROSITY SDSTOP Water leakage

Error level 1 2 3 4 5 6 10

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The value of a variable is read by an IF instruction. With the additional WRITE command the text is shown on the display. As soon as the fault has been eliminated, the procedure continues by pressing the START Key. The robot moves to the point which has been generated by the STORPOS command and continues the weld travel to the next programmed path point. The command ONERROR_JUMP_L01 Jump mark Jump command ONERROR command

causes a jump to a given jump target if an error occurs (see example 2). It is not possible to continue the welding travel. Example 1 LBSTOER.S

RESTART LIST 1=(5411,3,100,36,85,200,560,0,6,40,70,25,370,0,0,0,0,0,35,0,0) VAR ERRV PROC ERROR STORPOS (100,50,0,0) GP (55) ERRLEVEL (ERRV) IF ERRV = 3 THEN WRITE ('GAS') IF ERRV = 4 THEN WRITE ('WIRE') PAUSE GP (100) ENDP MAIN ONERROR CALL ERROR ROF (9) $ (1) GP (1,2) GC (3) GP (4,5) END

Example 2

LBSTOER.S RESTART LIST 1=(5411,3,100,36,85,200,560,0,6,40,70,25,370,0,0,0,0,0,35,0,0) MAIN ONERROR JUMP L01 ROF (9) $ (1) GP (1,2) GC (3) GP (4,5) L01: WRITE ('LICHTBOGENSTOERUNG') END

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Program functions

Block 9 - Standard

19.4 Switching of digital output in case of error messages By means of the function FUNCON_ERRMESS,x Output number Command Function On

digital outputs can be defined which shall be switched on in case of an error message to be acknowledged (e.g. "Limit of the working range is reached"). The respective output is set after an error occured and is switched off only if when the error was acknowledged by pushing the key "ESC".

20 Online point shift in the workpiece coordinate system The creation or shift of points (online) can be made in the workpiece coordinate system as well as in the basis and hand coordinate system (see block 3 chapter 3.4 "Workpiece coordinate system"). But this requires that the controller knows the definition of the workpiece related coordinate system. The command MESSAGES.S

INSERT/COORD:-SYSTEM MAIN DCO (100,101,102) STORPOSA (10,SPE,STA,IPOL;3;X,Y,Z,AL,BE,GA;E1,E2) STORPOSA (11,SPE;STA,IPOL;3;X,Y,Z,AL,BE,GA;E1,E2)

DCO_(P1,P2,P3) considers the respective defined directions for the commands "GETPOS" or "STORPOS". It has to be entered in front of the corresponding commands in the user program and remains valid until it is overwritten by another command.

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Index

Variables .......................................................................................................................... 2 1 Variables ................................................................................................................... 2 1.1 Declaration of variables ...................................................................................... 2 1.2 Commands for the variables ............................................................................... 5 1.3 Arithmetic operations .......................................................................................... 5 1.4 Relational inquiries .............................................................................................. 6 2 Counting loops ........................................................................................................ 8

3 Generating points during program run ............................................................... 10 3.1 Storage of point information .............................................................................. 10 3.2 Reading of point information ............................................................................. 11 3.3 Ambiguity of robot axes ..................................................................................... 20 3.4 Determination of the next point number ............................................................. 23 4 Changing the preset point resolution.................................................................. 25 5 Copying external points ....................................................................................... 26 5.1 External Point .................................................................................................... 26 5.2 Command COPYP ............................................................................................ 26 5.3 Generating points during path travel .................................................................. 27

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Copying / Generating points during program run ..................................................... 10

Program functions

Block 10 - Standard

Variables 1 Variables A multitude of different applications such as point generation or shift, air gap calculation of weld seams in combination with touch sensors and many other arithmetic operations can be installed in a program. Linkage operations (see block 9, chapter "2") which depend on the value of one or more variables can be realised just as with the digital inputs. When using variables, the following must be observed: -

A name consisting of maximum 8 characters is assigned to each variable. The first character must be a letter.

The variable name must not be identical with the name of a jump mark, a sub-routine or a CAROLA-command.

The variable must be declared in the declaration part of the program.

The value range of variables is between -2147483648 and +2147483647.

If a value has not been assigned to a variable, its value is -2147483648.

Only integers can be handled. If a division results in a number with fractional parts, it is rounded down.

With some exceptions, variables instead of parameters can be used for commands

1.1 Declaration of variables Equivalent to the subroutine technology, necessary variables as well as the subroutines must be defined in the declaration part of the user program.

Public + VAR - Variable for the use in the actual and further programs

VAR ZDIV !ZDIV = VARIABLE FĂ&#x153;R VERSCHIEBUNG IN Z-RICHTUNG VAR AP !AP = VARIABLE ANFANGSPUNKT DER VERSCHIEBUNG VAR EP !EP = VARIABLE ENDPUNKT DER VERSCHIEBUNG VAR X !X = ACHSE X

Extern + VAR - Indication that it refers to an external declaraion

VAR - Variable for internal use

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Available buttons VAR

Declaration of variables (applicable only within the program run) for the relevant names of variable VAR_PART1,PART2,STUECK

PUBLIC_VAR

Corresponds to the command VAR. PUBLIC allows access from another program to this variable PUBLIC_VAR_REIN,STUECK

EXTERNAL_VAR_REIN,STUECK_FROM_MENUE Indication of one or several variables which have been declared as PUBLIC_VAR in another program (e.g. MENU) and are required in this program

/Variable processing MAIN ABC:=ABC+1 WREAD ('BITTE VERSCHIEBUNG EINGEBEN X Y Z',XDIV,YDIV,ZDIV

"A:=A+1" is When the button actuated, a dialogue window opens showing a list of already defined variables in the user program. They can be selected by the cursor keys and used for further arithmetic operations. New variable names can be added in this dialogue field by the button "VAR".

Select variable...

The name of the variable is defined with the aid of the appearing alphanumeric keyboard.

AL !=WINKEL ALPHA AP !=ANFANGSPUNKT DER VERSCHIEBUNG BE !=WINKEL BETA E1 !=EXTERNE ACHSE 1 Select variable... E2 !=EXTERNE ACHSE 2 EP !=ENDPUNKT DER VERSCHIEBUNG GA ! WINKEL GAMMA Add

Addition of variables

When the input is confirmed, the new variable appears in this list.

AL !=WINKEL ALPHA AP !=ANFANGSPUNKT DER VERSCHIEBUNG BE !=WINKEL BETA E1 !=EXTERNE ACHSE 1 E2 !=EXTERNE ACHSE 2 EP !=ENDPUNKT DER VERSCHIEBUNG GA ! WINKEL GAMMA Add

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The dialogue field Variable offers another possibility to define variables.

Program functions

Block 10 - Standard

/Variable processing VAR STA MAIN WREAD ('PLEASE INSERT DEVIATION X,Y,Z',DIV ABC:=

Having quit the dialogue field the new variable is input in the preview bar where it can be completed. "Select" carried out the operation.

( VAR/ZAHL

Please enter value for calcul. operation ABC:=

/Variable processing VAR STA MAIN WREAD ('PLEASE INSERT DEVIATION X,Y,Z',DIV

By means of the numeric keyboard values are assigned to the variable resp. the necessary arithmetic operation is executed.

The created command line is input via the function "Insert".

DIVX:=DIVX+1 * / + Insert

Declare variablesDo you want to declare new added variables now?

YES

When you leave the dialogue field "Variables" the inquiry appears "Do you wish to declare the new variables now?"

If you answer "YES", the declaration is automatically inserted in the declaration section of the user program.

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1.2 Commands for the variables Input and output commands WRITE_(STUECK,REI)

Output command for the actual values of the variables STUECK (COUNT) and REI.

WRITE_(‘COUNT ‘, PARTS HAVE ALREADY BEEN WELDED.’) Output command where the output of the variable value COUNT (STUECK) is combined with a text. Command for the input of a value to a variable. The computer waits in the command line until the input is finished with the keys RETURN or ENT on the teach pendant (PHG)

WREAD_(SOLL)

WREAD_(‘HOW MANY PARTS ARE TO BE WELDED?’,HOWMUCH) Input command combined with text output READ_(‘SHALL POINT BE APPROACHED YES=1 NO=0’, SELECT) Input command as explained above under "WREAD". However, this READ-command is only executed if the keys Ctrl + W on the keyboard have been actuated simultaneously before this program line is executed.

When executing arithmetic operations with the variables, the result of an operation is always input in front of the variable marked with the equal sign (=) and the colon (:). -

Assignment of value COUNT:= 20

The value 20 is assigned to the variable COUNT.

Addition COUNT:= COUNT + 1

The value of the variable COUNT is increased by 1

Subtraction ACTUAL:= SET - COUTN

The variable IST (ACTUAL) gets the result from the Subtraction of the values SET and COUNT.

Multiplication SCHWZEIT:= SEAM * 7

The result from the Multiplication of the value of the variable SEAM and the factor 7 is assigned to the variable SCHWZEIT. .

Division TEILST:= ACTUAL / 16

The result from the Division of the value of variable ACTUAL and the number 16 is assigned to the variable TEILST.

It is also possible to perform several operations in one line. Example or

COUNT:=TEIL + SET - ACTUAL TEIL:=(A+B) / 4 * (B-A).

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1.3 Arithmetic operations

Program functions

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1.4 Relational inquiries As with inputs, the IF or IF NOT commands can be used with variables to provide conditional branching of the program. In the following examples the condition results in a comparison between two arithmetic values. These values may be composed of a variable and a constant, of two variables or an arithmetic operation. The subsequent statement could be any command in the CAROLA language. Also a list of instructions marked by the BEGIN and END commands can be executed. Example: IF_STUECK_=_15_THEN_... The subsequent statement indicated with "..." is executed if the value of the variable is (=) 15. IF_STUECK_>_SET_THEN_...

In the second example the subsequent statement is executed if the value of the variable STUECK (COUNT) is larger (>) than the value of the variable SET.

IF_ACTUAL_<>_20_THEN_... The subsequent statement is executed if the value of the variable is larger (>) or smaller (<) than 20. IF_SET_<_12_THEN_...

The subsequent statement executed if the value of the variable is smaller (<) than 12.

Program example In this program it is shown how program execution can be controlled by means of variables. In this example, the operator should enter a number of pieces. This batch is then executed. The following message appears on the monitor.

COUNT.S

VAR STUECK,ABFR,IST,REST LIST1=(5211,3,500,259,160,290,0,0,2,30,87,40,330,0,0,0,0,0,0,12) MAIN START:_WREAD_(‘PLEASE ENTER NUMBER OF PIECES: ‘,COUNT) ACTUAL:=0 ABL:_PAUSE $_(1) GP_(1..3) !

Working program run

GP (120..123) ACTUAL:=ACTUAL + 1 REST:=COUNT-ACTUAL

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Continued COUNT.S

IF_ACTUAL_=_COUNT_THEN_JUMP_FRA WRITE_(’,REST,’PARTS MUST STILL BE WELDED’) JUMP_ABL FRA:_WREAD_('ENTER NEW NUMBER OF PIECES? YES=1 NO=0 :’,ABFR) IF_ABFR_=_1_THEN_JUMP_START IF_ABFR_=_0_THEN_JUMP_FIN FIN:_WRITE_(‘PLEASE SWITCH TO T1!’) PAUSE END

For more examples, where variables are used in conjunction with other commands, please refer to the chapters on multi-program technology and STORPOS/GETPOS.

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There is certainly still a large number of application examples which can be simplified or which are only possible by using variables. The type of application of variables depends on the program structure and the welding task.

Program functions

Block 10 - Standard

2 Counting loop The commands within a counting loop are repeated successively as long as the value of the counting variable is larger or equal to the final value. The step size is a value which defines the value by which the counting variable changes per program run of the loop. If no step size is indicated, the counting variable increases by +1 with each program run. The variable must be declared with the VAR command.

FOR ANF:=1 TO 8 DO BEGIN GP (I) GETPOSA (I;SPE,STA,IPOL;KO;X,Y,Z,AL,BE,GA) END

FOR_ANF:=_1_TO_8_DO

FOR_ANF:=_1 _TO_8 _DO

Definition of counting variable to the value 1 Definition of end value Start command for loop

BEGIN

Start of sequence statement

END

End of sequence statement

In the above example, the commands are repeated until the value of the counting variables reaches the end value 8. With each program run the counting variable is increased by 1. After 8 executions of the sequence statement package the start value and end value are equal, the loop is exited and the program is continued. All CAROLA commands can be entered between BEGIN and END. However, a jump (JUMP, RUN etc.) out of the loop is not allowed. Sometimes it might be disadvantageous to change the counting variable always with "+1" per loop run. This is called step size. Using the STEP command, the step size can be changed as you like. Thus, a loop can be programmed to count backwards if the step size is "-1". Example: FOR_ANF:=_8_TO_1_STEP_-1_DO. It should be pointed out that the number values in the mentioned examples can be replaced by variables.

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Program example 1 This example shows a program where the robot is moved to a cleaning station after the welding process has been passed three times. The cleaning program is a sub-routine in the main program MASTER.

VAR ANF LIST 1=(5211,3,500,259,160,290,0,0,2,30,87,40,330,0,0,0,0,0,0,12) EXTERNAL PROC REI FROM MASTER MAIN START: FOR ANF:=1 TO 3 DO BEGIN PAUSE $ (1) ! programm run END

Program example 2 This program allows the user to determine the number of welding programs to be passed prior to approaching the cleaning station. The input is possible via keyboard.

VAR ANF,DURCH LIST 1=(5211,3,500,259,160,290,0,0,2,30,87,40,330,0,0,0,0,0,0,12) EXTERNAL PROC REI FROM MASTER MAIN IF DURCH < 1 THEN DURCH:= 1 START: FOR ANF:=1 TO DURCH DO BEGIN PAUSE $ (1) !programm run END CALL REI READ (‘NEUE ZAHL FUER DURCHLAEUFE ANGEBEN: ‘,DURCH) JUMP START END

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CALL REI JUMP START END

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Copying / Generating points during program run 3 Copying / Generating points during program run 3.1 Storage of point information In addition to the TEACH-IN mode, where the program points are input via the teach pendant (PHG), it is possible to produce points using the program command

VAR SPE,STA,IPOL,KOO,X,Y,Z,AL,BE,GA,E1,E2 MAIN WREAD ('DEVIATION IN X,Y,Z' ,X,Y,Z) STORPOSA (PKT,SPE,STA,IPOL;1;X,Y,Z,AL,BE,GA;E1,E2) Save point information

Alter resolution

Read in point information

STORPOS

= STORe POSition

This command serves for the storage of a point out of the program whereby the coordinate values can be used either as fixed values or as variables. This makes it possible to program the robot with fixed coordinates.

The STORPOS command can be used in three ways: 1. STORPOS_(.........) Storage of the actual position, e.g. determined by a sensor

2. STORPOSA_(...........) Absolute input of coordinates in reference to an indicated coordinate system

3. STORPOSR_(...........) Input of coordinates in Relation to the present position in an indicated coordinate system

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The command STORPOS is composed of: o

Point number

Point speed

Interpolation mode Input of operational mode (0 or 1) in which a point shall be approached Input 0 = CP (continuous path) Input 1 = PTP (point to point)

Status (see Welding parameter list "Setting of digital outputs") The input of digital outputs is effected using the binary number system: 0 = no output 1 = output 1 2 = output 2 3 = output 1 and output 2 4 = output 3 etc.

Coordinate system 0 = Input of incremental values 1 = Base coordinate system 2 = Hand coordinate system 3 = Workpiece coordinate system

Input of coordinates for: (values in 1/10 mm) X-direction Y-direction Z-direction

Input of solid angle for alpha beta gamma

Input of coordinates for external axes 1 to 6 Rotating axes (value in 1/100 degree) Linear axes (value in 1/10 mm)

The commands STORPOSA and STORPOSR additionally require:

(values in 1/10 degree)

If the coordinates X, Y, Z, alpha, beta, gamma are input, it is not necessary to set all values. The controller replaces the missing values automatically.

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Program functions

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Explanation of the STORPOS command

STORPOS_(100,50,0,0) This command stores the actual position of the robot when executing the command under the point number indicated in the STOROS command with the relevant additional inputs for speed, type of interpolation and status.

STORPOSR_(100,50,0,0;1;2000,100,10000,1500,300,2000) With this command a point with relative coordinates is stored, i.e. the coordinate values indicated in the STORPOSR command are added to the actual coordinate values at which the robot is located at the moment.

Using the STORPOSA_(100,40,0,0;1;7500,480,10000,1400,250,1150) command, a point can be programmed absolutely in a selected coordinate system.

Please note that contrary to the commands STORPOSA and STORPOSR a value indication for the coordinate system and coordinates is not admitted in the STORPOS command.

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Structure of the command STORPOS STORPOS_(100,50,0,0) STORPOSR_(100,50,0,0;0;2000,100,100000,1500,300,2000) STORPOSA_(100,50,0,0;0;7500,480,100000,1400,250,1150) Point number Speed Interpolation mode 0=CP,1=PTP Status Coordinate system 0=Axis values; 1=Basis; 2=Hand; 3=Workpiece Axis 1 or X-direction Axis 2 or Y-direction Axis 3 or Z-direction Axis 4 or alpha Axis 5 or beta Axis 6 or gamma ....;1000,2000,3000,4000,2000,1500)

For external axes: as above but in addition Extern 1 Extern 2 Extern 3 Extern 4 Extern 5 Extern 6

Please consider the separation sign semicolon ( ; ) in the command structure! A semicolon (;) must be input for separation before and after the parameters coordinate system and between the parameter for internal and external axes.

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Program functions

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Program example Point generation by command STORPOS

VAR X,Y LIST4=(5111,3,450,65,125,245,0,0,2,0,190,22,330,0,0,0,0,0,0,120,0,0) MAIN GP (1,2) INPUT: WREAD ('INPUT VALUES FOR LENGTH AND WIDTH ,X,Y) STORPOSR (3,100,0,0;1;X,0,0,0,0,0) STORPOSR (4,100,0,0;1;X,Y,0,0,0,0) STORPOSR (5,100,0,0;1;0,Y,0,0,0,0) STORPOS (6,100,0,0) $ (4) GC (3..6) GP (1) JUMP INPUT END

Layout

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Program functions

3.2 Reading of point information In contrast to the STORPOS command, with which points can be generated, the program command GETPOS = GET POSition is used to read point information or to determine the current robot position. In conjunction with the STORPOS command it is possible to change the position of points without approaching them first. All information is read as a Variable (see Variables) except for point number and coordinate system which can be input as a number or a variable.

The command GETPOS works in three different ways: 1.

GETPOS_(....) The actual position of the robot axes is read in any coordinate system. The position for example can be determined by a sensor.

GETPOSA_(....)

Point information is read in a desired coordinate system with absolute coordinates.

GETPOSR_(....) Point information is read in the desired coordinate system relative to the actual position of the robot.

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The commands GETPOSA and GETPOSR are composed of: o

Point number Read-in of information of the indicated point.

Point speed In this variable the speed of the point can be defined (e.g. 100).

Interpolation mode Point mode 0 = The point was stored in the operation mode CP = continuous path. 1 = The point was stored in the operation mode PTP = point to point.

Status maintains the value of the digital outputs 1 - 4 of the indicated point 1 - Welding on 3 - Welding and pulses on 4 - Shielding gas on 8 - Blow-through on

Coordinate system Defines the coordinate system where GETPOS shall calculate the position. 0 - Incremental Contrary to the following coordinate systems, the robot's position of each single axis (axis 1,2,3...) and not cartesian values (X,Y,Z...) are output with incremental calculation. 123-

Base coordinate system Hand axis coordinate system Workpiece coordinate system

Coordinates of internal axes 1. Cartesian values (values in 1/10 mm) X - value Y - value Z - value Solid angle (values in 1/10 degree) alpha beta gamma 2. Incremental values Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6

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(values in 1/100 degree)

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Program functions

Coordinates of external axes Axis 7 Axis 8 (Value indication Axis 9 - rotary axes in 1/100 degree Axis 10 - linear axes in 1/10 mm) Axis 11 Axis 12 With GETPOS the parameter coordinate system is the 1st parameter to be input. All prior parameters are not applicable.

Explanation of the GETPOS command The command GETPOS_(1;X,Y,Z,AL,BE,GA;E1) reads the actual position values of the robot when executing this command and files them in variables.

Using the command GETPOSR_(PT;SPE,IPOL,STA;1;X,Y,Z,AL,BE,GA;E1) the relative coordinates between the actual robot position and the given point are determined and filed in variables.

Using the command GETPOSA_(PT;SPE,IPOL,STA;1;X,Y,Z,AL,BE,GA;E1) the absolute coordinates of a point are determined and filed in the variables.

Please note that contrary to the commands GETPOSA und GETPOSR a value for point number, speed, operation mode and status must not be input in the GETPOS command.

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Structure of the command GETPOS GETPOS_(1;X,Y,Z,AL,BE,GA) GETPOSR_(PT;SPE,IPOL,STA;1;X,Y,Z,AL,BE,GA) GETPOSA_(PT;SPE,IPOL,STA;1;X,Y,Z,AL,BE,GA) Point number Speed Interpolation mode 0=CP,1=PTP Status Coordinate system 0=Axis values; 1=Basis; 2=Hand; 3=Workpiece Axis 1 or X-distance Axis 2 or Y-distance Axis 3 or Z-distance Axis 4 or alpha Axis 5 or beta Axis 6 or gamma For external axes as above but in addition: Extern 1 Extern 2 Extern 3 Extern 4 Extern 5 Extern 6

....;EXT1,EXT2,EXT3,EXT4,EXT5,EXT6)

It is important for GETPOS to enter a semicolon (;) after the parameter point number, before and after the parameter coordinate system and between the parameter for internal and external axes.

Notes:

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Program functions

Layout for the following two program examples

Program example 1 The absolute coordinates of the corner points 2, 3, 4 and 5 have to be determined by means of the GETPOSA command.

VAR X,Y,Z,AL,BE,GA,E1,X1,Y1,Z1,AL1,BE1,GA1,PT,SPE,IPOL,STAT VAR EXT1,EXT2

MAIN ST: WREAD (‘INPUT POINT NO.’,PT) GETPOSA PT;SPE,IPOL,STAT;1;X1,Y1,Z1,AL1,BE1,GA1;EXT1,EXT2) WRITE (X1,Y1,Z1) WAITS (5) JUMP ST END

After starting the program and entering the point number, the absolute coordinates of the desired program appear on the screen.

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Program functions

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Program example 2 On the same component, the dimensions of the part can be determined by means of the GETPOSR. After starting the program and entering the point number, the relative coordinates of the desired point to the actual position (point 2) appear.

7.6

VAR X,Y,Z,AL,BE,GA,PT,SPE,STA,IPOL MAIN GP (1,2) ST: WREAD (‘ENTER POINT NO.’,PT) GETPOSR (PT;SPE,STA,IPOL;1;X,Y,Z,AL,BE,GA) WRITE (X,Y) WAITS (5) JUMP ST END

3.3 Ambiguity of robot axes Resolution of ambiguities in the command STORPOS

The robot can approach a certain point with different positions of the axes (see illustration). This possibility is called ambiguity. For example, axis 1 of the robot can be in a certain position. The same point in space can be reached when axis 1 is reversed for 180° whereby axis 2 changes accordingly. Furthermore it is possible that the robot buckles "upward" (position A) or "downward" (position B) in case of the same point position.

Command SASTOPAT = Solve Ambiguity STOrpos PATtern Resolution of ambiguities in STORPOS With the aid of the command SASTOPAT the angle positions of the axes (for example axes 2 and 3 buckle upward) are basically preset thus avoiding ambiguities.

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Programming Manual ROTROL® II

Block 10 - Standard Illustration:

Program functions Ambiguity

(Position A)

(Position B)

Application of the commands SASTOPAT and STORPOS When using the command STORPOS which changes the cartesian coordinates to the robot axis angles - i.e. a pretransformation - various resolution possibilities exist due to the mechanical construction of the robot. Ambiguity is possible here.

The command GETPOS allows to change the robot axis angles to cartesian coordinates (re-transformation). Therefore there is no ambiguity.

The command SASTOPAT is also active in case of and

Point generation by the command STORPOS Pallet access (handling area)

The command SASTOPAT offers two possibilities for resolution: 1.

Generation of a comparative angle from a known point information SASTOPAT_(0;10)

Index (0); point number (10)

The spatial point input after the command SASTOPAT and generated in the command STORPOS is created by means of the axis positions, with which point 10 is programmed (for example axes 2 and 3 buckled upward).

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Application of the commands SASTOPAT and GETPOS

Program functions 2.

Block 10 - Standard

Direct input of comparative angles SASTOPAT_(1;10;0,0,0,-1600) Index (1); programmed point (not important); Axis 1,3,4,6

Corresponding angle values are input for the axes where ambiguity is involved. Ambiguity can occur on axes 1, 3, 4 and 6. The angle is indicated in 1/10Â°. The number input after the index 1 is a "dummy point number" and is not important. The reference point of the robot is the starting point for the comparative angle information. Starting from the input angles, the controller in axes 1, 3, 4 and 6 always checks the shortest way to the generated point.

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Program functions

3.4 Determination of the next point number The command NEXTP (NEXT Point) serves to determine the next point number existing. By using the NEXTP command, gaps in the point numbering can be recognized and skipped. The command NEXTP_(PKT;NPKT,LPKT,STATUS) is used in conjunction with variables. The meaning of the individual parameters are: NEXTP_(PKT; NPKT, LPKT, STATUS)

From this point number the point memory is checked; next point found, previous point, check status: 0 - no point found 1 - another point found

Program example:

In the following program, points can be corrected by a value which must be input in AUTOMATIC mode via the keyboard. Since the point numbers are not programmed numerically, the next point must be searched by means of the command NEXTP. A variable which is used in the commands GETPOSA and STORPOSA serves to file this point number. Please note that the last two digits of NEXTP are not used and that they can be ignored in the program.

VAR PNR,SPE,IPOL,STA,X,Y,Z,AL,BE,GA,E1,E2,E3 VAR AP,EP,INP,INP2 VAR XVER,YVER,ZVER,ALVER,BEVER,GAVER,E1VER,E2VER,E3VER VAR NPNR,I LIST 1=(5211,3,500,259,160,290,0,0,2,30,87,40,330,0,0,0,0,0,0,12) PROC VERSCH XVER:=0 YVER:=0 ZVER:=0 ALVER:=0 BEVER:=0 GAVER:=0 E1VER:=0 E2VER:=0 E3VER:=0 WREAD (‘ENTER START AND END POINT OF SHIFT:',AP,EP) WREAD (‘WHAT DO YOU WISH TO SHIFT GRUNDA.=1 HANDA.=2 EXTA.=3',INP) IF INP=1 THEN BEGIN WREAD ('INDICATE SHIFT IN X/Y/Z-DIRECTION',XVER,YVER,ZVER) END IF INP=2 THEN BEGIN WREAD ('INDICATE SHIFT IN AL/BE/GA-DIRECTION',ALVER,BEVER,GAVER) END IF INP=3 THEN BEGIN WREAD ('INDICATE SHIFT IN EXT1/EXT2/EXT3-DIRECTION',E1ER,E2ER,E3VER) END

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Program functions

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Continued:

PNR:=AP RECH: WRITE('VERSCHOBEN WIRD PUNKT',PNR) WAITS (1) GETPOSA (PNR;SPE,IPOL,STA;1;X,Y,Z,AL,BE,GA;E1,E2,E3) X:=X+XVER Y:=Y+YVER Z:=Z+ZVER AL:=AL+ALVER BE:=BE+BEVER GA:=GA+GAVER E1:=E1+E1VER E2:=E2+E2VER E3:=E3+E3VER SASTOPAT (0;PNR) STORPOSA (PNR,SPE,IPOL,STA;1;X,Y,Z,AL,BE,GA;E1,E2,E3) NEXTP (PNR,NPNR) PNR:=NPNR IF PNR>EP THEN JUMP FIN IF PNR=0 THEN JUMP FIN JUMPRECH FIN: ENDP

MAIN WRITE ('CRTL+W TO AKTIVAT SHIFTROUTINE') FOR I:=1 TO 300 DO BEGIN READ (‘DO YOU LIKE TO SHIFT THE POINTS?? YES=1',INP2) END I IF INP2=1 THEN_BEGIN CALL VERSCH INP2:=0 END GP (1,2) GC (3,4,5,6,7) GP (8) END

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Program functions

4 Changing the preset point resolution When shifting or generating points with long travelling units (LVE) it is possible to exceed the valid ranges of values of the axis coordinates in the commands GETPOS or STORPOS. In this case the controller aborts the run with the error message "Illegal range of values".

The command "FUNCON_RESFAK,.." (Resolution Faktor) allows to change the preset point resolution. For example, FUNCON RESFAK,100 results in a resolution of 1/100 mm or 1/100 degrees in the robot coordinate system.

The command FUNCOFF_RESFAK deactivates the function. Further points are shifted or generated with the preset point resolution.

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A change of the point resolution influences the travel accuracy of the robot axis.

Program functions

Block 10 - Standard

5 Copying external points 5.1 External Point Single points (point groups) are copied from another program into the calling (actual) program by the command line EXTERNAL_POINT(...)_FROM_... After selection of the function you input the desired points via the numeric keyboard. The system asks for the program name from which the points shall be copied. They are copied after the start of the actual program and are available as real point. The command, e. g. EXTERNAL_POINT(34..100)_FROM_P4342 Program name Points to be copied

is input in the declaration range of the target program (above MAIN). In the shown examle the points 34 to 100 of the program P4342 are copied. After processing the instruction this command can be deleted in the target program. 5.2 Command COPYP Alternatively to the above mentioned method points can be copied into the current program with the command COPYP_(...)_FROM_... Application possibilities: COPYP_(34..100)_FROM_P4342

to copy points 34 to 100 from program P4342 into the current program

COPYP_()_FROM_P4342

to copy all points of an external program into the current program

COPYP_(1..10,101)_FROM_P4342 to copy points (e.g. 1-10) of an external program into the current program; the target point number (e.g. 101) is given or COPYP_(1..10,101)

to copy points (e.g. 1-10) of the current program to the target point number.

The command is entered in the executive routine (after MAIN) in the target program.

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5.3 Generation of points during path travel In application fields of multi-layer welding, partially with the aid of seam tracking systems (e.g. arc sensor), it may be required to permanently store the determined shiftings. The command RPOINTS_(PKTA,PKTE) End point number Start point number

generates new points during path travel. The number of generated points depends on the number of programmed path points and the point number range indicated in the command RPOINTS.

Program example

RESTART LIST 1=(5211,3,100,35,220,132,700,0,2,0,60,22,330,0,0,0,0,0,0,120,0,0) MAIN SSPD (8,8) $ (1) GP (1..3) RPOINTS (103,106) GC (3,4,5,6) GP (7,1) END

In the above mentioned example four points with the numbers 103, 104, 105 and 106 have been generated during the weld path travel. The newly generated points have the same position of programmed points (3-6) plus the offset determined by seam tracking. As it refers to really programmed points, they can be approached in TEACH mode or integrated in the user program.

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Archiving

Index

1 Archiving and administration of user programs ...................................................... 2

1.1 General ............................................................................................................... 2 1.2 Formatting of disks ............................................................................................. 3 1.3 Standard disk drive ............................................................................................. 4 1.4 Directory (Index) .................................................................................................. 5 1.5 Copy ................................................................................................................... 6 1.6 Rename (changing program names) ................................................................... 7 1.7 Delete (deleting programs) ................................................................................. 7 1.8 Load (loading programs) ..................................................................................... 8 1.9 Save (saving programs) ...................................................................................... 9 2.0 SAVE ALL (saving all user programs) ................................................................. 9 2.1 LOAD ALL (loading a working set) .................................................................... 10

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Archiving

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Program administration 1 Archiving and administration of user programs 1.1 General The storage system allows the user to store CAROLA- programs on 3,5" disks, hard disks or net disk drives and to load from them.

Copy Directory

Delete Rename

Function Directory Copy

Selection of the source disk drive

Load

Rename

Delete

Load

Save

Quelle

Ziel

Selection of the target disk drive Save user programs on disk „SAVE ALL“

Save

Set Default

Load user programs „LOAD ALL“

Formatting disk

Selection of the standard disk drive

Beside the data transfer functions, this system also includes functions for the administration of disks such as directory, copying, renaming and deletion of files (user programs) or file types (program segments).

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Archiving

1.2 Standard disk drive The standard target and source disk drive is preset by the button "Set Default".

Function Directory Copy

Rename

Delete

Load

Save

The controller automatically offers this storage medium for all archiving operations. The character of the disk drive - displayed next to the button "Set Default" - shows the current adjustment.

Source

Target

Set Default

Disk drive character

Select default drive!

Harddisk/ Partition

Harddisk D:\

CMOS-Memory

Battery buffered working storage of the controller Danger to lose data in case of insufficient battery voltage.

Disk drive

The 3,5" disk drive has the character A:. It serves for the static storage of the user programs and has a capacity of 1.44 MB.

Temporary ram disk The temporary ram disk has the character B: and a capacity of 0.5 MB. The ram disk loses stored data when switching off the controller. Net disk drives

Net disk drives can be connected via LAN connections. The character is E1:.

Hard disk

The hard disk serves for the static storage of the user programs (in the same way as the disk). It is divided into the partitions D:; E:; F:; G: and has a total capacity of 100 MB.

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Disk drives to be selected:

Archiving

Block 11 - Standard

1.3 Formatting of disks The storage of data can only be made when the data carrier (disk) was adjusted (formatted) to the operating system of the Rotrol before use. To do this, close the write-protect window of the disk and insert it in the disk drive. Start the formatting process by pressing the button . Disks containing programs which are not needed any longer can be completely deleted by this procedure.

All existing data of the disk are lost after formatting!

Background information on disks In order to facilitate and speed up the data search on a disk, each disk is subdivided into tracks and sectors. For a better understanding: you can imagine tracks as concentric circles on the disk. 3.5" HD disks (1.44 MByte) are divided into 80 tracks and 18 sector. Every sector per track has a capacity of 512 Byte which results in a capacity of 1.44 MByte of a 3.5" HD disk. The purpose of this subdivision is to shorten the access time to a program or a file. Without this subdivision into tracks and sectors the complete disk would have to be searched from the beginning to the end when accessing a program. The subdivision enables the computer to store the position, i. e. track number, sector number and disk side, in a directory and to move the read/write head to the correct position when calling a program.

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Archiving

1.4 Directory (Index) By actuation of the button "Directory", subsequent selection of the source disk drive and again actuaction of the button "Directory" the user programs available on the selected disk drive (storage medium) are dispalyed. A double actuation of the button shows the directory of the storage medium preset via "Set Default".

Function Directory Copy

Rename

Delete

Load

Save

Source

Available user programs Target

selected function current disk drive Set Default

Directory of the selected disk drive.

The archiving system sets up four different file types which are marked by extensions (additional information "Program name.S"; "Program name.Z"; "Program name.P"; "Working set name.SET"). The presentation of the user programs in the directory can be selected as follows: By actuating the buttons it is displayed:

File names (user program name)

File type Point code

File types Source code, Intermediate code Z, Point code File type Source code

File type Intermediate code Z Detailed display of the file type

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Archiving

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1.5 Copy Programs or program segments are duplicated by the function "Copy". Should program corrections be made for any reasons, it is always advisable to effect them on a program copy in order to be able to fall back on the original program.

Function Directory Copy

Rename

Delete

Load

Source

Save

Choose the source and target disk drive after selection of the function "Copy". Kopiert wird vom Quelllaufwerk auf das Ziellaufwerk. Source disk drives Target disk drives

Target

Set Default

Then the user programs in the source disk drive are displayed.

Now select the program or program segment to be copied and enter a new program name on the simulated keyboard. Delete the existing program name with the button "Backspace".

Coursorposition im Textfenster Ă¤ndern

When several user programs are selected by dragging the finger over the buttons they can only be copied to another disk drive with their existing names. Before starting the copying process it is checked whether there is enough space for storage. In the case that the program or the program segment already exists, the user must release it by answering the question Target file already exists Do you wish to overwrite?

with the button "YES" or abort it by pressing the button "NO". If any errors are recognised before COPY is executed (e.g. insufficient storage capacity), a corresponding message appears and the contents remain unchanged.

Archiving operations cannot be cancelled!

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Archiving

1.6 Rename (Changing program names)

A program that exists in the CMOS memory (main memory) of the robot, on disk or on net disk drives can obtain another program name.

Function Directory Copy

Rename

Delete

Load

Save

Source

After selection* of the program to be renamed the new program name is entered via the simulated keyboard. The program is renamed on the selected disk drive after confirmation. * Actuation of the buttons

Target

Rename

Source

File name

Rename

Set Default

Enter new program name

1.7 Delete (Deleting programs)

Function Directory Copy

Rename

Delete

Source

Target

Set Default

Load

Save

The number of programs in the main memory and even the storage space itself is limited. Therefore it may be that the existing memory is insufficient or the number of the programs to be loaded simultanously is exceeded when generating or reloading programs. This means that you have to delete one or more programs with the function Delete. Confirm after selection of the program name or segment. The program is deleted in the main memory - disk drive.

Pay attention to save the programs which are still needed on a disk. Deleted programs cannot be restored and are definitely lost.

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User programs which are not needed any longer in the main memory or disk drives can be removed with the function "Delete".

Archiving

Block 11 - Standard

1.8 Load (Loading programs) User programs and single program segments can be reloaded from the selected source disk drive into the CMOS memory of the robot controller via the function "Load". Function Directory Copy

Rename

Delete

Load

Save

Source

Target

Each robot program has a program head (header). All robot specific data is determined in this program head. If a program is to be loaded from the disk, the operating system checks if the data stored in the program correspond to the operating system data. A difference results in an error message.

Set Default

The following abbreviations describe what kind of differences have been found: Program segments TYP GAZ PAL REF NUM CHK CZ1 SOV LEN

Robot type Total axis number of the robot system Point resolution Reference positions of the robot axes Controller number Check sum Compiler version Operating system version RAM memory size

.SET

L L L L L L L L L

L S L L L L S L L

S S S L L L S L L

S S S L L L S L S

L = slight errors The operating system asks if the program part shall be loaded. The user is responsible for errors which may occur. S = serious errors The program part cannot be loaded. The operating system aborts the loading procedure. If loading is conditional, a Header error message appears, e.g.: HEADER ERROR in CS :

NUM,CHK,SOV.

It is then up to the user to decide whether the program is safe to load and run or not. Loading is impossible if the Header contains different information about number of axes or robot types. The error message appears, e.g. HEADER ERROR in CS :

NUM,CHK,GAZ.

Only the program text (S-code) and the Z-code are loaded. Page 8

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1.9 Save (Saving programs)

Function Directory

For data protection during program creation or program changing it is advisable to regularly make a backup copy of these user programs (several times a day). After completion of the programming and a successful test run all existing copies should be updated thus avoiding the existence of Copy Rename Delete Load Save different program versions.

Source

Target

Set Default

Select the function "Save", then the target disk drive and again "Save". Now select the program or program segment to be saved from the following list. Saving is made in the indicated target disk drive.

As with the function "Copy" the operating system checks the existence of program segments on the indicated disk drive (perhaps the same program name) and asks the user to release overwriting.

2.0 SAVE ALL (Save all user programs) The function â&#x20AC;&#x17E;SAVE ALLâ&#x20AC;&#x153; stores all user programs of the program memory of the controller as working set on the target disk drive. Working sets are a reflection of the program memory and contain the individual user programs as well as additional information such as the current TCP and TOV value of the controller. The controller asks for the name* of the working set after selection. This name must only have eight characters and gets the extension Working set name.SET Before starting the storage the computer checks whether there is enough storage capacity on the disk. The same applies for the loading procedure into the program memory. In case of insufficient storage capacity the procedure is aborted.

* At present the operating system uses the controller number as program name.

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Archiving operations cannot be cancelled!

Archiving

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2.1 LOAD ALL (Loading a working set) Contrary to single programs a working set cannot be added to existing programs because it refers to a reflection of the main memory.

Function Directory Copy

Rename

Delete

Load

Source Erase the total memory ? (Y/N)

Save

When loading a working set, the former main memory is restored, i.e. all stored programs, the TCP and TOV value are reloaded into the main memory. In this case you have to answer the question to delete the complete main memory with "YES".

Target YES

Set Default

Current programs in the main memory are overwritten resp. definitely deleted.

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List of commands

Index

List of commands ...................................................................................................... 2 Alphabetical index ..................................................................................................... 6

Programming Manual ROTROL速 II

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List of commands

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List of commands Command

Subject

Block Page

Call of weld parameter lists Call of weld parameter lists - end crater list Call of weld parameter lists - tack seam list Call of weld parameter lists - start list -

Block Block Block Block

7 7 7 7

4 4 4 4

Partial circle Switching on the ignition monitoring Definition of the digital output during arc monitoring Actuation of the ignition routine Amount of linkable arcs Axis oscillation

Block Block Block Block Block Block

5 8 8 8 5 9

9 3 9 4 9 46

Start of a sequence statement Start of a sequence statement (counting loop) Welding torch blow-through

Block 9 11 Block 10 8 Block 7 56

Call of a subroutine Parallel shift Parallel shift Off Parallel shift On Full circle Circle orientation Copying of points

Block 9 Block 9 Block 9 Block 9 Block 5 Block 5 Block 10

13 18 19 19 8 10 26

Determine workpiece coordinate system for shifts Delete parallel shift Definition of a subrouting with application of variables Tool-Center-Point defination via points Delete user program (generated by GENNAME) Drive Axis absolut Drive Axis relativ

Block Block Block Block Block Block Block

52 19 16 18 38 5 5

Alternative statement after THEN End of a sequence statement End of a sequence statement (counting loop) End of program Actuation of the end monitoring End of procedure End of procedure (advanced subroutine technology) Determination of the error type during an arc error

Block 9 9 Block 9 1 Block 10 8 Block 4 3 Block 8 8 Block 9 13 Block 9 16 Block 9 50

Symbols $_(..) $E $H $S

A ARC ARCCON ARCERR ARCIGNIT ARCNO AWEAVE

B BEGIN BLAST

C CALL CHANGE CHOFF CHON CIR CIRO COPYP

D DCO DECH DEFSUBF DEFTCP DELETE_PRGXXXXX DRIVEA DRIVER

9 9 9 3 9 5 5

E ELSE END

ENDCON ENDP ENDSUBF ERRLEVEL

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Programming Manual ROTROL速 II

Block 12 - Standard

List of commands

Command

Subject

Block Page

ERRMESS ERRORS

Switching digital outputs in case of error messages Display of the last error messages

EXTERNAL DEFSUBF.. EXTERNAL PROC EXTERNAL VAR EXTERNAL_POINT EXTTCPOFF EXTTCPON EXTTOOL

Call of external procedures (advanced subroutine technology) Call of external procedures Use of external variable Copying of points Deactivate external TCP Activate external TCP Define external TCP

Block 9 Block 9 Block 2 Block 9 Block 9 Block 10 Block 10 Block 3 Block 3 Block 3

Definition of a counting loop Global list definition

Block 10 8 Block 7 41

Shielding gas On (in connection with Funcon) Definition of the digital output during arc monitoring Insert movement command (straight line) Straight movement in mode TEACH Generation of program names binäre Abfrage digitaler Ausgänge Reading of point information Status information from the power source Reading the system TCPs Reading a time Placing text messages Insert movement commands (PTP) PTP movement in mode TEACH

Block 7 Block 8 Block 5 Block 3 Block 9 Block 9 Block 10 Block8 Block 9 Block 9 Block 9 Block 5 Block 3

56 9 4 11 37 22 15 10 28 31 40 4 11

Anzeigen der aktuellen Streckenenergie Festlegen der Homeposition (in Verbindung mit Funcon)

Block 8 Block 2

10 16

Program linkage with digital inputs Inquiry of digital inpints

Block 9 Block 9

8 22

Jump command

Block 9

Weld parameter list definition Free list access

Block 7 Block 7

2 59

Searching the next point number Hold command

Block 10 23 Block 9 31

52 49 13 16 14 3 26 19 19 19

F FOR FUNCON_LISTSRC

G GAS GASERR GC GENNAME GETOUT GETPOS GETSDSTAT GETTCP GETTIME GOTOXY GP

HEATINP HOMEPOS

I IF_IN INWORD

J JUMP

L LIST LISTACC

N NEXTP NOP

Programming Manual ROTROL® II

Page 3

List of commands Command

Block 12 - Standard Subject

Block Page

Call of a subroutine in case of an arc error Arc monitoring Activate linear oscillation Activate sinusoidal oscillation Oscillating orientation Binary-coded switching on of digital outputs Reloading programs

Block Block Block Block Block Block Block

Stopping the program run Procedure start (subroutine) Printing program runs Reducing the PTP speed Publication of subroutine elements Publication of variables

Block 9 Block 9 Block 2 Block 5 Block 9 Block 10

29 13 10 14 13 3

Reading a variable value (on demand) Switching off digital outputs Changing the preset point resolution Storage of current program Storage of the program state Leaving a procedure (advanced subroutine technology) Premature leaving of a procedure Changing the oscillating frequency Generation of points during path travels Automatic start of user programs

Block 10 Block 9 Block 10 Block 4 Block 6 Block 9 Block 9 Block 9 Block 10 Block 9

5 20 25 3 8 16 13 43 27 35

Resolution of ambiguities Save program runs Store user program (name generated by GENNAME) Programmed stop in case of arc error Programmed stop in case of arc error Stop in case of arc error (Quinto SD) Stop in case of arc error (Quinto SD) Switching on digital outputs Path transitioning Setting the system TCPs Setting a time Changing the TCP during program execution Deactivation of the transition Activation of the transition Storage of points during program run Changing the TOV value during program execution Point transition Subroutine call (advanced subroutine technology) Verschleifbares Schalten von Ausgängen

Block 10 Block 11 Block 9 Block 8 Block 7 Block 7 Block 8 Block 9 Block 5 Block 9 Block 9 Block 9 Block 5 Block 5 Block 10 Block 9 Block 5 Block 9 Block 9

20 9 38 7 57 56 6 20 14 27 33 26 13 13 10 27 13 16 23

O ONERROR ONLCON OSC LIN OSC SIN OSCDIR OUTWORD OVERLAY

9 8 9 9 9 9 9

50 5 46 46 46 23 36

P PAUSE PROC PRINT PTPMAX PUBLIC PROC PUBLIC VAR

R READ RESET RESFAK RESTART RETSUBFUNC RETURN ROF RPOINTS RUN

S SASTOPAT SAVE SAVE E,PRGXXXXX SDSTOP SDSTOPCP SET SETDD SETTCP SETTIME STCP STOFF STON STORPOS STOV STV SUBFUNC .. SWITCH OUTBYTE

Page 4

Programming Manual ROTROL® II

Block 12 - Standard

List of commands

Command

Subject

Block Page

SWITCH SWITCH SINGLE SWITCH TANDEM SWITCH TANDEM1 SWITCH TANDEM2 SWITCH RESOUT SWITCH SETOUT SYNCOSC

Interpolational switching of outputs and functions???? Configurate single wire welding (Tandem welding) Configurate Tandem welding Configurate Tandem welding Configurate Tandem welding Interpolational switching off digital outputs ???? Interpolational switching on digital outputs ???? Switching the oscillating synchronous signals

Block Block Block Block Block Block Block Block

7 7 7 7 7 9 9 9

17 17 17 17 17 21 21 48

Tool Center Point Selection of the operating mode Tool Orientation Vector

Block 3 Block 3

17 19

Advanced output of error message

Block 9

List of used vaariables Declaration of a variable

Block 2 16 Block 10 3

Delay on the weld path end Command to wait Command to wait Command to wait Low water recognition in the welding machine (Quinto SD) Wire pulse ON Wire retract Definition of the digital output in case of arc error Wire retract Serial parameter transmission Reset of error messages in the Quinto SD Reading a variable value Transfer of error messages into the error memory Activate hand axis oscillation Output of a self-defined screen message Output of self-defined messages on external computer or printer

Block 7 Block 9 Block 9 Block 9 Block 7 Block 7 Block 7 Block 7 Block 7 Block 7 Block 7 Block 10 Block 9 Block 9 Block 10 Block 9

T TCP TOV

U USRMSG

V VAR

WAITEND WAITI WAITM WAITS WATERSHT WIGWIRE WIREBACK WIREERR WIREON WPSPAR WPSRESET WREAD WRERR WRISTOSC WRITE

Programming Manual ROTROL速 II

8 30 29 29 56 36 56 9 56 43 57 5 50 47 5 39

Page 5

List of commands

Block 12 - Standard

Alphabetical index A ADJUSTMENT T1 ADJUSTMENT T2 AUTOMATIC AUTOMATIC-mode

Operation mode ADJUSTMENT T1 Operation mode ADJUSTMENT T2 Operation mode AUTOMATIC Execute user programs in automatic mode

Block Block Block Block

1 1 1 6

9 9 10 6

Cartesian coordinate system

Block 3

Travel type CC - Cartesian Coordinate Copying programs Positioning the cursor in the editor

Block 3 Block 11 Block 4

6 6 4

Deleting programs Display directory of disk drives

Block 11 Block 11

7 5

Processing programs Editing user programs Safety regulations Step by step execution of user programs Execution of user programs

Block Block Block Block Block

5 2 6 2 2

Start file AUTOEXEC Formatting disks

Block 6 15 Block 11 4

Hand coordinate system Approaching the robot's zero position

Block 3 Block 2

12 15

Systeminformation Grundlagen digitaler Eingänge

Block 2 Block 2

12 11

Keyboard layout

Block 4

B Base coordinate

C CC operation Copy Cursor movements

D Delete Directory

E Editing commands Editor EN 775 EST EXE

4 4 1 6 6

F File Autoexec Formatting

H Hand coordinate HOME-Position

I INFO INPUT

K Keyboard

Page 6

Programming Manual ROTROL® II

Block 12 - Standard

List of commands

L Leeway of operating modes Switching into other operating modes during program run Line start Program start after process interruption Load Laden von Programmen LOAD ALL Laden von Arbeitsset

Block 6 7 Block 6 8 Block 11 8 Block 11 10

M MAIN Mode PROG Mode TEACH

Program start mark Program creation in the programming mode Operating mode TEACH

Block 4 Block 5 Block 3

3 2 4

Operation mode OFF Continuation of welding after an arc error Grundlagen digitaler AusgĂ¤nge

Block 1 Block 6 Block 2

9 11 11

Travel type RC - robot coordinate system Renaming programs Robot coordinate system

Block 3 6 Block 11 7 Block 3 12

Saving programs Saving programs View of the special characters Target and source disk drives of the controller

Block 11 Block 11 Block 4 Block 11

9 9 5 3

Workpiece coordinate system

Block 3

O OFF Overlapping start OUTPUT

R RC operation Rename Robot coordinate

Save SAVE ALL Special characters Standard disk drives

W Workpiece coordinate

Programming Manual ROTROLÂŽ II

Page 7

Index - Options

List of Blocks - Options -

External axes 1 External axes ..................................................................................................... 2 2 Synchronisation of external axes ........................................................................ 3 3 Circles with external axes................................................................................. 10 4 Referencing external rotary axes with rotation ranges >360Â° ............................ 10 5 Manipulation of point informations for external axes ......................................... 11 6 Manual movement of external axes .................................................................. 17 7 Asynchronous movement of external axes ........................................................ 19 8 Master / Slave .................................................................................................. 22 9 Synchronous axis ............................................................................................. 26 10 Parameterisation of external axes .................................................................. 27

Multi-layer welding

Parallel shifting with a sensor

Transformation and imaging

Centre point referenced circle programming

Seam tracking systems (Arc sensor / analogue sensor)

Freely programmable oscillating patterns

Parallel Task

Point editor

Parameter interpolation

List of commands

Programming Manual ROTROLÂŽ II

V7.xx

Options

External axis

Block 1 - Option

Index Freely programmable external axes 1 External axes ....................................................................................................... 2 2 Synchronisation of external axes ...................................................................... 3 2.1 Programming the definition points .................................................................. 4 2.2 Definition of kinematic chain of the external axes ............................................ 6 2.3 Synchronous movement of internal and external robot axes during programming .................................................................................................. 8 2.4 Extorioff .......................................................................................................... 9 3 Circles with external axes................................................................................. 10 4 Referencing external rotary axes with rotation ranges of more than 360Â° .. 10 5 Manipulation of point information for external axes (MPE) ........................... 11 5.1 General ......................................................................................................... 11 5.2 Selection and functions offline ....................................................................... 11 1. Absolute shift ................................................................................................ 11 2. Relative shift ................................................................................................. 12 3. Exchange point coordinates ......................................................................... 12 4. Copying of point coordinates ........................................................................ 13 5.3 Selection and functions online ....................................................................... 14 6 Manual movement of external axes (MANAX)................................................. 17 6.1 General ......................................................................................................... 17 6.2 Selection and functions offline ....................................................................... 17 6.3 Selection and functions online ....................................................................... 17 6.4 Operating panel ............................................................................................ 18 7 Asynchronous movement of external axes .................................................... 19 7.1 General ......................................................................................................... 19 7.2 Positioning an ADRIVE axis ......................................................................... 19 7.3 Determination and allocation of the axis state ............................................... 20 7.4 Positioning control ........................................................................................ 21 8 MASTER / SLAVE .............................................................................................. 22 8.1 Application .................................................................................................... 22 8.2 Programming ................................................................................................ 22 9 Synchronous axis ............................................................................................. 26 10 Parameterisation of external axes ................................................................. 27

Programming Manual ROTROLÂŽ II

Page 1

External axis

Block 1 - Option

Freely programmable external axes 1 External axes When storing points, the coordinates of the existing external axes (max. 12, axis numbers 7-18) and the internal axes (1-6) are stored and integrated into the movement of the robot mechanics (also see:block 3 of the standard manual - chapter "Moving external axes" and "Storage of points"). In this normal case of application the Achse 7 external axes serve as "positioners" - the workpiece resp. the robot mechanics is placed in a certain position - thus enlarging the working range of the system. Achse 9

Achse 8

Achse 11 Achse 10

Optional functions and commands such as Function

Commands

Synchronous movement of external axes

EXTDEF EXTCHAIN EXTSYNON EXTCIR

Circles with external axes -rotation range = 356 degreesSoftware referencing of external axes Asynchronous movement of external axes

Manual movement of external axes Manipulation of external axes Autosyn (switch off synchronous rotation of two external axes) Master-Slave

SOFTREF ADIVEAX DRIVESTAT WAITONAX MANAX MPE

Programming process*

ONLINE ONLINE ONLINE

ONLINE ON-/OFFLINE ON-/OFFLINE

CHSYN MASTERON MASTEROFF SYNCON SYNCOFF

* Programming processes: Online Offline On-/Offline

(Definition and execution is made during the program run) (Definition and execution is made by separate dialogues in the main menu) (Application either online or offline)

increase considerably the functionality and application possibilities.

Page 2

Programming Manual ROTROL速 II

OFFLINE

ONLINE

Block 1 - Option

External axis

The exact adherence to given speeds (welding parameter list) on various radii of a positioner and the exact positioning of the wire tip on the welding path during a rotary or longitudinal movement of one or several external axes requires a description of the spatial position of these axes to the robot coordinate system.

The spatial position of each axis is calculated by means of programmed definition points. The opposite dialogue boxes are used to input the necessary information (axis number, axis type, definition points and the kinematic chain) in the user porgram.

Definition of the synchronisation EXTDEF_(2;0;801,802,803,804) Definition points Type of external axis 0 - rotatory 1 - linear number of external axis 1 - axis 7 2 - axis 8 12 - axis 18

EXTDEF = EXTern DEFinition Definition of the kinematic chain of the external axes (see page 7) EXTSYNON = EXTernal SYNchronisation ON = Switch on synchronisation EXTSYNOFF= EXTernal SYNchronisation OFF = Switch off synchronisation

EXTORIOFF = EXTernal ORIentation synchronisation OFF Switching off the orientation synchronisation during synchronous movement (see page 9)

Programming Manual ROTROL速 II

Page 3

2 Synchronisation of external axes

External axis

Block 1 - Option

2.1 Programming the definition points An approachable fixed point has to be programmed at least 2 times, but maximum 8 times in the different positions of the axis to be synchronised (see diagrams). These points should cover a working range of the axis to be synchronised that is as large as possible and should be almost equally distributed. The torch orientation is not significant for TEACHING. The path accuracy of a welding path is dependent on the accuracy of the definition points. Therefore, an exact TCP and a high accuracy of points is essential.

It is recommended that a high point number is chosen for the definition. e.g.: axis 7 - points 700-707

axis 8 - points 800-807 etc.,

which will not be overwrittten during program execution. When the programming is made in a subprogram, the synchronous movement can be activated in all further user programs.

Diagram: Programming the definition points (min. 2 points) for linear axes (gantry / longitudinal track --> LVE) Axis 7

Points 700 - 701

Please note the different position of the external axis 7.

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Programming Manual ROTROL速 II

Block 1 - Option

External axis

Axis 8

Points 801-803

Axis 9

Points 901 - 903

Diagram: Programmation of the definition points (min. 3 points) of the rotation rotational axes (turn table, turn-tilt table, orbital table)

When programming the definition points of an axis, only the axis to be synchronized may be moved. All other axes are not allowed to change their position. If another axis (LVE) must be moved to reach to axis to be defined it is important to chose a position from which a maximum working range of the axis to be defined can be covered. Programming Manual ROTROL速 II

Page 5

External axis

Block 1 - Option

2.2 Definition of kinematic chain of external axes Command EXTCHAIN_(..,..)

external chain

This command defines external axes which are involved with the synchronization. If more than one external axis is involved, the sequence of numbers in the EXTCHAIN command indicates the order of precedence of the external axes, e.g. it is indicated which of the external axis has the main or the secondary role. In the EXTCHAIN command the number of external axis or axes is indicated. The sequence of numbers for external axis (axes) starts with "1". In order to define the kinematic chain, the external axes have to be divided in two groups: 1. 2.

external axes which move the robot and external axes which move the workpiece

As, in practice the robot arm is often moved by a linear axis, in normal cases the linear axes are also the main axes. An exception is the revolving turret, where the robot is mounted. The order in the command EXTCHAIN therefore indicates the rule of precedence of the external axes.

Example:

External linear axis as axis 7

EXTCHAIN_(1)

Example:

Two rotary axes

On a turn/tilt table, axis No. 8 is the turning axis and axis No. 9 is the tilting axis. If axis No. 8 is moved, the spatial position of axis No. 9 does not change. Whereas, if axis No. 9 is moved, the spatial position of axis No. 8 is automatically changed. As axis No. 9 influences the position of axis No. 8, the main external axis is axis No. 9. This is defined by the following Axis 9 command:

1st. external axis, axis 9 = tilting axis 2nd external axis, axis 8 = turning axis EXTCHAIN (3,2) changed position axis 8

Page 6

Programming Manual ROTROL速 II

Block 1 - Option One linear and two rotary axes

Example:

External axis

EXTCHAIN (1,3,2) Order of precedence 1 - axis 7 - linear axis - 1st ext. axis Order of precedence 2 - axis 9 - tilt axis - 3rd ext. axis Order of precedence 3 - axis 8 - rotary axis - 2nd ext. axis

Example:

Linear axis, revolving turret with vertical carriage

EXTCHAIN (1,2,3)

Order of precedence 1 - axis 7 - linear axis Order of precedence 2 - axis 8 - revolving turret Order of precedence 3 - axis 9 - height carriage

Program example:

Programming Manual ROTROL速 II

Page 7

External axis

Block 1 - Option

2.3 Synchronous movement of internal and external robot axes during programming

Due to the synchronization of external axes, the control enables to simultaneously move external and external axes in TEACH mode. The wire tip (TCP) follows the movements of the external axes while the torch orientation remains constant. It is kept exactly on the same position. In the case of a correction of point, where external axes are also involved, a changing over between "internal" and "external" axes is not required.

Actuation of the synchronous movement

Conditions For the synchronous movement, the computer needs information about the spatial position of external axes and about the kinematic chain. Therefore, a user program with this system information must be run prior to working in synchronous TEACH operation (EXTDEF, EXTCHAIN). External axes, which are not described by an EXTDEF command are not considered during the synchronous movement and can only be moved externally. If the control does not know this system information but despite this, you switch over to synchronous movement, the following error message appears on the teach pendant display:

Number of external axes out of range

Practical performance o o o

Reading in the system information (deplete EXTDEF and EXTCHAIN) Selection of TEACH mode Select the function SYNCHRON EXTERN

If the internal axes are active during selection of the function SYNCHRON EXTERN they still remain active until the changing over to external axes, where the function SYNCHRON EXTERN is activated. During operational mode SYNCHRON EXTERN, the speed of the mounting flange is not controlled! Page 8

Programming Manual ROTROL速 II

External axis

Block 1 - Option

2.4 EXTORIOFF Switching off the orientation synchronisation during the synchronous movement with external axes

The synchronous movement of external axes supplies a constant, defined process speed along a path, a defined position of the TCP and a defined adaption of the welding torch orientation in relation to the workpiece. Certain applications are executed without a synchronous orientation movement of the welding torch in order to force the robot to run smoother. During the synchronous movement only the welding speed and position in relation to the workpiece is controlled. Switching off the orientation with EXTORIOFF only becomes effective after having switched on the synchronous movement with EXTSYNON in general. A command EXTORIOFF following the command EXTSYNON switches off the orientation synchronisation again. It remains switched off for all program sequences until it will be switched on again by the command EXTSYNON. The command does not influence existing user programs with synchronous movement . Example: EXTDEF (1;0;10,11,12,13,14) EXTCHAIN (1) GP (100) EXTSYNON GC (101..110) EXTORIOFF GC (200..205) EXTSYNOFF GP (1000)

The points 101 to 110 are approached in synchronisation both to the position and the orientation. At the points 200 to 205, only the postion in relation to the workpiece will be kept. In this case the orientation is interpolated linear and treated as during a non-actuated synchronous movement.

Programming Manual ROTROL速 II

Page 9

External axis

Block 1 - Option

3 Circles with external axes Circles which are positioned in the center of a rotary axis with a working o range of only 356 cannot be reached (covered) completely. The remaining 4° and the given overlap distance are covered by the robot axis in the last third of the circular movement. The function is switched on with the command FUNCON_EXTCIR,ACHSE.. Number of external axis

After having executed the circle, the function is switched off again with the command FUNCOFF_EXTCIR The synchronisation of external axes (see "Synchronisation of external axes" in this block) is a condition for this function.

4 Referencing external rotary axes with a rotation range of more than 360° The multipass technology often requires rotary axes with more that one rotation (>360°) thus avoiding for example a switch off of the arc between the different filler passes (lack of fusion) of a weld seam. The number of the rotations is depending on the speed ratio of the motor gear unit and may vary. To avoid unnecessary rotations back to the HOME position, the actuation of the command

FUNCON_SOFTREF,Nr. Number of the external axis

resets the number of the executed rotations, i.e. if the axis is turned for 730°, the calculatory value of 2*360° will be subtracted. Then the actual axis position is 10° away from the HOME position. The software referencing of all external rotary axes is possible but only one external axis can be referenced per command. To avoid errors, the command SOFTREF should not be called on the positions 0°, 360°,720°.. etc. or 180°,540°,900°..etc. The distance to these position may not fall short of +/- 5°.

Page 10

Programming Manual ROTROL® II

Block 1 - Option

External axis

5 Manipulation of point information for external axes (MPE) 5.1 General Robot applications with external axes often need user programs to be shifted along a linear axis onto a second workplace. Moreover there is the facility of copying user programs from one freely programmable workpiece positioner to a second without extensive programming. The function "Manipulation of Point information for External axes" makes it possible to change the points of a user program that have already been taught in an offline and online procedure .

5.2 Selection and functions offline New and independent user programs are mainly generated offline. The selection is made on the first menu level of the teach pendant.

1. Absolute shift An external axis is given an absolute value. e. g. stop external axes MPE_A_TEST.P(7,100) target point axis number program name absolute (stopping axis 7) Shifts all point coordinates of axis 7 to the position of axis 7 defined by point 100, in the TEST program. If, for example on point 100, the point coordinate of axis 7 is 20.000 increments, then all points in axis 7 are stored exactly at this position.

Programming Manual ROTROL速 II

Page 11

External axis

Block 1 - Option

2. Relative shift An external axis is given an Offset. e.g. Shift the point coordinates of external axes MPE_R_TEST.P(8,4,100) target point source point axis number program name relative (shifting by the vector between point 4 and point 100)

Shifts all point coordinates of axis 8 relative to the Offset determined by point 4 and point 100 in the TEST program. If for example at point 4, the point coordinate of axis 8 is 20.000 increments and 25.000 increments for point 100, then all points in axis 7 are shifted by 5.000 increments in a positive direction.

3. Exchange the point coordinates Stored point coordinates of two similar external axes are exchanged. e.g. exchanges the coordinates of all points of axis 7 with axis 8.

MPE_E_TEST.P(7,8) axis number 8 axis number 7 Program name Exchange (exchange of the axis coordinates of axes 7 and 8) Alternatively C for copying! MPE_E_TEST.P(7,8,1,50) As above, but only points 1 to 50 inclusive are changed.

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Programming Manual ROTROL速 II

External axis

Copying of point coordinates Stored point coordinates of an external axis are copied onto another external axis.

MPE_C_TEST.P(7,8) Copies the coordinates of all points of axis 7 to axis 8. MPE_C_TEST.P(7,8,1,50) Only points between 1 and 50 are used. This addition is possible with all MPE commands. Copying Alternatively E for exchange!

To define the absolute position or the shift Offset, a point has to be programmed. While the command is being executed, axis working limit violations are monitored and displayed.

Please make a copy of the source program if it is to be retained; this can then be modified as required. This precaution prevents unintended changes being made in the original program, especially when using the absolute shifting on axis, should the manipulation not work out.

When point data is exchanged between two external axes, the operating system does not check to see whether this results in a sensible program. This is the user's responsibility ! Only the software limit switches of the axes concerned are checked to see that they match. The only practical applications of this type of command are where the axes concerned have identical "mechanical" and "electrical" layouts, possibly in conjunction with additional Offline transformation of the robot coordinates.

Programming Manual ROTROL速 II

Page 13

Block 1 - Option

External axis

Block 1 - Option

5.3 Selection and functions online

Analogue to the "Offline-MPE" a manipulation of point information even inside the program - i.e. online - is possible. A practical example for the online command is the shut down of external axes during the cleaning operation.

The parameters first and last point to be shifted are optional parameters which have not to be input. All points are treated with the exception of those which are required for the calculation of the MPE command (source point / target point).

Relative shifting MPE_(1,7,100,200,45,78) last point to be shifted 78 first point to be shifted 45 target point 200 source point 100 axis number 7 MPE type 1 In the above example axis 7 is shifted around the vector, which is defined by the distance of point 100 to point 200 for the points 45 - 78 (first and last point to be shifted). The parameter MPE - type, in the example value 1, defines a relative shifting. Absolutverschiebung MPE_(2,7,100,45,78) last point to be shifted 78 first point to be shifted 45 target point 100 axis number 7 MPE type 2 In the example axis 7 is shut down at the position, which it has at point 100 for the points 45-78. The parameter "MPE type", in the example value 2, defines an absolute shifting.

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Programming Manual ROTROL速 II

Block 1 - Option

External axis

Exchange of point information MPE_(3,8,11,45,78) last point to be shifted 78 first point to be shifted 45 first external axis 11 second external axis 8 MPE type 3 In the example the positions 8 and 11 are exchanged for the points 45 - 78. The parameter MPE type, in the example value 3, defines the changing of point information. Copying of point information MPE_(4,8,11,45,78) last point to be shifted 78 first point to be shifted 45 target axis 11 source axis 8 MPE type 4 In the example axis 11 is shut down at the same position of axis 8. The parameter "MPE type ", in the example value 4, defines the copying of point information.

Program example: Subroutine for torch cleaning with shut down of axes 7 and 8 during the cleaning program.

PUBLIC_PROC_REI STORPOS_(100,100,1,1) Store the point 100 at actual position. MPE_(2,7,100,1,7) Shut down of axis 7 (points 1 to 7) MPE_(2,8,100,1,7) Shut down of axis 8 (points 1 to 7) GP_(1..4) SET_(4) WAITS_(2) RESET_(4) WAITI_(IN(4)) GP_(3,5..7) ENDP

Programming Manual ROTROL速 II

Page 15

External axis Program example

Bezugspunkte

Block 1 - Option Shift of point information via axis 8

Procedure - Programming of the first segment on the workpiece (points 1-8). - Programming of the first reference point (point 100) for the relative shift on the first segment of the workpiece. - Programming of the other reference points (points 103,203,303,403 etc.) for the second, the third etc. segment. The reference points (100/103, 100/203,100/303 etc.) define the difference of the point coordinates of axis 8 and must be programmed very exactly.

- Copying of the taught points on the first segment by the command COPYP (Real points are generated for the other sections). - Calculation of the new axis coordinates (axis 8) for the other segments by the command MPE. Copying the path points of the first section for the other segments

Calculation of the new axis positions for the other segments

The commands COPYP and MPE can be deactivated or deleted after successful execution because real points were generated on the different segments. Page 16

Programming Manual ROTROL速 II

Block 1 - Option

External axis

6 Manual movement of external axes (MANAX) 6.1 General The MANAX option permits to manually move an external axis during the program execution. The respective axis is decoupled from the control (system) and can manually be moved via buttons on the additional operation panel. This may, for example, be necessary when loading workpieces.

6.2 Selection and functions offline The programming is basically restricted to the commands , MANAX_(11,Nr.) Axis number State (11 = switch on)

MANAX_(10,Nr.) Axis number State (10 = switch off)

which switches the function MANAX (manual axis) The selected axis is uncoupled from the robot controller after having switched on the function and can be moved by using a separate operation panel (see the following description).

6.3 Selection and functions online

Online, the function is switched on or off by the respective command in the user program. The manual movement of an external axis is done in the same way as the offline programmation.

Programming Manual ROTROL速 II

Page 17

External axis

Block 1 - Option

6.4 Operation panel In addition to the MANAX command, an external axis is decoupled by means of a key switch installed on the separate operation panel. In the "ROBO" position, the axis is moved by the robot controller. In the "MANU" position manual movement is possible. The manual operation is indicated by a lamp "MANU on". Two further buttons are installed on the operation panel, so that the axis can be moved in MANAX operation in both directions. In the case that the two buttons are simultaneously operated, the axis goes back in HOME position. Chart:

Operation panel

Not Aus Linkslauf

Rechtslauf

ROBO

MANU

Manuell Ein

Principally, manual operation is only possible if a valid MANAX command was performed and if the key switch is in position "MANU" . The sequence is not important.

It must be considered here that after having switched off the MANAX operation, the respective axis is then again moved by the robot controller. You should therefore ensure that the next point can be reached without collision . When using turning positioners, the base position of the external axes being in loading position must be approached before re-coupling (EMERGENYOFF situation in the operation mode Automatic)

Page 18

Programming Manual ROTROL速 II

Block 1 - Option

External axis

7 Asynchronous movement of external axes 7.1 General Asynchronous movement of external axes offers the facility of positioning a freely programmable external axis independently of the robot movement. This function is used for positioning turning devices (e.g. CR 402 - DP - see illustration). The external axis provided for this function must be preconfigured in the robot controller and is automatically activated at each system start. It remains active until switched off by program command. When the function is inactive, the external axis can be programmed and moved like any other axis.

7.2 Positioning of an ADRIVE axis With the command ADRIVEAX_(7,1800,100) Speed Position in 1/100 degrees Number of external axis

the corresponding external axis is positioned. In the meantime the robot can execute other program commands. If drive commands are being executed during positioning (e.g. cleaning the welding torch), the danger of collision between internal robot axes and external axis must be considered when programming spatial points.

Programming Manual ROTROL速 II

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External axis

Block 1 - Option

7.3 Determination and allocation of the axis state The command ADRVSTAT_(Axis,variable) Variable for the state value Axis number

determines the actual state of the external axis and inputs it in the specified variable. The meaning of the state values are as follows: State value 0 1 2 3

Meaning The axis is not configured for the function asynchronous movement. The movement was aborted (EMERGENCY-OFF, release switch etc.) The axis is moving. The axis has reached the targeted position.

The axis state clearly informs about the actual state (position) of external axis. So the user program can be branched correspondingly in order to avoid collisions.

The allocation of the axis state is made by the command DRIVESTAT_(Axis, value) 0= 1=

Deactivation of the function asynchronous movement Activation of the function asynchronous movement for a normal user program 2 = Activation of the function asynchronous movement for the parallel task Number of the external axis

When the function asynchronous movement is deactivated, the axis can be treated in the same way as a normal freely programmable one. So it is possible to moce the axis in the operational mode TEACH. During an active function the axis is position by program command. This command can be transmitted out of a normal CAROLA program or out of a parallel task (see separate documentation "Parallel task").

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Programming Manual ROTROL速 II

Block 1 - Option

External axis

7.4 Positioning control The command WAITONAX_(Nr.) axis number ensures that the positioning of the external axis is completed before loaded workpieces are processed. If the robot movement is faster than the positioning of the external axis, the robot waits in the program line with the command WAITONAX until the positioning has been completed.

A command ADRIVEAX or WAITONAX (e.g. line start) which has not been executed results in an increased risk of collision. If the command ADRIVEAX is executed when the function is not active, the program run is interrupted.

Example: Approach to turn table position 1

PUBLIC PROC POS1 SET (7) LP1:IF NOT IN (7) THEN JUMP LP1 RES (7) DRIVESTAT (8,1) ADRIVEAX (8,0) WRITE ('*** TABLE MOVE TO POS.1! ***') IF X = CLEAN THEN CALL SPR WAITONAX (8) LP2:IF NOT IN (5) THEN JUMP LP2 SET (8) LP3:IF NOT IN (8) THEN JUMP LP3 RES (8) SELE:=0 WRITE ('') ENDP POS1

Drehtischabsteckung "zur端ck" Aktivieren der Funktion "ADRIVEAX" Positionieren der Achse 8 starten

Warten auf beenden der Positionierung

Drehtischabsteckung "vor"

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External axis

Block 1 - Option

8 MASTER / SLAVE 8.1 Application The MASTER/SLAVE option is used on systems, where two robots operate on one positioner or operate together on the positioner of the other robot. The two robot controls can be operated as individual (independent) systems. The advantage of this function is that the two robots can be moved synchronously on the moving workpiece during the weld path. Definition MASTER Robot /SLAVE Robot The robot, which positions the external axis used in common, is declared to be the "MASTER" robot by means of a program command. The second robot is given the position data of the moved axis via communication system and is declared to be the "SLAVE" robot by means of a program command.

8.2 Programming The two robots are programmed independently of each other. Please consider that -

the external axis can only be moved by the MASTER roboter, the two controls have to be informed about the geometrical position of the relevant external axis (see chapter "Synchronization of external axes"), the robot and the relevant robot axis are defined as "MASTER" or "SLAVE" (see MASTERON/MASTEROFF command in this chapter).

For programming a point with the SLAVE robot, the position of the external axis must be set by the MASTER robot; the SLAVE robot is then positioned at the workpiece and the point is stored. It is important that the SLAVE robot is programmed symmetrically to the program run of the MASTER robot. This means: -

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programming of same contours same weld seam lengths same weld speeds.

Programming Manual ROTROL速 II

Block 1 - Option

External axis

The command SYNCON_(Nr;A,B) optional transmit-receive variable for mutual transmission of values to the partner robot consecutive numbering of the SYNCON command, which avoids an asynchronous program run

at the seam start position actuates the synchronous movement of the two robots on the moved external axis. Both robots start the "synchronous movement". The command SYNCOFF_(No;A,B) deactivates the synchronous movement at the end of the weld path. In addition the SYNCOFF command can be used for the synchronization of program sections; for example to ensure a simultanous leaving of the weld path. Variable values can also be transmitted to the partner robot. In the case of several synchronous weld paths it is required that both robots wait for the same synchronisation signal. Example: When the MASTER is given the command SYNCON_(14), it waits until the SYNCON_(14) command also reaches the SLAVE robot. The program run is synchronously continued. With a different numbering, e.g. the program run is asynchronous, the procedure is interrupted with the error message Syncon / Syncoff-Parameter different

If the command is input on the teach pendant (PHG), the number is consecutively counted and preset by the computer.

Programming Manual ROTROL速 II

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External axis

Block 1 - Option

In systems, where both robots are used alterntely on the external axis of the other robot, the robot which controls the axis must be determined as "MASTER" and the other one as "SLAVE". The command MASTERON_(..) Axis number MASTER axis declares this robot to be the MASTER robot. The command MASTEROFF_(..) Axis number SLAVE axis declares this robot to be the SLAVE robot.

Determine the Master and the Slave robot by means of the a/m commands before programming points (e.g. synchronisation points for the corresponding external axis).

Restrictions During MASTER-SLAVE operation the following functions are not possible or are restricted:

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not possible

restricted

line start sensor functions (Oldelft) start-end and tack weld lists parameter looping circles with external axes

overlap start arc monitoring

Programming Manual ROTROL速 II

External axis

Block 1 - Option

Program example MASTER-Roboter 1 MAIN 2 CALL_SYN 3 MASTERON_(7) 4 GP_(1,2) 5 SYNCOFF_(1) 6 SYNCON_(2) 7 GC_(3,4) 8 ARC_(4,5,6) 9 SYNCOFF_(2) 10 GP_(7,1) 11 END |

Programmsynchronpunkt Synchronfahrt Nahtanfang

Programmsynchronpunkt

SLAVE-Roboter 1 MAIN 2 CALL_SYN 3 MASTEROFF_(7) 4 SYNCOFF_(1) 5 GP_(1,2) 6 SYNCON_(2) 7 GC_(3,4) 8 ARC_(4,5,6) 9 SYNCOFF_(2) 10 GP_(7,1) 11 END |

With the first program synchronous point it is ensured that the SLAVE robot only approaches the component as soon as the MASTER robot has positioned the external axis. The SYNCON command activates the synchronous movement of the two robots at the contour and deactivation is carried out with the SYNCOFF command. This program synchronous point also guarantees that the component is left simultanously.

Programming Manual ROTROL速 II

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External axis

Block 1 - Option

9 Synchronous axis When a workpiece (component) is clamped between two external axes, they must be moved in synchronisation of position and speed to avoid a distortion of the workpiece. These axes are called Master axis (e.g. axis 7) and Slave axis (e.g. axis 8). The Master axis is always the first axis of the two synchronous axes. The Slave axis is always the subsequent axis following the Master axis in a synchronous angle. After booting the controller, a synchronous monitoring is switched on principally which interrupts a movement when an error occurs, e.g. a position misalignment of the Master or the Slave axis. The controller sends the message: „ Axis .. electr. shaft asynchronous „ To adjust the position, the synchronous monitoring of the Master axis must be switched off. This is made via the commands

CHSYN_(7,0) Synchronous monitoring OFF Axis 7

The command CHSYN (7,1) Synchronous monitoring ON Axis 7

switches the synchronous monitoring on again. To adjust the axes, the movement of the Slave axis must be prevented by means of an additional keyoperated switch (SF8 - Slave axis OFF) which has to be actuated during the adjustment, the position of the Slave axis must be determined (incremental display in the mode TEACH). Then the Master axis is moved to the position of the Slave axis. The difference between the two axis positions should be < 10 increments. Every time the movement keys are tapped, the incremental display of axis 7 is updated. The synchronous monitoring must be switched on again after the adjustment. Page 26

Programming Manual ROTROL® II

Block 1 - Option

External axis

10 Parameterisation of external axes

POSTOLE

POSTOLR

TOLACT

FUNCON_RESTORP Changing the preset resolution for external axes e.g.: RESTORP,7,2 2/10mm resp. 2/100 degrees Axis number (in the example axis 7)

Attention: The positioning accuracy is influenced in this case.

Programming Manual ROTROL速 II

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External axis

Block 1 - Option

FUNCON_ENCRATIO When the workpiece is driven indirectly, the encoder coupling resp. the speed ratio (limit value max. 1:20) are adapted to the workpiece diameter.

z.B.: FUNCON ENCRATIO,7,400,800 Diameter of the workpiece Diameter of the drive roller Axis number

FUNCOFF_ENCRATIO The command FUNCOFF_ENCRATIO must be given at the end of the program. It restores the original configuration.

FUNCON_EXTOFF For the tool insertion external axes must be moved to a certain position (insert position) which may not be quit (personal protection) as long as the robot executes a user program on another external axis. To be on the safe side, the command

FUNCON_EXTOFF,Nr. Axis number can switch on the drive control stopper and the brake of the corresponding axis thus avoiding the axis to move. The command FUNCOFF_EXTOFF switches the function off again. The axis can now be moved. Conditions: To switch the control stopper and the brake the corresponding hardware must be available.

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Programming Manual ROTROL速 II

Multi-layer welding

Block 2 - Options

INDEX

1 Multi-layer welding .......................................................................................................... 2 1.1 General information ............................................................................................. 2 1.2 Chart: Storage of a root layer ............................................................................. 3 1.3 Description and function of point type filter .......................................................... 3 1.4 Chart: Storage of three different root layers ......................................................... 4 1.5 Calculation of filling runs ...................................................................................... 5 Chart: Complete program structure ....................................................................... 6 1.6 Extended multi-layer welding ............................................................................... 7

Programming Manual ROTROL速 II

Page 1

Multi-layer welding

Block 2 - Options

Multi-layer welding 1 Multi-layer welding 1.1 General information For reasons of stability of components, it can be required to weld over a seam with a certain number of filling runs. On the basis of the programmed root it is possible by means of the multi-layer programming to genrate all further layers by programming merely one point or by defining geometrical offsets. When extensive contours are concerned, the more time-intensive part of TEACHING of points is not required for filling and cover runs.

Multi-layer programming consists of the commands ROOTON, ROOTOFF, ROOTCPY, FILL, LAYDEFNUM, LAYDEFPNT, PICTURE, and LAYACT

A variant on multi-layer programming merely utilizes the commands

ROOTON =

root on

ROOTOFF =

root off

for defining the root layer

and FILL = fill

for generating the filling run(s).

The function ROOTCPY = copy root makes a copy of the commands exchanged between ROOTON/ROOTOFF for the given root weld. After entering the start nummber, the commands with the topical point numbers are input in the working program. Page 2

Programming Manual ROTROL速 II

Block 2 - Options

Multi-layer welding

1.2 Chart: Storage of a root layer

3 4

5 6

MAIN GP_(1,2) ROOTON_(1) GP_(3) GC_(4,5) ARC_(5,6,7) GC_(8,9) ROOTOFF_(1) GP_(10) Number of root layer

Within a program it is possible to define a maximum of five subsequent different root layers. The parameter put into brackets after ROOTON or ROOTOFF indicates the number of the root layer.

1.3 Description and operation of the point type filter The designated value is defined as distance measurement and is used to divide the root contour points of the root into different point types. The following point types are defined : · · · · · · · ·

Main path points Intermediate points at parallel straight lines Start points for path deviation Intermediate points for path deviation Endl points for path deviation Start points for circles Supporting points for circles End points for circles

The dimension of the filter size (Default value = 100 (10 mm) ) is 1/10 mm. Hereby all root contour points which have not been programmed as circle points by ARC or CIR, are broken down into main path points and auxiliary path points. Main path points are recognised by means of the following two criteria : a)

The distance to the previous and succeeding point in the contour is higher then the given filter size

A collection of points was recognised because of the filter size.

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Multi-layer welding

Block 2 - Options

The main path point of the collection of these points (at least two) is the one which has the smallest angle of the straight sections which encircle it. This breakdown of points is required to enable a meaningful filling pass to be constructed. All the points recognised as main path points are given the appropriate offset which was created by the representative point corresponding to the filling pass. All auxiliary points are allocated to a certain main path point. They are therefore arranged in the filling pass in such a way that the distance on the path to the main point is the same as in the root pass. In welding practice the auxiliary points are basically used to lead the orientation of the welding torch continuously "around a corner" (considerable modifications in Alpha, Beta, Gamma and at the same time reduced TCP path).

Value range of parameters : Parameter <Contourindex> <Pointtypefilter

min.1 1

Range - max. 5 32767

Unit

Default

1/10mm

Configur no

100

1.4 Diagram: Storage of three different root layers

MAIN GP_(1) ROOTON (1) GP (2) GC_(3) ARC_(3,4,5) ROOTOFF (1) GP_(6) ROOTON_(2) GP_(7) GC_(8) ARC (8,9,10) GC (11) ROOTOFF (2) GP_(12) ROOTON_(3) GP_(13) GC_(14..16) ROOTOFF etc.

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Contour 1

Contour 3 Contour 2

ROOTON (1)

ROOTON (2)

ROOTOFF (1) welding direction

ROOTOFF (3) ROOTOFF (2)

Programming Manual ROTROL速 II

ROOTON (3)

Block 2 - Options

Multi-layer welding

1.5 Calculation of filling runs For the calculation of the filling run it is required that the contours have been followed (see charts) and the first point (seam start) of the filling run(s) has been defined.

1. 2.

Further filling runs are calculated with the command FILL. The parameters are composed of: FILL_(1,3,70,73) Start point number The start point number defines the number of the first point to be generated in this filling run.

Point number "Seam start - Filling run" This point defines distance and direction of the filling run on the root weld.

Number of filling run This number has no influence on the function FILL. In case of an error when generating a filling run, this number is displayed in addition to an error message. In order to find the cause of an error more easily, it is advisable to record here the successive number of the layer.

Number of root The number of the root to which this filling run refers will be defined before by ROOTON und ROOTOFF definiert.

Example The root consists of the points 3 to 44. Direction and distance of the filling run to the root are defined by point number 70. By means of start point number 73, the points 73 to 114 are generated for the filling run. Point Point Point Point

3 4 5 6 路

of the root becomes point of the root becomes point of the root becomes point of the root becomes point

Point

of the root becomes point 114 of the filling run.

73 74 75 76 路

of the filling run. of the filling run. of the filling run. of the filling run.

For multi-layer programming it is not necessary to re-calculate the points of the filling runs must not be re-calculated during each program run but only once. For this reason, the FILL command can be deleted after a program run has been finished. Programming Manual ROTROL庐 II

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Multi-layer welding

Block 2 - Options

The ROOTON and ROOTOFF commands should remain in the program until same has completely been created and can then be deleted, too.

Chart:

Complete program structure

3 70

5 6

MAIN GP_(1,2) ROOTON_(1) GP_(3) GC_(4,5) ARC_(5,6,7) GC_(8,9) ROOTOFF_(1) GP_(10,11,12) FILL_(1,1,70,73) GP_(73) GC_(74,75) ARC_(75,76,77) GC_(78,79) GP_(80,1) END

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Programming Manual ROTROL速 II

Block 2 - Options

Multi-layer welding

With the exception of a later point correction, the aforementioned version does not allow to modify the torch angles and distances of the individual filling runs or merely sections of the filling runs. The commands LAYDEFNUM alternatively LAYDEFPNT, PICTURE and LAYACT enable to define and activate various seam geometries (torch angle, distance of filling run) for different sections of the weld groove. The individual sections of the weld groove are defined by the command PICTURE (= weld groove section / weld pattern)

Example:

RESTART LIST_1_=_(5211,1,0,250,0,0,0,0,2,0,0,22,330,0,0,0,0,0,0,120,0,0) MAIN LAYDEFNUM_(1,1,0,0,200,10,20) LAYDEFNUM_(2,1,0,0,200,10,20) LAYDEFNUM_(2,2,0,200,200,15,25) LAYDEFNUM_(3,1,0,0,200,-10,20) GP_(1,2,3) ROOTON_(1) PICTURE_(1) GP_(3) $_(1) weld groove section 1 / weld pattern 1 GC_(4) PICTURE_(2) ARC_(4,5,6) weld groove section 2 / weld pattern 2 GC_(7) PICTURE_(3) GC_(8) weld groove section 3 / weld pattern 3 ROOTOFF_(1)

Programming Manual ROTROL速 II

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1.6 Extended multi-layer welding

Multi-layer welding

Block 2 - Options

The command PICTURE is composed of the parameters: PICTURE_(1,0) Workpiece level

0 = The workpiece level is calculated self adaptive on the basis of the programmed contour. 1 = Independent of the programmed contour the XY level of the robot base system is always used. Weld groove section / Seam number (1 to max. 17)

The angles of attack and distances for the filling runs are determined for each weld pattern via the commands "LAYDEFNUM" or "LAYDEFPNT". For each PICTURE a maximum of fifteen filling runs with different angles of attack and distances an be defined. The command LAYDEFNUM is composed of the parameters: LAYDEFNUM_(1,1,0,20,20,15,25) Inclination angle in degrees (> 0o = pulling, 0o = neutral, < 0o = pushing) Elevation angle in degrees (> 0o = steep, < 0o = flat welding torch angle) Displacement in 1/10 mm in Z direction Displacement in 1/10 mm in Y direction Reference layer( 0 = root, 1 = first filling run ...) Definition number of filling runs (Example first filling run) Weld groove section / Weld pattern

Example Definition of angles of attack and distances for a weld groove with four filling runs (Angle of attack and distance are defined numerically) RESTART LIST_1_=_(5211,1,0,250,0,0,0,0,2,0,0,22,330,0,0,0,0,0,0,120,0,0) MAIN LAYDEFNUM_(1,1,0,0,200,10,20) LAYDEFNUM_(1,2,0,0,200,10,20) LAYDEFNUM_(1,3,0,200,200,15,25) LAYDEFNUM_(1,4,0,0,200,-10,20) The command LAYDEFPNT is composed of the parameters: LAYDEFPNT_(0,100,4,5,200,1,1) Definition number of filling runs (example first filling run) Weld groove section / Weld pattern Auxiliary point (if a straight line is defined as root is is required to program an auxiliary point for the level definition) Second point of weld groove (root) First point of weld groove (root) Offset point (defines the filling run distance) Geometry type (0 = straight line, 1 = circle/ref. circle

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Programming Manual ROTROL速 II

Block 2 - Options

Multi-layer welding

Example Definition of angles of attack and distances for a weld groove with four filling runs (Angle of attack and distance are defined via points)

RESTART LIST_1_=_(5211,1,0,250,0,0,0,0,2,0,0,22,330,0,0,0,0,0,0,120,0,0) MAIN LAYDEFPNT_(0,100,4,5,200,1,1) LAYDEFPNT_(0,200,4,5,200,1,2) LAYDEFPNT_(0,300,4,5,200,1,3) LAYDEFPNT_(0,400,4,5,200,1,4) .. The weld pattern geometries such defined are considered when generating the filling run points via the command FILL (see paragraph 1.3). Their priority is higher than the given offset point. However, it is required to allocate the individual weld pattern geometries to the different weld groove sections. Allocation via the command LAYACT.

Example RESTART LIST_1_=_(5211,1,0,250,0,0,0,0,2,0,0,22,330,0,0,0,0,0,0,120,0,0) MAIN LAYDEFNUM_(1,1,0,0,200,10,20) LAYDEFNUM_(2,1,0,0,200,10,20) LAYDEFNUM_(2,2,0,200,200,15,25) WELD PATTERN GEOMETRYLAYDEFNUM_(3,1,0,0,200,-10,20) DEFINITION GP_(1,2,3) ROOTON_(1) ROOT DEFINITION PICTURE_(1) WELD GROOVE SECTION 1 GP_(3) $_(1) GC_(4) PICTURE_(2) WELD GROOVE SECTION 2 ARC_(4,5,6) GC_(7) PICTURE_(3) WELD GROOVE SECTION 3 GC_(8) ROOTOFF_(1) ROOT DEFINITION OFF GP_(9) LAYACT_(1,2,1) ALLOCATE SEAM GEOMETRY FILL_(1,1,1,103) GENERATE FILLING RUN GP_(103) GC_(104) ARC_(104,105,106) GC_(107,108) ..

Programming Manual ROTROL速 II

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Multi-layer welding

Block 2 - Options

The command LAYACT is composed of the parameters: LAYACT_(1,2,1) first weld pattern geometry (LAYDEFNUM_(3,1..) for the 3rd weld groove section second weld pattern geometry (LAYDEFNUM_(2,2..) for the 2nd weld groove section first weld pattern geometry (LAYDEFNUM_(1,1..) for the 1st weld groove section

The number of parameters in the LAYACT command must be equal to the number of the PICTURE commends in the weld groove (root weld) . The generated points include the respective angles of attack and distances. Please enter "zero" at the corresponding position in the LAYACT command, if no filling run point shall be generated for this weld groove section.

The command LAYACT refers only to the last ROOTON / ROOTOFF sequence. For that reason the commands LAYACT and FILL should possibly be programmed directly after ROOTOFF. The third parameter in the command FILL is insignificant for the weld pattern programming.

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Programming Manual ROTROL速 II

Touch sensors

Block 3 - Options

Index Parallel shifting with a sensor 1 Parallel shifting with a sensor ................................................................................. 2 1.1 General ........................................................................................................... 2 1.2 The dialogue window ...................................................................................... 3 1.3 The command structure................................................................................... 3 Program example: Scanning with gas shroud sensor ........................................... 4 Program example: Searching procedure .............................................................. 4 2 WHENPAR ............................................................................................................ 6 2.1 Parameter of the search function .................................................................... 6

Programming Manual ROTROL速 II

Page 1

Touch sensors

Block 3 - Options

Parallel shifting with a sensor 1 Parallel shifting with a sensor 1.1 General Touch sensors are mainly used to find the correct weld seam position on workpieces requiring certain tolerances. Besides, they enable the determination of workpiece position and in combination with other commands (e.g. GETPOS, STORPOS..) gap and weld seam widths. This requires the use of different sensors and probes adapted to the tasks. The most common sensor is the HS700K. It works with a high-frequency contact voltage of 60V resp. 700V. The 700V version is used for problematic workpiece surfaces with rolling skins, scale, strong rust deposit or surfaces with color coats. The advantage of the high voltage is the high field intensity so that contact will be made even on nonbright surfaces. The CLDS laser sensor offers the possibility of a contactless scanning of weld seam positions. A laser beam detects the workpiece edges and is also able to detect even small edges (min. 2 mm). The programtechnical handling is the same in all cases.

Gasd端sensensor

Tick-tick sensor

Wire sensor CLDS laser sensor

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Programming Manual ROTROL速 II

Block 3 - Options

Touch sensors

1.2 The dialogue window

The dialogue window for the programmation of touch sensor routines is opened " in the dialogue field "Insert" and subsequent after pressing the button " selection of the touch sensor " ".

Programming the sensor routine Define the presettings for the search function

Display of the preset search functions 1-4

fast contact shroud sensor on or off

1.3 The command structure The command WHEN_IN(..)_DURING_GC(..)_THEN_............ is used in order to shift a programmed point on a given search path with the CHANGE command. The search path is indicated by two points. This search function can be applied in the three levels X, Y and Z whereby the deviation in the prior search level is being considered. The command is composed of: 1. WHEN_IN(..)

interrogation of a digital input

2. DURING_GC_(..)

indication of the search path

Programming Manual ROTROL速 II

Page 3

Touch sensors

Block 3 - Options

Program example: Scanning with gas shroud sensor

LIST 1=(5611,1,0,47,90,210,0,0,2,0,0,22,0,0,0,0,0,0,0,0,0,0) LIST 100=(5611,0,0,20) MAIN ! Status der SchweiĂ&#x;parameterliste auf "0" PAUSE GP (1,2) $ (100) SET (1) !Einschalten des Sensors GP (3) !Startpunkt Suchbewegung WHEN IN(1) DURING GC (5) THEN JUMP L001 RESET (1) PAUSE !Sensorsignal nicht gekommen DECHANGE L001: RESET (1) DECHANGE CHANGE (004) GP (6..8) $ (1) GC (9) GP (10,11) DECHANGE GP (1) END

Program example:

Searching procedure

The robot follows the programmed search path (points 3 - 5) with a constant speed (weld parameter list 100), thereby interrogating the state of the given input (in the example: input 1). The controller is given an input signal as soon as the gas nozzle touches the component or after recognition of the component edge by the CLDS, for example. The robot stops its searching procedure. Using the CHANGE command, the possibly existing difference to the programmed shifting point (point 4) is accepted as vector. All following points (points 6 - 11) are shifted by this vector (see chapter "Online parallel shifting" , Block 9 of standard instructions).

The state of the active weld parameter list (in the example: weld parameter list 100) must be set to "Zero" to prevent the arc ignition during the searching procedure.

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Programming Manual ROTROLÂŽ II

Block 3 - Options

Touch sensors

Graphical representation

3 4

End of the search path in the workpiece (generated point 5 by setting the searching length).

Gas shroud has contact ("Shifting point" point 4)

Beginning of the search path point 3

Correction of the welding path

uncorrected weld seam position

corrected weld seam position

This command and the corresponding sensor can be used for searching and determination of the seam start points. The further weld seam can be followed by the arc controlled seam tracking system (please refer to block 8).

By an extension in the software and hardware of the robot control the robot travel speed can be increased on the searching paths (distances). This extension is activated with the command FUNCON_FASTSENS This is a prerequisite for the CLDS laser sensor. Programming Manual ROTROL速 II

Page 5

Touch sensors

Block 3 - Options

2 WHENPAR When using the command WHENPAR a numeric keyboard appears for the pre-settings of four different adjustments for the use of a gas shroud sensor. The command is entered on operation system level.

When programming the search routine you are requested to indicate the function number. If parameter values are marked zero and if no search function is preset, you are requested to enter same during programming.

Parameters of the preset search functions

2.1 Parameters of the search function The parameters to be input are:

-Whenpar-Index: 1-4: - Outut number - Input number - Search length - Search speed

Page 6

Standard values current function numbers Sensor type HS700K No. 2 =700 V / Nr. 1 = 60 V Sensor No. 1 depending on component tolerances usually 20 cm/min

Programming Manual ROTROL速 II

Block 4 - Options

Transformation of points

Index Transformation and Imaging

2 Online 3-D-Transformation ..................................................................................... 2 2.1 Definition of the Online 3-D-Transformation .................................................... 3 2.2 Calculation and activation of the 3-D-Transformation ...................................... 3 2.3 Switching off the 3-D-Transformation .............................................................. 3 2.4 Re-activation of the 3-D-Transformation .......................................................... 3 2.5 Program example: Online 3-D-Transformation .............................................. 4 3 Offline 3-D-Transformation ..................................................................................... 5 3.1 Definition of the transformation ....................................................................... 5 3.2 Execution of the Offline 3-D-Transformation .................................................... 6 3.2.1 Definition of the Offline 3-D-Transformation ............................................... 6 3.2.2 Execution of the transformation ................................................................. 7 3.3 Restrictions in Offline 3-D-Transformation ....................................................... 7 4 Online/Offline Imaging ............................................................................................ 8 4.1 General ........................................................................................................... 8 4.2 Online imaging (see online transformation) ..................................................... 8 4.3 Offline imaging (see offline transformation) ..................................................... 9 4.4 Balance requirements ..................................................................................... 9 5 TCP-Transformation ............................................................................................. 10 5.1 General ......................................................................................................... 10 5.2 NEWTCP ...................................................................................................... 10 5.2.1 Determination of the TCP differences ..................................................... 10 5.2.2 Diagram: Check point with different torches ............................................ 11 5.2.3 Command syntax ..................................................................................... 11 5.3 Execution of a TCP transformation................................................................ 12 5.4 Program example Online TCP transformation: .............................................. 12 5.5 Offline TCP-/TOV-Transformation ................................................................. 13 5.5.1 Determination of theTCP-/TOV difference between source and target TCP/TOV ................................................................................................ 13 5.5.1.1 TCP Transformation ............................................................................. 13 5.5.1.2 TOV Transformation ............................................................................. 13 5.6.2 Execution of the Offline TCP/TOV -Transformation .................................... 14 6 Offline Change Function ....................................................................................... 15 6.2 Execution of the Offline Change Function ...................................................... 16 7 Offline Transformation with external axes (CEC) .................................................. 18 7.2 Application example for the command CEC ................................................. 19 8 Behaviour in case of transformation errors ...................................................... 24 Programming Manual ROTROL速 II

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1 Online/Offline Transformation ................................................................................. 2 1.1 General ........................................................................................................... 2

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Transformation of points

Transformation and Imaging 1 Online/Offline Transformation 1.1 General The 3-dimensional transformation allows to move along a second workpiece with identical design in shifted and rotated position without the necessity of important programming work (online transformation) or to generate real points for an independent user program on the shifted, rotated workpiece (offline transformation). Three additional points on the source workpiece and three more on the target workpiece are programmed for the calculation of the rotation and shift. The offline transformation only considers external axes if they were synchronised first (see chapter "External axes") and the kinematic chain (CEC) was indicated - i.e. the chain resulting from the movement.

Example: Offline transformation with external axes

turned and tilt target workpiece programmed source workpiece

2 Online 3-D-Transformation During the online transformation only the existing points of a user program are approached in a shifted mode corresponding to the shift and rotation that was calculated via the command TRAN. The source program resp. the original coordinates of the points are maintained.

TRON: re-activate stopped transformation TRAN: Input of the source and target points for calculation of the transformation

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TROFF:stop actual transformation

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For definition of the 3-D-transformation it is absolutely necessary to determine another three points on the original workpiece and three points on the shifted/rotated workpiece. With these points which have the same positions on the workpieces and which form a triangle with the largest possible distance, a relation between the original workpiece and the transformed one can be defined. Restrictions of rotation only occur due to the mechanical accessibility of the transformed points and paths. The accuracy of transformation depends on the precise teaching of the 6 points and the correctly adjusted TCP.

Points can be corrected only on the source part. External axes are not considered during the transformation . (Please see "Transformation with external axes - CEC")

2.2 Calculation and activation of the 3-D-Transformation TRAN_ ( <Q1> , <Q2> , <Q3> , <Z1> , <Z2> , <Z3> ) Point numbers in target part Point numbers in source part

All points which are run in accordance with the TRAN command are subject to the 3-D-transformation, i.e. are run in shifted mode. If a new TRAN command follows, the first command becomes invalid.

2.3 Switching off the 3-D-Transformation - command TROFF This command terminates the 3-D-transformation. The shifting vectors, however, are not deleted and can be re-activated.

2.4 Re-activating the 3-D-Transformation - command TRON With the TRON command, the last selected transformation can be re-activated (after TROFF).

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2.1 Definition of the Online 3-D-Transformation

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Transformation of points

2.5 Program example: Online 3-D-Transformation

LIST_1=(5211,1,0,47,90,210,0,0,2,0,0,22,0,0,0,0,0,0,0,0,0,0) MAIN XY: PAUSE $ (1) GP (1..3) GC (4..11) GP (12,13) TRAN (100,200,300,101,201,301) !- Activate the transformation GC (4..11) !-These points are approached in transformed manner TROFF !-Switch off the transformation CALL REI TRON GP (12,13) GC (... JUMP_XY END

Workpiece 1 Definition point 200 Definition point 300

Workpiece 2

Definition point 100

Definition point 201

Definition point 101

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Definition point 301

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Transformation of points

3 Offline 3-D-Transformation By means of the offline transformation a user program is -

copied, transformed and converted to a new shifted program

Advantage of the Offline 3-D Transformation: After conversion the source and target program can be corrected individually. Transformed points can: Definition of the transformation

replace the old points be stored under a new name in the same program or be stored in another program.

Define the kinematic chain Execution of the transformation

3.1 Definition of the transformation As with the online transformation, three definition points (100,200,300) are added to the source program (original program) to determine the spatial position of the component. turned and tilt target workpiece programmed source workpiece e.g.: points 1-45

Workpiece 1

Definition point 300

Definition point 100

Definition point 200

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Transformation of points

The target program is created by programming or copying. Here, another three definition points (101,201,301) are taught. All other points can be deleted after copying so that only the three definition points remain in the target program. The shift between original and shifted component is determined by these definition points, which are positioned identically on both components and form a triangle with longest possible sides.

Definition point 101

Workpiece 2

Definition point 301

Definition point 201

3.2 Execution of the Offline 3-D-Transformation To be able to execute a transformation with external axes the definition of the external axes must have been made (see chapter “Synchronisation of external axes”) and the kinematic chain (see chapter "Offline transformation with external axes") must have been indicated. Then the Offline 3-D-Transformation is defined (DTR) and executed (TRAN). The steps synchronisation and indication of the kinematic chain are not necessary if the transformation is done without external axes. 3.2.1 Definition of the Offline 3-D-Transformation DTR_Source.P(Q1,Q2,Q3)_TO_Target.P(Z1,Z2,Z3) Source = Name of the program originating the definition points Q1....Q3. Q1...Q3 =

Numbers of the definition points

Target = Name of the program originating the definition points Z1...Z3. Z1...Z3 = Numbers of the definition points

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Transformation of points

3.2.2 Execution of the transformation

Source =

Name of the program containing the original points

Target =

Name of the target program

pna = Point number of the first original point to be transformed pne = Point number of the last original point to be transformed pnz = Point number of the first transformed point. The numbering of the following transformation points is effected in relation to the original points. If the inquiries "Transfer all points?" and "Store under the same point number?" are answered with NO, the source points to be transformed (pna, pne) and the target point numbers to be generated (pnz) can be indicated. Command input for the example: -

Create copy of the user program The user program workpiece 2 is created (copy of workpiece 1) Teaching the definition points Workpiece 1 - points (100,200,300), workpiece 2 - points (101,201,301) Execution of the synchronisation (EXTDEF, EXTCHAIN..) Execute synchronisation program CEC _(1,2,3)_ TO_(1,4,5) Indication of the kinematic chain DTR_Example1.P(100,200,300)_TO_Example2.P(101,201,301) Definition of the transformation TRAN_Example1.P(ALL)_TO_Example2.P(1) Execution of the transformation

3.3 Restriction in Offline 3-D-Transformation -

The maximum size of a program to be transformed must not exceed 50 % of the available memory capacity.

With robots in overhead position, ambiguity may occur by offline transformation.

External axes are not considered during transformation. (Please also refer to "Transformation with external axes - CEC".) Programming Manual ROTROL速 II

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TRAN_Source.P(pna..pne)_TO_Target.P(pnz)

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Transformation of points

4 Online/Offline imaging 4.1 General Imaging of program points is carried out in the same way as the transformation (see pages 2 to 7 in this block). It is applied when workpieces are located in mirror imaged position to the original workpiece. Original workpiece

Example:

mirror imaged position turned Definition point 101

Definition point 100

Definition point 200

Definition point 300

Definition point 201

Definition point 301

4.2 Online imaging (see Online transformation)

For ONLINE-Imaging, instead of the command

TRAN

the command MIRROR

TRON

the command MIRRON

TROFF

the command MIRROFF

Mirron: re-activate actual imaging Mirror: Input of source and target points for the calculation of imaging

Mirroff: stop actual imaging

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Transformation of points (see Offline transformation)

For OFFLINE imaging, instead of the command DTR TRAN

the command the command

DMI MIRROR

are used.

Definition of the imaging

Execution of the imaging

4.4 Balance requirements A complete imaging of the workpiece also requires the imaging of the robot effector (robot welding torch). It is not easily feasible to change the effector each time the job switches from the original to the imaged copy. Therefore, this unit must fulfill certain symmetric requirements with regards to its shape and location at the robot so that the actually necessary imaging of the hand coordinates system may be replaced by redirection of one of the robot axes. The symmetric requirement is that the symmetric level of the effector equals the X/Z level of the manual coordinatees system. A common welding torch is applicable if it is bent downwards when the robot is in reference point.

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Transformation of points

5 TCP-Transformation 5.1 General By means of the ONLINE TCP transformation it is possible, e.g. for robotic systems with one torch changing system (CPWS), to effect programming without changing the welding torch with only one torch. Using only one command, the TCP for the welding torch, which is required for a program section, is selected and at the same time a transformation of the originally programmed points for this section is executed during the program run. So it is possible to deplete any program sequence with another torch without having to program it again.

NEWTCP: Determination of a new central tool point

Switching off the transformation Activation of the transformation

As this transformation is effected "Online", point informations are not changed, i.e. the program is depleted in its original form when removing the transformation command.

5.2 NEWTCP The basic requirement for ONLINE TCP transformation is the definition of the TCP of the torches to be used. This definition is effected within a program run by the command NEWTCP = NEW Tool Center Point

For a better understanding we recommend to study the chapter “Tool Center Point” first.

5.2.1 Determination of the TCP differences The system TCP serves as a basis for the definition of additional TCPs. All further TCPs are determined by the difference to this system TCP. Therefore a check point (reference point) is programmed in any program using the original torch (system TCP). A further point is programmed at this check position for each additional torch.

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5.2.2 Diagram: Check point with different torches

Check point 300 Torch distance 490mm

Check point 100 Torch distance 590mm

5.2.3 Command syntax The complete command for NEWTCP is NEWTCP_(100,300,3) TCP-INDEX (TCP number) Check point programmed with a further torch Check point programmed with the original torch

The value TCP-INDEX (3rd value) determines one of the 5 TCP numbers under which the TCP, which was determined by NEWTCP, is to be listed. Both the system and the other TCPs can be modified in the operational mode "TCP". As the TCPs calculated in the operational mode "TCP" are stored, a further execution of NEWTCP is not necessary. It is therefore possible, for example, to effect the TCP definition in a program set up for this purpose and to delete it after execution. Programming example with one original and two further torches to be defined. The "original torch" means the torch, that is being adjusted on the reference gauge:

MAIN NEWTCP (100,200,2) NEWTCP (100,300,3) END

!- calculated TCP gets no. 2 !- calculated TCP gets no. 3

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5.3 Execution of a TCP transformation

Both, recall of the new TCP and transformation are effected by only one command: GUNCHAON = GUN CHAnge ON Example: GUNCHAON_(3) The value in brackets indicates the TCP index (TCP number) of the torch which should be used after this command in the program run. Both, the TCP index and the value of this TCP have to be defined first by the command "NEWTCP". The new TCP remains activated until the transformation is switched off.

The transformation is switched off by the command: GUNCHAOFF = GUN CHAnge OFF After switching off the transformation all points are again approached in their old position.

5.4 Program example Online TCP transformation:

MAIN NEWTCP (100,300,3) Definition of the new TCP (see chapter "NEWTCP") GP (1..4) GC (5..8) GP (9,10) GC (11..14) GP (15..17) GC (18..21) GP (22,23) GUNCHAON (3) Selection of TCP with INDEX 3 and activation of the transformation GP (24) GC (25..28) GP (29..31) GC (32..35) These points are approached in a transformed way GP (36..38) GC (39..42) GP (43,44) GUNCHAOFF Switching off the transformation (all following points GP (45) are approached as programmed) GC (46..49) GP (50,51) GC (52..56) GP (57,1) JUMP ST END

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Transformation of points

5.5 Offline- TCP-/TOV-Transformation By means of the OFFLINE TCP/TOV transformation it is possible to transform a program so that it can also run when the dimensions of the torch deviate from those of the original one. The system TCP only determines the path behaviour and not the position of points. Thus, it is not sufficient to input merely the TCP of the new torch. The transformation is effected separately for TCP and TOV in 2 operations. If a transformation should be effected for TCP and TOV, it must be taken into consideration that this must be effected separately from each other. Difference determination between source and target TCP

Difference determination between source and target TOV

5.5.1 Determination of the TCP-/TOV difference between source and target TCP/TOV 5.5.1.1 TCP transformation DTCP

Definiere Tool Center Point

Example: DTCP_(0,0,2450;0,0,2200) Target TCP TCP of the new welding torch Source TCP

TCP of the original torch, with which the program was defined originally

With the DTCP command the difference between the two torches used is determined. 5.5.1.2 TOV - Transformation DTOV

Define Tool Orientation Vector

Example: DTOV_(-1,0,-1;1,0,-1) Target TOV TOV of the new welding torch Source TOV

TOV of the original torch, with which the program was defined originally

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Transformation ausf端hren

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Transformation of points

5.6.2 Execution of the Offline TCP/TOV transformation CHGUN =

CHange GUN = Change welding torch

Example: CHGUN_PROG1.P(1..125)_TO_PROG1.P(1) Target program Source program IIn the above mentioned example the points 1 - 125 of the source program "PROG1" are transferred to the target program "PROG1". As the names of the source program and the target program are identical, the transformation is effected within this program. If a new name is chosen as target program, the source program remains in its original version. The values put into brackets (1..125) indicate the range of points which shall be transformed. In order to transform all points of a program, it is also possible to put "ALL" in the bracket. Any non existing points in the source program do not lead to an error message, but are overridden/ bypassed. The number put into brackets after the name of the target programs (in the example "1") indicates the point number from which the transformed points shall appear in the target program.

Example:

CHGUN_ORI.P(ALL)_TO_TARGET.P(51)

In this example the point range of the source program (program name = ORI) will appear in the target program (program name = TARGET) with new point numbers. Example: Point number 1 in the source program = point number 51 in the target program Point number 2 in the source program = point number 52 in the target program As this shift of the point range requires a new text (EDI) it is advisable to choose the point range of the target program equally to that of the source program. Example:

CHGUN_PROG1.P(ALL)_TO_PROG2.P(1) CHGUN_PROG1.P(1..73)_TO_PROG2.P(1)

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6 Offline Change function The offline change function is applied when workpieces are shifted parallel to the original workpiece. Consequently, a 3-D parallel shift of stored points is possible.

Definition of the shift vector

replace the old points, be stored under a new point number in the same program, or be stored in another program

Execution of shift

After the transformation has been effected, the original program and the target program can be corrected independently from each other. To determine the shift vector, a point is stored at a marked position at the original workpiece (source point). In addition, a point is stored at the relevant position (target point) of the shifted workpiece. A "shift vector" is created for the two points and is added to all points of the source program.

Source point 100

Target point 101

Shift vector

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These new points can

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Transformation of points

The defined change function can be applied in series of several change commands to different points or ranges of points. If a range of points is shifted, only the start and end point of the range must be defined in the storage. Non defined points are skipped. Each transformed point is given a point number so that the distance to the start point number of the transformed series of points and the distance between the original point and the start number of the non-transformed series of points is identical. Both start point numbers are indicated in the transformation command. The storage location is monitored when new points are created. Furthermore, it is checked whether the created points are situated within the radius of action of the machine. The properties of the non-transformed points such as PTP/CP, override, function outputs are transferred to the affiliated transformed points.

6.1 Include external axes in the Offline Change function Workpieces which are arranged parallely to an axis of the robot coordinate system are suitable for shifting only when the construction (design) of the positioners is identical. Movements of the external axes in the source program must be transferred to the corresponding axes in the target program. The transformation of the external axis coordinates by means of the function CEC (see chapter "Transformation with external axes"). This would also be possible by using the point editor, the MPE command or GETPOS- STORPOS commands.

6.2 Execution of the Offline Change function 6.3.1. Definition of an Offline Change function

With the DCH command the shift vector between source point and target point is determined. DCH_Source.P(qp)_TO_Target.P(zp) source qp target zp

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= = = =

name of source program source point name of target program target point

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Transformation of points

6.3.2 Execution of the shift The shift is carried out with the CHA command.

Source = Name of the program which contains the original points. Target = Name of the target program pna = Point number of the first original point to be transformed pne = Point number of the last original point to be transformed pnz = Point number of the first transformed point. The numbering of the following transformation points is effected in relation to the original points.

Procedure of program transformation by means of 3-D-parallel shifting -

Create copy of the user program The user program workpiece 2 is created (copy of workpiece 1) Teaching the definition points Workpiece 1 - points (100), workpiece 2 - points (101) Execution of the synchronisation (EXTDEF, EXTCHAIN..) Execute synchronisation program CEC _(1,2,3)_ TO_(1,4,5) Indication of the kinematic chain DCH_Workpiece1.P(100)_TO_Workpiece2.P(101) Definition of the shift vector CHA_Workpiece1.P(ALL)_TO_Workpiece2.P(1) Addition of the shift vector

Alternatives: CHA_Workpiece1.P(2..10)_TO_Workpiece2.P(2) CHA_Workpiece1.P(1..15)_TO_Workpiece2.P(8) CHA_Workpiece1.P(1..15)_TO_Workpiece2.P(1)

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CHA_Source.P(pna..pne)_TO_Target.P(pnz)

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Transformation of points

7 Offline transformation with external axes (CEC) To include external axes in a transformation and to differ them from the standard transformation -

Offline Change, Offline Transformation and Offline Imaging

they must be defined correspondingly before transformation is executed. This contains that: 1. the external axes must have been synchronised (see chapter "synchronisation of external axes" in Block External Axes),

2. the kinematic chain was input.

The kinematic chain is input by an additional command (CEC). The system only knows that external axes are to be included in the transformation after having entered this command. After completion of the offline transformation, this command CEC is deleted. The command must be input again for any subsequent transformation.

7.1 The command CEC and the priorities for the value indications CEC

Change External Cinematics

The numerical values in the CEC command indicate the numbers of the freely programmable external axes. They start with the numerical value 1. 1 = 2 = etc.

external axis external axis

1 2

= =

axis 7, axis 8

As with their synchronisation, the external axes are also listed according to their priority in case of the command CEC, e.g. first external axis secondary external axis

LVE Rotating axis

CEC_(1,2)_TO_(...)

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Transformation of points

7.2 Application examples for the command CEC

Command:

Shift in an external axis

CEC_(1)_TO_(1)

1 = external axis 1 = axis7

Example 1

Gantry-type carriage axis7

Table 1

Table 2

In this example axis 7 is a linear axis. The working program is transformed from table 1 to table 2, taking into account axis 7. Table 1 and table 2 are not freely programmable external axes, but fixed working stations.

Procedure:

CEC_(1)_TO_(1)

Standard offline programming is then carried out by means of the commands: DTR and TRA for transformation DMI and MIR for imaging DCH and CHA for offline change function

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Block 4 - Options Example 2

Transformation of points Fixed robot Two similar external axes, e.g. turntable axis 7 and axis 8

Command:

CEC_(1)_TO_(2)

Axis 7

Axis 8

Procedure:

CEC_(1)_TO_(2)

Then carry out the standard offline programming by means of the commands DTR and TRA for transformation DMI and MIR for imaging DCH and CHA for offline change function

This example assumes that both external axes have the same direction of rotation, e.g. direction of rotation (-) of both tables clockwise.

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Example 3

Transformation of points

Fixed robot two similar turning/tilting axes axis 7 = turning axis of table 1 1 —> ext.1 axis 8 = tilting axis of table 1 —> ext.2 axis 9 = turning axis of table 2 —> ext.3 axis 10 = tilting axis of table 2 —> ext.4

Command: CEC_(2,1)_TO_(4,3) Axis 7

Axis 9

Axis 8

Axis 10

Procedure: CEC_(2,1)_TO_(4,3) Then carry out the standard offline programming by means of the commands DTR and TRA for transformation DMI and MIR for imaging DCH and CHA for offline change function

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Block 4 - Options Example 4

Transformation of points Robot on LVE —> Ext.1 = axis 7 two similar positioners,

Command:

axis 8 and axis 9 axis 10 and axis 11

CEC_(1,3,2)_TO_(1,5,4)

Gantry axis 7

axis 11

axis 9

axis 10

axis 8

Procedure:

CEC_(1,3,2)_TO_(1,5,4)

Then carry out the standard offline programming by means of the commands DTR and TRA for transformation DMI and MIR for imaging DCH and CHA for offline change function This example assumes that both external turning axes have the same direction of rotation, e.g. direction of rotation (-) of both tables clockwise.

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Transformation of points Robot on linear axis 7

In this example the movement of the rotary axis of the turning/tilting table (axis 8) should be transferred to the rotary axis of the additional turning device (axis 10). It should be noted that the tilting axis of the turning/tilting table is not moved in the original program. Command:

CEC_(1,3,2)_TO_(1,4)

Axis 10

Axis 9 Axis 7

Axis 8

Procedure: CEC_(1,3,2)_TO_(1,4) Then carry out the standard offline programming by means of the commands DTR and TRA for transformation DMI and MIR for imaging DCH and CHA for offline change function

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turning/tilting table axis 8 = rotation axis —> ext.2 axis 9 = tilting axis —> ext.3 additional turning device Axis 10 —> ext.4

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Transformation of points

8 Behaviour in the case of transformation errors Errors may occur during the transformation of points because of ambiguities in the robot axes positions. The axes positions are calculated in such a way that final position violations are caused (i.e. the point information is outside the robot working range). Consequently, the transformation of the point is interrupted with the error message F1567:

Reference angle -2872 - 1 - 1 0 360 0

F1566:

Driven angle (1/10 degree) 1700 91 128 -51 379 81

Change reference angle?

F1502: Transformation error at point No. __ in the original F0216: Axis __ at positive/negative limit switch !!

In the following menu it is possible to inform the system about reference angles for the individual axes which should be taken into consideration for a renewed point transformation. After input of the reference angles the system tries again to perform the transformation. If top layer violations are again determined, the system interrupts the transformation again. This procedure is repeated until this menu is quit by pressing the ESC key. The point is not transformed and is kept on the original position. It must be defined later in TEACH mode in the target program.

Increased danger of collision if 1. the point is not transformed or 2. a wrong reference angle is indicated.

The continuation of the transformation is inquired by the system with the message F1574: Interrupt transformation ? Y/N.

Transformation is continued when pressing the N key.

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Transformation of points

The transformation requires -

the correct synchronisation of all external axes (see "Synchronous movement of external axes" - Block 1, ROTROL Programming Manual - Options),

the correct cinematic linkage (EXTCHAIN command) of all external axes,

as well as the integration of external axes by the CEC command (see page 18 in this block).

All axes involved in the transformation can only be considered after the synchronisation has been carried out.

When transformation errors occur in combination with external axis, the CEC command must be input again, if with the TRAN command (alternatively MIR command) the following message appears:

Transformation systems not yet defined

The CEC command must be input again if the robot axes are outside their working ranges and if the transformation is interrupted.

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Block 5 - Options

Centre point referenced circle programming

Index

Centre point referenced circle programming

1 Centre point referenced circle programming .................................................................. 2 1.1 Definition command ............................................................................................ 2 1.2 Execution command ............................................................................................ 3 1.3 Programming example with two circles .............................................................. 4

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Centre point referenced circle programming

Block 5 - Options

Centre point referenced circle programming 1 Centre point referenced circle programming The centre point referenced circle programming enables the rapid and simple programming of several circles.

Centre point referenced circle programming is composed of 1. a definition command and 2. an execution command.

Furthermore, shifting in connection with touch sensors is possible because only one point (centre point of circle) is shifted. This function is frequently used in the field of cutting and flame cutting technology as the centre point and the radius can often be taken from one drawing.

Circle definition

Execute circle

1.1 Definition command CIRDEF_(101,102,103,500) Radius Definition points

The definition points define the circle plane, which means the orientation and position of the circle in space. Program these points on the circle surface. They should form a triangle of largest possible size. The torch orientation of the three definition points is decisive of subsequent circles. The indication Radius is effected in 1/10 mm. The radius indicated here is only applicable if no radius is input in a subsequent circle command (CIRA). The command CIRDEF is valid for all subsequent circles (CIRA) until the next CIRDEF command is entered.

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Centre point referenced circle programming

1.2 Execution command

CIRA_(23,12,700,100)

Overlapping in 1/10 mm Radius in 1/10 mm Start point Centre point

Centre point

Start point

The parameters indicated in "CIRA" are:

The circle path is started at the place, where the line between centre point and start point cuts the circle line.

The start point must not be placed on the circle line.

Radius By setting this value the radius input in the command CIRDEF for this circle is overwritten.

Overlapping Defines the distance being welded for more than 360° or in case of a negative value for less than 360°. The input is made in 1/10 mm on the circle path.

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Centre point referenced circle programming

Block 5 - Options

The circle command may be reduced by the parameters -

overlapping overlapping and radius

overlapping, radius and start point

e. g. CIRA_(23) Centre point If no value for overlapping is input, the value "0" applies. If no radius is input, the robot uses the radius you entered in the command CIRDEF. If no start point is input in the CIRA command, the actual position of the robot is taken as start point.

1.3 Programming example with two circles

LIST 4=(5411,3,450,65,125,245,0,0,2,0,190,22,330,0,0,0,0,0,0,120,0,0) MAIN PAUSE CIRDEF (101,102,103,600) GP (1,2) CIRO (3) $ (4) CIRA (3) GP (2) CIRA (4,101,200,50) GP (5,1) END

In the example, the first circle is effected with the radius which is defined in the command CIRDEF (here 60 mm). The second circle is effected with a radius of 20 mm, an overlapping of 5 mm and the start point 101. Page 4

Programming Manual ROTROL速 II

Block 6 - Options

Laser sensor/Arc sensor/Analogue sensor

Index Seam tracking systems 1 Seam tracking systems ........................................................................................... 2

2 The arc controlled seam tracking system (arc sensor) ....................................... 5 2.1 Activation / Deactivation of the arc sensor .................................................... 5 2.2 Lateral and vertical correction speed ............................................................. 5 2.3 Lateral correction ............................................................................................. 6 2.4 Vertical correction ............................................................................................ 6 2.4.1 Definition / Determination of the vertical set value ........................................ 6 2.5 Requirements on torch position and arc ....................................................... 7 2.6 Limitations ......................................................................................................... 8 2.7 Seam tracking of the TIG welding procedure ................................................ 9 2.7.1 TIG welding procedure without current pulse ................................................ 9 2.7.2 TIG welding procedure with current pulse ..................................................... 9 3 Measurement of the vertical set value on the path beginning .......................... 10 3.1 Definition of the parameter ............................................................................ 10 3.2 Activation of the measurement ..................................................................... 10 4 Seam tracking with a freely defined oscillating pattern ..................................... 11 5 Transfer of deviations to seam points ................................................................. 12 6 Offset storage during seam tracking ................................................................... 13 6.1 Changing the maximum offset number........................................................ 14 6.2 Activation of offsets ....................................................................................... 14 6.3 Seam tracking with offset administration of a 3-layer weld seam ............. 16 7 Analogue sensor .................................................................................................... 17

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1.1 General .............................................................................................................. 2 1.2 Application possibilities................................................................................... 3 1.2.1 Laser sensor ................................................................................................ 3 1.2.2 Arc sensor (arc controlled seam tracking system) ....................................... 3 1.2.3 Analogue sensor .......................................................................................... 3 1.3 The dialogue windows in summary.................................................................. 4

Laser sensor/Arc sensor/Analogue sensor

Block 6 - Options

Seam tracking systems 1 Seam tracking system 1.1 General Seam tracking systems such as laser sensor, analogue sensor and arc sensor are used for the path tracking which means that the real weld path deviates from the programmed path. Workpiece tolerances or distortion by heat are possible reasons. Different applications (flame cutting, welding), weld forms (lap seams, fillet seams and Vtype welds), material and the accessibility of the pathes determine essentially the use and the application possibility of these systems.

If a weld seam is welded with a seam tracking system, the path does not follow exactly the programmed contour, but it is determined by the measuring results of the seam tracking system. If the controller determines a deviation from the programmed path course, the programmed path is changed. The deviations determined during the search path (offsets) are stored and added to the other points in form of a vector.

For multi-layer welding, the course of the first weld seam is detected and the determined shift is stored. All further weld seams (layers) are newly calculated by the robot controller (addition of the determined shift) and welded with a respective shift.

Because the seam tracking systems - except the laser sensor - are not suitable for searching the start position of the path, a combination of touch sensor (e.g. gas shroud sensor) and arc controlled seam tracking system is often used.

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Laser sensor/Arc sensor/Analogue sensor

1.2 Application possibilities

The laser is used for MIG-/MAG and TIG welding. The position (touch sensor function), the course (seam tracking) and the weld groove volume can be searched or determined independently of the material to be weld (aluminium, Cr-Ni steel, normal steel). A special laser software evaluates the measuring data coming from the camera and compares them with a pre-programmed form (template). The correction data are determined and transferred to the robot controller. The lateral and the vertical direction of the welding torch are corrected. Besides, parameters such as welding speed, oscillating amplitude and deposition rate can be influenced and adjusted to reality. See special documentation "Laser sensor"

1.2.2 Arc sensor (arc controlled seam tracking system) The arc sensor is used for MIG-/MAG and TIG welding tasks. Measuring values being necessary for the determination of the position are determined by means of the arc - by measuring the welding current with maximum oscillating amplitude - which requires oscillation during the welding travel. A correct seam tracking depends on exactly adjusted welding parameters and the material in use. Field of application: Steel Cr-Ni steel Aluminium Cored wires

main application field partly applicable not applicable partly applicable

The lateral and the vertical direction of the welding torch are corrected. 1.2.3 Analogue sensor Analogue sensors are mainly used for flame cutting. Here the robot corrects its position (e.g. distance of the cutting nozzle) on the basis of a comparison voltage supplied by the sensor. (See FUNCON_ANASENS, ANAIN, ANAOUT in this chapter)

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1.2.1 Laser sensor

Laser sensor/Arc sensor/Analogue sensor

Block 6 - Options

1.3 The dialogue windows in summary The dialogue windows of the seam tracking systems LASER and Arc/Analogue sensors are as follows: Dialogue window Laser

- see special documentation laser sensor -

Command: RPOINTS point storage during seam tracking

Switching on/off the sensor guide

Activate static measurement Determine the parameters of the sensor guide

Determination of te correct sensor TCP/ Template selection TOV

Definition of the sensor type

Dialogue window Arc sensor

Offset storage for the multilayer technology

Activate/stop seam tracking

Take-over of deviations to the target point

Lateral/vertical limitation during seam tracking

Delete offsets

Measuring the vertical set value Display of the input voltage values of the analogue sensor

Switching on/off functions Command: RPOINTS point storage during seam Activation of an analogue tracking sensor (in connection with FUNCON)

The touch sensors are described in block 3 -Options- chapter "Touch sensors". Page 4

Programming Manual ROTROL速 II

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Laser sensor/Arc sensor/Analogue sensor

2 The arc controlled seam tracking system (arc sensor) 2.1 Activation / deactivation of the arc sensor The arc sensor is activated resp. deactivated in the user program by means of the command SSPD_(..,..)

= Search SPeeD.

A seam misalignment is corrected in two directions.

Diagram:

SSPD_(0,0)

no seam tracking

SSPD_(20,0)

only lateral correction vertical

SSPD_(0,10)

only vertical correction

SSPD_(15,10) =

lateral

lateral correction and vertical correction

SSPD_(15,10) VERTICAL correction speed LATERAL correction speed

Lateral and vertical correction are active simultaneously and therefore result in a correction of the robot path in the shortest way in the direction towards the seam groove. If a misalignment is determined, the robot reacts in lateral and vertical direction. The command SSPD must be input in the user program - before the welding path. If no new SSPD command is input, the SSPD command is valid for all seams in one program.

2.2 Lateral and vertical correction speed With the aid of a dynamic control process the correction speed is calculated, depending on the figures entered in the SSPD command and the deviation from the set position, determined at the weld seam. This results in a high correction speed with large deviation and high values in the SSPD command or low correction speed with small deviation despite high values in the SSPD command.

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Examples:

Laser sensor/Arc sensor/Analogue sensor

Block 6 - Options

2.3 Lateral correction The first numerical value determines the LATERAL CORRECTION speed (correction direction 90 degrees to the wire direction). The LATERAL CORRECTION determines the correction values from the two measuring points on the seam side. If both measuring values are equal, the torch tip is exactly placed in the groove of the weld seam. If they are not equal, a misalignment exists and a correction takes place in the direction of the seam groove.

2.4 Vertical correction The second numerical value determines the VERTICAL CORRECTION speed (correction direction in wire direction). The VERTICAL CORRECTION determines the correction values in the center of the oscillating amplitude. Analogous to the welding parameters adjusted during seam tracking, a determined length of the free end of the wire must be kept. It is indicated in the welding parameter list by means of a set value. This set value is called VERTICAL SET VALUE..

2.4.1 Definition / Determination of the vertical set value An optimum arc is only achieved when, among others, the weld voltage, wire feed and wire length = wire distance are adjusted to each other by adapting (initial weld) the parameters wire feed and voltage/pulse frequency of the welding parameter list according to the programmed wire distance. When the wire distance varies due to workpiece tolerances, it is imperative that the arc gets worse. This correction requires a set value which restores the relation of the a/m factors. It is therefore only adjusted resp. determined after initial welds and optimisation of a weld parameter list.

The vertical set value (without unit) is adjusted on the teach pendant until the programmed wire distance is restored. This can be seen on the arc itself. Please consider that a changing of the parameter has a delayed effect on the wire distance due to the adjustment behaviour. Therefore, please re-adjust the wire distance step by step.

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Laser sensor/Arc sensor/Analogue sensor

But it can be preset - if it is known - directly in the parameter "vertical set value" of the weld parameter list (see block 7 -Standard- chapter "Welding functions").

Note: High adjustment speeds shorten the time which is needed for the adjustment of the correct vertical set value before the torch touches the weld material thus causing an EMERGENCY-OFF situation or before the wire distance is too large for a stable arc. When the adjustment speeds are too low, the necessary welding path may be not sufficient to adjust the requested wire distance. Use an adjustment speed which is suitable for the welding process based on the expected deviation and the necessary welding speed. The values of the adjustment speeds are in the range of SSPD (5,5) to SSPD (40,40). The maximum input value for the lateral and vertical adjustment is 255.

2.5 Requirements on torch position and arc Selection of the process (spray arc, pulsed arc, short arc) has no direct influence on the adjustment values mentioned below. The welding parameters must be selected so that the arc is not placed exactly over the weld pool (flow). The arc length should be kept as short as possible. The stability of the arc process generally forbids a higher oscillating frequency at a high amplitude at the same time. This becomes valid especially in the case the smaller theangle of the groove is (e.g. for V-grooves). The number of the position measurements increases. The torch orientation in fillet welds of normal position should be some degrees from the bisecting line of the angle into the direction of the upper sheet (see figure). The torch position can be neutral to pushing without influencing the weld scanning (see figure).

Angle of contact Angle of tilt Weld direction

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Laser sensor/Arc sensor/Analogue sensor

Block 6 - Options

Diagram: Seam tracking

LIST 1=(5411,1,0,47,90,210,700,0,2,0,0,22,0,0,0,0,0,0,0,0,0,0) MAIN START: PAUSE SSPD (15,10) $ (1) GP (1,2) GC (3) GP (4,1) END

vertical set value Switch on seam tracking and lateral and vertical correction speed

Real weld start position programmed weld start position

The programmed seam course is corrected by the arc sensor. The path point on the end of the weld seam only determines the length of the seam. 2.6 Limitations The correction travel of the robot can be limited by the following commands in connection with the command FUNCON. The limitation - input in 1/10 mm - is set separately for the vertical and lateral adjustment. The maximum correction of the determined deviations is made on the basis of the programmed weld path until these distances are reached. Examples: FUNCON_DEVIUPDN,100,100 Vertical limitation (10 mm) upwards Vertical limitation (10 mm) downwards

FUNCON_DEVILR,100,100 lateral limitation (10 mm) right lateral limitation (10 mm) left

Please consider the TOV adjustment ! The TOV adjustment defines the oscillating level and the wire direction and must therefore be checked. The TOV adjustment is described in the Programming Manual - Standard, block 3. Page 8

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Laser sensor/Arc sensor/Analogue sensor

2.7 Seam tracking of the TIG welding procedure The arc sensor can be used for the determination of deviations in the same way as for the MAG welding. The following conditions must be fullfilled. 2.7.1 TIG welding procedure without current pulse The vertical and lateral direction can only be tracked if -

the address of the MAD2 card is set to decimal 11 (B) by means of the DIP switch, the configuration of the MAD2 card is adjusted to seam tracking

and

o o o

the command FUNCON_ANASENS,4 is input (this especially adjusts the seam tracking for the TIG welding procedure), the command SSPD_(Value, value) is input and the parameter "pulse frequency" of the TIG weld parameter list is set to "zero".

The necessary measuring values of the weld current are acquired synchronously to the oscillating movement. The vertical set value is approx. 300.

2.7.2 TIG welding procedure with current pulse Only a vertical change can be determined in the TIG welding procedure with current pulse. To do this, -

the address of the MAD2 card must be set to decimal 11 (B) by means of the DIP switch, the configuration of the MAD2 card is adjusted to seam tracking

and - in the user program o o o o

the command FUNCON_ANASENS,4 is input (this especially adjusts the seam tracking for the TIG welding procedure), the command SSPD_(0, value) must be input and the parameter "pulse frequency" of the TIG weld parameter list must be in the range of 1.5 to 14 Hz because of measuring reasons, oscillation must not be used.

The necessary measuring values of the weld current are acquired synchronously to the main and the base current. The vertical set value is approx. 300.

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- in the user program

Laser sensor/Arc sensor/Analogue sensor

Block 6 - Options

3 Measurement of the vertical set value on the path beginning The function enables the value determination of the parameter "Vertical set value" on a programmed contour. Unlike the common parameter determination (see chapter 2.4.1) the robot postion - wire distance - is not changed but the value of the parameter "Vertical set value" of the active weld parameter list. It is adjusted corresponding to the actual wire distance. The vertical set value is adjusted within the distance input in the command "FUNCON_ SSMOFFS". The distance should be as short as possible but the arc must be stable at the end. 3.1 Definition of the parameters The command FUNCON_SSMOFFS,20,1 0 = inactive lateral adjustment 1 = active lateral adjustment Distance to adjust the vertical adjustment in millimeter

- defines the distance in which the parameter "Vertical set value" is changed and - switches on resp. off the lateral adjustment. 3.2 Activation of the measurement The interpolation command SWITCH_NEWOFFS activates the measurement for the parameter "Vertical set value". The vertical set value is input in the weld parameter list after the indicated distance. When the vertical measurement is finished the function is deactivated.

LIST 1=(5411,1,0,47,90,210,700,0,2,0,0,22,0,0,0,0,0,0,0,0,0,0)

MAIN FUNCON SSMOFFS,20,1 START: PAUSE SSPD (15,10) $ (1) SWITCH NEWOFFS ! 1. Activate the vertical measurement GP (1,2) GC (3) SWITCH NEWOFFS ! 2. Activate the vertical measurement GP (4,5)

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Laser sensor/Arc sensor/Analogue sensor

4 Seam tracking with a freely defined oscillating pattern When using freely defined oscillating patterns it is necessary - contrary to the normal sinusoidal oscillating pattern - to determine the measuring points where the weld current has to be measured. Measurement is made during the execution of the indicated cycle of a defined oscillating pattern (see block 7 "Freely defined oscillating pattern"). 4.1 Generation of the oscillating pattern The requested oscillating pattern is generated and included in the program, e.g. OSCVEC_(0,-3;100,3;2,3;0,0;0,0;-1,3;100,3;1,-3;-1,-3).

This generated pattern must be called up in the program at the required place by means of OSC_<Name>. 4.2 Determination of the measuring points The actual value of the weld current to be compared must be measured on the slopes of the respective oscillating pattern. The corresponding cycle number has to be inserted into the command "STCLK".

STCLK_(1,6)

Programming example

OSCDEF FORM1 OSCVEC (0,-3;100,3;2,3;0,0;0,0;-1,3;100,3;1,-3;-1,-3) STCLK (1,6) !Measuring points after reaching cycle 1 and 6 END FORM1 LIST 1=(5211,3,0,109,63,61,68,0,2,59,40,0,180,0,0,0,0,0,0,0,0,0) MAIN PAUSE SSPD (2,2) GP (1,3) OSC FORM1 $ (1) GC (4) SSPD (0,0) GP (5,1) END

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Laser sensor/Arc sensor/Analogue sensor

Block 6 - Options

4 Take-over of deviations to seam points Recognized deviations are transferred (pre-transformed) to the succeeding path points. For most applications this means that only a slight deviation has to be corrected at the following path points. Example

pre-transformed position

the deviation recognized here is added to the succeeding points and used as target position.

programmed position In some applications the succeeding path points are shifted in different or even opposite direction. As a result, the recognized vector (deviation) even increases the deviation to be corrected at the next point. For these applications it is recommended to take the next point in its original position as target point. This is done with the command FUNCON_NSTYPE.

Example enlarged deviation in case of pre-transformation programmed position real position

The deviation is determined here from the programmed point This function is switched off with the command FUNCOFF_NSTYPE.

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Laser sensor/Arc sensor/Analogue sensor

5 Offset storage during seam tracking Deviations (offsets) which are measured during seam tracking can be stored and transferred to the succeeding seam points as often as required for further passes (filling run and cover run). Offset storage for the multilayer technology

It is possible to store either ten single offsets or

twenty offset lists.

Single offsets: When executing paths with activated single offset (S) all points are approached with a displacement corresponding to the stored offset. Offset lists: When selecting a list of offsets (M) the robot stores an offset during seam tracking for any point within a drive command. When executing paths with stored lists of offsets all points are approached with a displacement corresponding to the respective offset.

However, the preset number of one hundred points (offsets) must not be exceeded.

Examples: When programming twenty lists of offsets, i. e. twenty different root runs, each root run may contain max. five points (offsets). When programming ten lists of offsets, i. e. ten different root runs, each root run may contain max. ten points (offsets).

If less than five points are programmed in the weld path, the number of singleoffsets or lists of offsets does not increase.

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Laser sensor/Arc sensor/Analogue sensor

Block 6 - Options

5.1 Changing the maximum offset quantity It is possible within the declaration part (above MAIN) to increase the max. number of points or the number of lists of offsets. The value entered in the command DEC_OFFLEN_(--) increases the standard presetting to the indicated number of points. Example: DEC_OFFLEN_(200) In the above mentioned example, it is possible to program twenty different root runs each having ten points (offsets) or twenty-five root runs each having eight points.

Please note that the system memory may be insufficient if the number of points entered is too high.

5.2 Activation of offsets Command: DEVOPS_(nr.)

Generating a single offset with continuous numbering (e.g. SSPD_(10,10)).

DEVOPS_(nr.)

Activating a single offset with relevant number (SSPD_(0,0)).

DEVOPM_(nr.)

Generating a list of offsets with continuous numbering with active seam tracking (e.g. SSPD_(10,10)).

DEVOPM_(nr.)

Executing a list of offsets with relevant number with deactivated seam tracking (SSPD_(0,0)).

DEVOPM_(nr.,soffset)

Executing a list of offsets with relevant number and start offset.

DEVCL

Deactivating the offsets (Can be reactivated by means of DEVOPS or DEVOPM.) The offset determined is not deleted.

DEVER

Deleting all stored offsets

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Laser sensor/Arc sensor/Analogue sensor

When using offset storage, please pay special attention to: -

The offset list is automatically generated with the necessary length during seam tracking. It depends on the number of points in the drive command (the same point number is counted twice).

When executing paths (e.g. second and third pass without seam tracking) with stored list offset, the number of points must be identical to the number of points in the search command.

By indicating a start offset the number of points reduces to the remaining points.

Executing the filling run with offsets (The start offset is indicated)

.. SSPD_(10,10) DEVOPM_(1) GP_(2) GC_(3,4) ARC_(4,5,6) GC_(7) DEVCL ..

.. SSPD_(0,0) DEVOPM_(1,3) GP_(4) ARC_(4,5,6) GC_(7) DEVCL ..

Storage of offsets within the root run

Start offset is 3

The commands DEVOPS and DEVOPM are the same for searching and executing a weld seam. If the corresponding offset list is empty, one or several offsets are stored. If offsets are stored, these are added to the programmed points.

In the case of an unequal number of points, the following error message will appear "F0153 : Stored number of offsets unequal to the required number".

If more than the stored number of offsets is called in, the following error message will appear "F0154 : Reserved space of lists of offsets too small".

If the max. number of points (offsets) is achieved, the following error message appears "F0155 : Offset store full ! "

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Laser sensor/Arc sensor/Analogue sensor

Block 6 - Options

5.3 Seam tracking with offset administration of a three-layer weld seam

Faulty weld seam

Optimised welding by transfer of the offsets

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MAIN DEVER $_(1) GP_(2,3) SSPD_(15,10) DEVOPM_(1) GC_(4,5) DEVCL SSPD_(0,0) $_(2) GP_(9,10) DEVOPM_(1) GC_(11,12) DEVCL GP_(15,16) DEVOPM_(1) GC_(17,18) DEVCL DEVER END |

Block 6 - Options

Laser sensor/Arc sensor/Analogue sensor

6 Analogue sensor In addition to the "arc sensor" function, seam tracking is also possible by means of an "analogue sensor". The basic difference is that the analogue sensor is a touch, i. e. contacting, sensor mounted on the torch support. Activation of the analogue sensor is effected by the command: FUNCON_ANASENS ANAlog SENSor FUNCtion ON

If analogue sensors are only applied for vertical sensing, it must be noted that an input of the value for lateral correction speed in the SSPD command has no effect. Deactivation of the analogue sensor is effected by the command: FUNCOFF_ANASENS ANAlog SENSor FUNCtion OFF

In the case that after switching off the analogue sensor in the program run, a further weld seam with activated seam tracking (SSPD-value >0) follows, the robot uses the values of the arc sensor. For testing purposes, the input values can be determined with the commands ANAIN_(1,A) ANAIN_(2,B)

for the lateral deviation for the vertical deviation

and displayed on the screen with the command: WRITE_(A,B)

Digital value output or output in millivolt is possible. Please use the commands FUNCON_ANASENS,0 FUNCON_ANASENS,1

digital display millivolt display

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After activation, the analogue sensor uses all commands which have been described in the chapter "Arc Sensor".

Block 7 - Options

Freely programmable oscillating patterns

Index

1 Oscillating pattern resp. oscillating form............................................................... 2 1.1 Symmetry .......................................................................................................... 3 1.2 Waiting times..................................................................................................... 3 1.3 Example ............................................................................................................. 3 1.4 Display of the oscillating pattern .................................................................... 4 1.5 Activation of the oscillating pattern ................................................................ 4

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Freely programmable oscillating patterns

Block7 - Options

Oscillating pattern resp. oscillating form 1 Oscillating pattern bzw. oscillating form As already stated in the chapter "Oscillation" (Programming Manual - Standard), the oscillation movement of the robot represents a sinusoid curve. However, practice has shown that this oscillating form alone is not sufficient. In order to comply with these requirements, the sinusoid movement can be replaced by an oscillating pattern which has been created by the operator himself. These patterns are built by means of a coordinate system. Dialogue fields Call of the dialogue field for the creation of own oscillating patterns

Input name for the oscillating pattern

Input seam tracking clock

Define the oscillating pattern Display of the defined pattern

Pre-defined oscillating patterns

By means of the appearing alphanumeric keyboard the name of the oscillating pattern is input with maximum eight characters. Special characters are not allowed. The definition starts before the command line MAIN with the command "OSCDEF_Name of oscillating pattern" and ends with "END_Name of oscillating pattern". Oscillating patterns are defined by single cycles. The number of cycles is limited to 26 and input in the command OSCVEC for the direction X (welding direction) and Y. The values in the OSCVEC command are pure numerical values in the range of 0 - 9. They do not indicate the oscillating width but the ratio between the values that is important. Page 2

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Block 7 - Options

Freely programmable oscillating patterns

To create the oscillating pattern, the controller first asks for the total number of the necessary cycles. Then the ratios for the opening cycle* (cycle no. 0 vector start) and for the determining cycles of the oscillating pattern are called. * The opening cycle of an oscillating pattern is only be executed once. 1.1 Symmetry In order to obtain the symmetry of an oscillating pattern, the sum of all the X values must be at least + 1, the sum of the Y values must be 0, when adding the particular cycles (cycle 0 is not considered). 1.2 Waiting times If 0 is indicated for the X and Y values of a cycle, a waiting time of the length of one calculation cycle is produced on this position. Sometimes it is necessary to input several waiting cycles. Since the maximum number of cycles is limited to 26, it is possible to enter the value 100 as X component and the number of required waiting cycles is Y component.

The input 100,6 means the same as 0,0;0,0;0,0;0,0;0,0;0,0 OSCDEF_<Name> OSCVEC_(0,-3;0,0;3,3;-2,3;0,0;0,-6) waiting cycles STCLK_(1,3) END 1.3 Example The following example shows a triangle which is used for vertical seams: Commands: OSCDEF_<Name>

OSCillating DEFinition (Definition of an oscillating pattern)

OSCVEC_(0,3;0,0;4,-3;-2,-3;0,0;0,6) Cycles 0 1 2 3 4 5

OSCillating VECtor Determination of an oscillating pattern

STCLK_(Cycle left,cycle right)

Seam Tracking ClocK

Indicates in which cycle it is ensured (seam tracking). END_<Name>

End of freely programmed oscillating pattern

The command STCLK determines the cycles where the weld current shall be measured for the position determination during seam tracking (see block 6 Options- chapter "Arc sensor"). Programming Manual ROTROL速 II

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Freely programmable oscillating patterns

Block7 - Options

1.4 Display of the oscillating pattern A cycle of the created oscillating pattern is displayed by pushing the button "DEMO". More cycles are created by pushing the button "More". The definition of the oscillating pattern appears in the head of the display and can be compared with the displayed pattern. This makes it easier to recognize definition errors. The sum of the X-coordinate, the Y-coordinate, the number of the used cycles and the waiting cycles are also displayed.

1.5 Activation of the oscillating pattern After definition of the oscillating pattern, it is called up in the main program by means of the command OSC_<Name>. The following table shows the oscillating patterns, which are possible in one program. OSC_SIN = Sinusoid form OSC_LIN = Longitudinal seam form SIN and LIN are given names or forms OSC_<Oscillating pattern name> = freely defined oscillating forms Linear oscillating forms

Sinusoid oscillating Call of freely forms defined oscillating forms

After use of a freely defined oscillating form, the instruction “OSC_SIN” must be used to reset the standard form.

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Block 7 - Options

Freely programmable oscillating patterns

Programming example:

Vertical seam with freely defined oscillating pattern

OSCDEF_FORM1 OSCVEC_(0,-3;100,5;3,3;100,2;-2,3;100,5;0,-6) STCLK_(1,5) END_FORM1

LIST_1=(5211,3,0,96,68,77,70,0,2,69,40,0,180,0,0,0,0,0,0,0,0,0) MAIN AA:PAUSE OSC_FORM1 ROF_(10) SSPD_(2,2) $_(1) GP_(1,3) GC_(4) GP_(5,1) JUMP_AA END |

X Cycle 3 Waiting time

5 3

Cycle 4

Cycle 6

Cycle 2

Cycle 1 Waiting time

Cycle 5 Waiting time

Cycle 0

-4 -3 -2 -1

1 2 3 4

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Block 8 - Options

Parallel task

Index

Parallel task

Subject ...................................................................................................................... Page

1 Parallel task .................................................................................................................. 2 1.1 Commands ......................................................................................................... 3 1.2 Command description ......................................................................................... 3 1.3 Simple tasks similar to SPS ................................................................................ 7 1.4 Communication tasks .......................................................................................... 8 1.5 Communication tasks for the operation of a barcode scanner ............................ 8 1.6 Communication tasks for a profibus .................................................................. 11 1.7 Approach and calculation of points .................................................................... 13

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Parallel task

Block 8 - Options

PARALLEL TASK 1 Parallel task The parallel task is a user program which can be executed in the background at the same time and mostly independent of a normal user program. It allows to take over and execute -

positioning tasks (positioning of an external axis via the command ADRIVEAX)

simple tasks similar to SPS (clamping of a tool via a two-hand operation)

Communication tasks

without interruption of the original program run of the robot.

Start the command BKJOB_Name Program name

on the operating system level or from a user program (possibly AUTOEXEC).

An active parallel task is indicated by a blinking rectangle in the head line of the screen. You can find out the program name and the memory requirements of an active parallel task via the command "INFO".

The command KILL_Name Program name

stops the execution of the parallel task. Test the functionality of a parallel task in the operating mode EXE.

ATTENTION!! The parallel task run is not interrupted by an EMERGENCY-OFF. Therefore it is not possible to allocate any active safety relevance according to machine guideline (treatment of door contact or EMERGENCY-OFF switches).

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Parallel task

1.1 Commands The usable commands (Carola programming language) of a parallel task are restricted to the following: GETPOS, STORPOS, SASTOPAT DCO GP, GC PTPMAX SET, RESET JUMP INWORD, OUTWORD

MAIN, END BEGIN IF..THEN..ELSE FOR_I:=... VAR PROC, ENDP, RETURN ANAOUT, ANAIN BOOL TXSTR, RXSTR STRVAR, GENSTR Specific commands of the parallel task are:

ADRVSTAT GETSTAT GETVAR, SETVAR GTIMER, STIMER KILL PLCGET, PLCSET, PLCSYNC, PLCPEEK It does not make sense to use the following commands: WAITS, WAITM, WAITI WAITONAX Inapplicable commands are: BKJOB DRIVESTAT 1.2 Command description (positioning tasks) We explain the tasks on the example of an external axis to be positioned. If an external axis which is configured for the function "asynchronous movement" (see programming manual Block 2 chapter 2.2 - Options) has to be positioned from the parallel task, it must be allocated to this task. Allocation is made in a normal Carola program with the command DRIVESTAT_(Axis, value). 0=

Deactivation of the function "asynchronous movement 1 = Activation of the function "asynchronous movement" for a normal user program 2 = Activation of the function "asynchronous movement" for the parallel task Number of the external axis

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The command ADRVSTAT_(Axis, variable) Variable for the state value Axis number

determines the current state of the external axis and enters it in the indicated variable. The meanings of the state values are: State value 0 1 2 3

Meaning The axis is not configured for the function "asynchronous movement". The movement was stopped (EMERGENCY-OFF, release key etc.). The axis moves. The axis has reached the targeted position.

The command GETSTAT_(VAR) Variable

informs about the current controller state (operating mode, EMERGENCY-OFF, etc) so that the program run of the parallel task can be adapted to the most different controller conditions. Example: The command ADRIVEAX positions an external axis. The movement is interrupted by pushing the EMERGENCY-OFF switch. Determine the current controller state and process another command ADRIVEAX to reach the targeted position. The following conditions are entered in a bit code: Bit mask:

Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Bit 8 Bit 9 Bit 10 Bit 11 Bit 12 Bit 13 Bit 14

= = = = = = = = = = = = = = =

the key START is actuated the key STOP is actuated the switch EMERGENCY-OFF is actuated power is on the dead man switch is actuated the operating mode OFF is active the operating mode T1 is active the operating mode T2 is active the operating mode AUTOMATIC is active a parallel task is active the operating mode TEACH is active the interpreter is running Start situation Stop situation EMERGENCY-OFF situation

The different conditions can be filtered out individually or in groups via the command BOOL.

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Parallel task

The Bool Operation BOOL_(Operation, Var1,Var2,Ergebnis) Result of the linkage of the variable Var1 and the variable Var2 Var2 = second input value Var1 = first input value Operation = Selection of the linkage to be executed Value Linkage AND OR NOT XOR

0 1 2 3

allows to link input values (Var1, Var2) and to file the result in another variable (result) which can be interrogated so that the program run can be continued correspondingly.

Program run VAR_ START,STOP,EMERGENCY OFF,FRT,LSTG,OFF,Tl,T2,AUTO,PAR,TEACH VAR_IPR,SSTART,SSTOP,SEMERGENCY OFF,A,B,S MAIN START:=1 STOP:=2 EMERGENCY OFF:=4 LSTG:=8 FRT:=16 OFF:=32 T1:=64 T2:=128 AUTO:=256 PAR:=512 TFACH:=1024 IPR:=2048 SSTART:=4096 SSTOP:=8192 SEMERGENCY OFF:=16384 PTPMAX_(25) B:=1000 ADRIVEAX_(7,B,50) L1:_ADRVSTAT_(7,A) SETVAR_(1,A) SETVAR_(2,B) IF_A_=_1_THEN_BEGIN GETSTAT_(S) BOOL_(AND,S,START+STOP+NOTAUS,S) IF_S=START_THEN_ADRIVEAX_(7,B,50) IF_A=_3_THEN_BEGIN ADRIVEAX_(7,B,50) B:=(-B) ADRIVEAX_(7,B,50) END JUMP_L1 END

!ADRIVE-Get state

!ADRIVE-Movement was stopped !Get current ROTROLII state and !filter it out !ADRIVE restart !ADRIVE-Movement was finished -> Restart !in opposite direction

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Parallel task

Block 8 - Options

Extract from the above mentioned program

0 0 0

START

0 0 0

STOP

0 0 0

NOTAUS

0 0 0

LSTG

0 0 0

FRT

1024 512 256 128 64

AUS

AUTO

PAR

TEACH

GETSTAT_(S) BOOL_(AND,S,START+STOP+EMERGENCY OFF,S) IF_S=START_THEN_ADRIVEAX_(7,B,50)

0 0 0

1 0 0

1 1 1

Preset (EMERGENCY OFF / STOP / START) Actual state of controller (GETSTAT_(S)) Result of the linkage (decimal = 1)

The example above shows the linkage of the the actual state* of the controller with a bit pattern which was generated with the preset variables EMERGENCY OFF, STOP and START. The decimal value of the preset variable is seven and is placed on bit 1, bit 2 and bit 3 in the binary system. *The actual state is read out via the command line "GETSTAT_(S)". It reflects the current system state of the controller. Actuate the "START" key and the corresponding bit (bit 1) is set. The decimal value is entered in the variable S. In the example it is one (1) (see page 4 - bit pattern). The command Bool "AND" operates the variables thus ensuring that the current system state allows to continue the program run (positioning of the external axis). EMERGENCY-OFF and STOP signals do not exist any more, so the result of the linkage is one (1), too. BOOL_(AND,S,START+STOP+EMERGENCY OFF,S) IF_S=START_THEN_ADRIVEAX_(7,B,50) The linkage result is filed in the result variable "S". Execution is made by the following IF instruction.

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Parallel task

1.3 Simple tasks similar to SPS Tasks similar to SPS require a cyclic run of the program. Commands which finish or stop the program run for a certain time (WAITS, WAITM, WAITI, WAITONAX) are integrated but it does not make sense to use them. The commands STIMER and GTIMER serve to program time delays. Sixteen timers which are independent from each other can be set with the command STIMER_(No., VALUE)

Time in ms Number of the timer

and read in with the command GTIMER_(Nr., VAR) Variable value (read time in ms) Number of the timer.

A timer is expired if the value is zero or negative.

VAR TIl, TI2, Ml, M2, S MAIN Ml:= 0 M2:= 0 L1: IF_IN(11)_THEN_BEGIN IF_M2_=_1_THEN_BEGIN GTIMER_(2,TI2) IF_TI2_>_0_THEN_Ml:_= 1 END ELSE_BEGIN IF_Ml_=_0_THEN_STIMER_(1,500) M1:=1 END END ELSE_M1:=0 IF_IN(12)_THEN_BEGIN IF_M1_=_1_THEN_BEGIN GTIMER_(1,TI1) IF_TI1_>_0_THEN_M2:=1 END ELSE BEGIN IF_M2_=_0_THEN_STIMER(2,500) M2:=1 END END ELSE_M2:=_0 BOOL_(AND,Ml,M2,S) SETVAR_(1,S) IF_S_=_1_THEN_SET_(5) ELSE_RESET_(5) JUMP_Ll END

! Read timer 2

! Set timer 1

! Read timer 1

! Set timer 2

! Linkage ! Inform the Carola program about result

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Explanations regarding the a/m program example: The program example shows the programming of a two-hand operation to close a clamping unit. Two digital inputs (input 11 and 12) are interrogated which must obtain an "ON" signal within a programmable time (STIMER). When the time which is controlled by the command GTIMER is expired the corresponding variables (M1 or M2) are reset and "AND" operated by the command BOOL. The result variable must have the value "one (1)" to fulfill the following "IF instruction". This is only the case when the two variables M1 and M2 are set to the value One (1).

1.4 Communication tasks There are fifty global variables for the communication between the parallel task and a normal user program which are written with the command SETVAR_(Nr., Wert) Value which shall be written in the global variable Number of the global variable

and which can be read with the command GETVAR_(Nr., VAR) Variable value Number of the global variable.

The value of a global variable is retained even after having switched off the controller.

1.5 Communication tasks for the operation of a barcode scanner The data exchange between a barcode scanner and the robot controller is made via serial interface. According to the respective systems the interfaces COM1, COM5 or COM6 are used. The command TXSTR_('STR_BEZ','COM_NR') Communication interface - COM1, COM5 or COM6 String description OPEN Opens the indicated interface CLOSE Closes the indicated interface S1..S5 Sends the data which are filed in buffer Sn via the indicated interface

sends data which are filed in the buffer (S1..S5) via the indicated interface. The command Page 8

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Parallel task

RXSTR_('STR_BEZ','COM_NR') Communication interface - COM1, COM5 or COM6 String description OPEN Opens the indicated interface CLOSE Closes the indicated interface S1..S5 Receives and files data in buffer Sn

receives data from the indicated interface and files them in the data buffers (S1..S5).

The command STRVAR_(STR_BEZ;BUFFERINDEX,VAR1,VAR2,..VARn) Variable name Buffer index = 0..255 (from which it is read) STR_BEZ = String description S1..S5

transfers data bytes from the indicated buffer index of the data buffers (S1..S5) to the variables. After execution the variable "Buffer index" contains the total number of the data in the buffer.

The command GENSTR_(STR_BEZ,GEN_PARA,..) Data block to be formed consisting of text, constants or variables (value range 0..255) STR_BEZ= String description (S1..S5)

forms a string or a data block consisting of text, variables and constants. The variables and constants are filed as byte. The total size of a string buffer is max. 255 characters. Example: parallel task for a barcode reader type Datalogic DL-910 VAR I,E1,E2,V1,V2,V3,V4,V5,V6,V7,V8,V9,VA,VB,VC,VD,VE,VF PROCEDURE INIT GENSTR(‘S2’,6) ! GENERATE ACKNOWLEDGESTRING (ACK) RXSTR(‘CLOSE’,’COM6') ! CLOSE EVENTUALLY OPEN CONNECTION RXSTR(‘OPEN’,’COM6') ! OPEN CONNECTION TXSTR(‘S2’,’COM6') ! TRANSMIT ACK TO RELEASE READER ENDP MAIN CALL INIT SETVAR(1,0) L1: GETVAR(1,I) IF I = 0 THEN BEGIN RXSTR(‘S1’,’COM6')

! BASEINITIALISATION ! INIT VARIABLE

! GET VARIABLE ! 1ST RUN OR RELEASE FROM MAIN PROGRAM ? ! YES, READ DATA (IF AVAILABLE) ! AND PUT IT INTO VARIABLES STRVAR(‘S1’;I,V1,V2,V3,V4,V5,V6,V7,V8,V9,VA,VB,VC,VD,VE,VF) IF I > 3 THEN BEGIN ! DATA COUNT > 3 ? TXSTR(‘S2’,’COM6') ! YES, TRANSMIT ACKNOWLEDGE (ACK) I:=I-3 ! SUBTRACT DATA TAIL (CR-LF-ENQ)

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Continuation: E1:= V1-48 ! ASSEMBLE BAR CODE IN 1. VARIABLE IF I > 1 THEN E1:= E1*10+V2-48 IF I > 2 THEN E1:= E1*10+V3-48 IF I > 3 THEN E1:= E1*10+V4-48 IF I > 4 THEN E1:= E1*10+V5-48 IF I > 5 THEN E1:= E1*10+V6-48 IF I > 6 THEN E1:= E1*10+V7-48 IF I > 7 THEN E1:= E1*10+V8-48 IF I > 8 THEN E1:= E1*10+V9-48 IF I > 9 THEN BEGIN ! NO. OF DIGITS > 9 ? E2:= VA-48 ! YES, USE 2. VARIABLE IF I > 10 THEN E2:= E2*10+VB-48 IF I > 11 THEN E2:= E2*10+VC-48 IF I > 12 THEN E2:= E2*10+VD-48 IF I > 13 THEN E2:= E2*10+VE-48 IF I > 14 THEN E2:= E2*10+VF-48 SETVAR(3,E2) ! BAR CODE 2. VARIABLE TO MAIN PROGRAM END SETVAR(2,E1) ! BAR CODE 1. VARIABLE TO MAIN PROGRAM SETVAR(1,I) ! NO. OF DIGITS TO MAIN PROGRAM, RELEASE FOR MAIN PRG. END ELSE I := 0 ! IGNORE DATA COUNT <= 3 END JUMP L1 ! LOOP BACK (ENDLESS LOOP) END

Carola program to process the data which were determined in the parallel task. VAR CNT,B1,B2 PROCEDURE GETCODE L1: GETVAR(1,CNT) IF CNT = 0 THEN JUMP L1 GETVAR(2,B1) IF CNT > 9 THEN GETVAR(3,B2) SETVAR(1,0) ENDP

! ! ! ! !

GET VARIABLE LOOP UNTIL DATA PRESENT (CNT > 0) GET 1. VARIABLE (DIGIT 1..9) IF NO. OF DIGITS > 9 GET 2. VARIABLE ENABLE NEXT CYCLE IN PARALLEL TASK

MAIN CALL GETCODE

! START MAIN PROGRAM ! WAIT FOR BAR CODE ! DISPLAY THE RECEIVED CODE IF CNT > 9 THEN WRITE (‘NO. OF DIGITS:’,CNT,’ BAR CODE:’,B1,B2) ELSE WRITE (‘NO. OF DIGITS:’,CNT,’ BAR CODE:’,B1) !EXAMPLE FOR PROGRAM SELECTION ACCORDING TO THE BAR CODE !GENERATE PROGRAM NAME USING THE 5 MOST SIGNIFICANT DIGITS GENNAME (‘5’,’PRG’,B1) RUN PRGXXXXX

! GENERATE PROGRAM NAME ! EXECUTE THE PROGRAM

END

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Parallel task

Extract from the a/m parallel task program: ! ! ! !

GENERATE ACKNOWLEDGESTRING (ACK) CLOSE POSSIBLY OPEN CONNECTION OPEN CONNECTION TRANSMIT ACK TO RELEASE READER

The command line "GENSTR_('S2',6)" generates a string named S2. It includes the constant "6" for the release of the barcode scanner. The command "RXSTR_('CLOSE','COM6') closes a possibly open connection to the serial interface COM6. The command "RXSTR_('OPEN','COM6') opens the connection and makes it possible to transfer the string "S2" via the command "TXSTR_('S2','COM6'). The barcode scanner is prepared to read a barcode again.

RXSTR(‘S1’,’COM6')

! YES, READ DATA (IF AVAILABLE) ! AND PUT IT INTO VARIABLES STRVAR(‘S1’;I,V1,V2,V3,V4,V5,V6,V7,V8,V9,VA,VB,VC,VD,VE,VF) IF I > 3 THEN BEGIN !DATA COUNT > 3 ? TXSTR(‘S2’,’COM6') ! YES, TRANSMIT ACKNOWLEDGE (ACK)

The command "RXSTR_('S1','COM6')" activates the reception of the barcode scanner data via interface (COM6) into the string (S1). The following command "STRVAR_ ('S1';I,V1,V2,V3,V4..)" transfers the data to the indicated variables which are then available for processing.

1.6 Communication tasks for a profibus The bus system for the communication in small cell nets and with field units is based on the European Standard EN50170 and is now accepted worldwide in the field sector. The advantage of the PROFIBUS DP (DP= Decentralised peripheral equipment) is the rapid cyclic communication of a small volume of data. Data transfer rates of up to 12 Mbit/s are possible. The command PLCGET (DB,DW,VAR) Variable where the data byte is filed Offset of the data byte to read within the data module Number of the data module to read (not used with profibus)

reads a data byte on the address which was determined by DB and DW.

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GENSTR(‘S2’,6) RXSTR(‘CLOSE’,’COM6') RXSTR(‘OPEN’,’COM6') TXSTR(‘S2’,’COM6')

Parallel task

Block 8 - Options

The command PLCSET_(DB,DW,WERT) Value which is filed in the data byte Offset of the data byte to be described in the data module Number of the data module to be described (not used for profibus)

writes a data byte of the address which was determined by DB and DW. The commands PLCGET/PLCSET mean that the parameter DB (data module) has to be indicated when switching on the profibus but it is not evaluated. The profibus job always starts the data range from 0, the Rotrol controller always accesses the range with data module number 0.

PLCSYNC_(SYNC-Nr,PROFI-ADRs...,VAR_TO_SEND,RECEIVE-VARs..) Variables where the received values which have been sent by the partners are filed.

Value to be sent to the partners Profibus address[es] of the synchronisation partner Number of the Sync-command. The partner robot must send the same sync-number for matching purposes.

The command synchronises the partners listed in PROFI-ADR and exchanges variables with them if they were indicated. Synchronisation is only made if all sent SYNC numbers are the same.

The command PLCPEEK_(DB,DW,VAR) Variable where the data byte is filed Offset of the data byte to read within the data module Number of the data module to read (not used for profibus)

reads a data byte on the address of the output field determined by DB and DW. The handling and the hardware equipment of the profibus system are described in a special document.

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Parallel task

1.7 Approach and calculation of points

Points (axis positions) are not approached in parallel task but there is a way of calculating them. The points of the current Carola program are copied in a temporary memory where they can be treated by means of the commands GP, GC, GETPOS.., STORPOS

Copy the changed point information back to the current Carola program by using the command "COPYP_(..)_TO_ ....".

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or others.

Block 9 - Options

Point editor

Index

Point editor

1 Point editor(PED) ................................................................................................. 2 1.1 General .......................................................................................................... 2 1.2 Selection of the point editor ........................................................................... 2 1.3 Operation of the point editor........................................................................... 2 1.4 Point manipulations ....................................................................................... 3

Programming Manual ROTROL速 II

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Point editor

Block 9 - Options

Point editor 1 Point editor (PED)

1.1 General By means of the point editor all or some points of a user program can be copied, deleted, changed or renumbered by direct keyboard input. Shifts can be effected in the robot and in the base coordinate systems as well as in coordinate systems relating to the workpiece.

1.2 Selection of the point editor This displays shows how to select first the point editor via buttons and then the user program. The point information of the different points are also shown. The point editor is operated via the keyboard. Quit the point editor by pressing the key "E" and confirmĂng the following inquiry. A further interrogation enables you to reject the modifications that have been carried out on the point information.

1.3 Operation of the point editor With the following keys you select

Cursor left

Previous point

Cursor right

Next point

TAB

Jump x points forward *

BACKSPACE

Jump x points backwards *

HOME

Jump to the initial point

Define the jump width for the two keys TAB and DEL in menu 2 (F7).

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Point editor

The following additional keys can be used in order to choose a field of a point: Cursor up

Previous field of point

Cursor down

Next field of point

PgUP

Status field

PgDn

Last coordinate field of point

Calculating operations and exit from the point editor are made via the keys: F1

Confirm modifications

Exit the point editor

1.4 Point manipulations After the selection the main menu of the point editor appears, in this example the program named P110. CARL CLOOS SCHWEISSTECHNIK ROTROL V 07.00, 13.05.01

[A:]

ADJUSTMENT T1

SYSTEM: BKS ; TCP: -26 -46 4549; LIN:[0.1MM]; ROT:[0.001 GRD]; PRG: P110

STATUS SPEED A1-A4 X -L Y -L Z -L ALPHA -R BETA -R GAMMA-R EXT1 -R

PTP PTP 100 100 0000 0000 13649 12941 -46 -1959 14906 5496 -55958 -45861 90000 165712 55964 76755 -6 0

PTP 100 0000 12781 -1770 3520 -45861 165712 76757 0

PTP 100 0000 13134 -1943 3520 -45862 165711 76758 0

5 PTP 100 0000 13320 -1600 3520 -45861 165712 76759 0

6 PTP 100 0000 13445 -1972 3520 -45862 165712 76758 0

7 PTP 100 0000 13821 -1860 3520 -45862 165713 76757 0

8 PTP 100 0000 13657 -2210 3520 -45860 165711 76759 0

Fields of point 1 F1-BLOCKEDIT F2-JUMP F3-SYSTEM F4-DELETE F5-COPYING F6-RENUMBER F7-MENU2

Coordinate system The screen shown in the example indicates the first eight points of the program in the base coordinate system. This is indicated in the first line with the designation "System: BKS" (Base Coordinate System).

TCP Since the coordinates describe the position of the TCP, it is also indicated in the first line. If you are working with different torches, please pay attention to the TCP which is used in the point editor. Programming Manual ROTROL速 II

Page 3

Point no.

Point editor

Block 9 - Options

Relative value modifications can already be carried out without having chosen an editing column before. When a point field has been selected with the cursor keys, the value can be increased or decreased with the "+" bzw. "-", with the exception of the fields Status and A1-A4. Use menu2 to define the factor by which the values are to be modified. With the keys 1, 2, 3 and 4 the corresponding outputs can be switched on or off in the field "A1-A4". By pressing the C or P key it is possible to change over between CP and PTP on the field Status. After actuating the ENTER key an editing column appears in front of the corresonding field. Absolute values as well as a relative value modification to the existing value can be carried out. In the following example at Point 3 the Y value is set to 0, the value for X is increased by 100 and the speed reduced by 30.

CARL CLOOS SCHWEISSTECHNIK ROTROL V 07.00, 13.05.01

[A:]

ADJUSTMENT 1

SYSTEM: BKS

; TCP: -26 -46 4549; LIN:[0.1MM]; ROT:[0.001 GRD]; PRG: P110

Point no.

EDIT

STATUS SPEED A1-A4 X Y Z ALPHA BETA GAMMA EXT1

PTP 100 0000 -L +100 12781 -L =0 -1770 -L 3520 -R -45861 -R 165712 -R 76757 -R 0 - 30

PTP 100 0000 13134 -1943 3520 -45862 165711 76758 0

PTP 100 0000 13320 -1600 3520 -45861 165712 76759 0

6 PTP 100 0000 13445 -1972 3520 -45862 165712 76758 0

7 PTP 100 0000 13821 -1860 3520 -45862 165713 76757 0

PTP 100 0000 13657 -2210 3520 -45860 165711 76759 0

PTP 100 0000 13999 -2396 3520 -45860 165711 76758 0

Actuate the F1 key to confirm the modifications and the new coordinates are displayed on the screen: CARL CLOOS SCHWEISSTECHNIK ROTROL V 07.00, 13.05.01 SYSTEM: BKS Point no. STATUS SPEED A1-A4 X -L Y -L Z -L ALPHA -R BETA -R GAMMA -R EXT1 -R

Page 4

[A:]

ADJUSTMENT T1

; TCP: -26 -46 4549; LIN:[0.1MM]; ROT:[0.001 GRD]; PRG: P110 3 PTP 70 0000 12881 0 3520 -45861 165712 76757 0

4 PTP 100 0000 13134 -1943 3520 -45862 165711 76758 0

PTP PTP 100 100 0000 0000 13320 13445 -1600 -1972 3520 3520 -45861 -45862 165712 165712 76759 76758 0 0

7 PTP 100 0000 13821 -1860 3520 -45862 165713 76757 0

PTP PTP 100 100 0000 0000 13657 13999 -2210 -2396 3520 3520 -45860 -45860 165711 165711 76759 76758 0 0

Programming Manual ROTROL速 II

Block 9 - Options

Point editor

Further to a pure value indication for individual coordinates the following functions are available: -

F1 BLOCKEDIT Simultaneous editing of several points

Similar to the function EDIT described above, it is possible to carry out absolute and relative modifications by BLOCKEDIT. After selection of BLOCKEDIT, the point range in which you intend to carry out modifications is entered. Example: EDITING OF POINT NUMBERS:

43..67

In the following example, points 43 - 49 of axis 7 should get the value 0 (Reference point). CARL CLOOS SCHWEISSTECHNIK ROTROL V 07.00, 13.05.01

Point no. STATUS SPEED A1-A4 X Y Z ALPHA BETA GAMMA EXT1

; TCP: -26 -46 4549; LIN:[0.1MM]; ROT:[0.001 GRD]; PRG: P110 EDIT

-L -L -L -R -R -R -R

ADJUSTMENT 1

PTP 100 0000 12881 0 3520 -45861 165712 76757 = 0 14232

44 PTP 100 0000 13134 -1943 3520 -45862 165711 76758 45345

PTP PTP 100 100 0000 0000 13320 13445 -1600 -1972 3520 3520 -45861 -45862 165712 165712 76759 76758 1420 41237

PTP PTP PTP 100 100 100 0000 0000 0000 13821 13657 13999 -1860 -2210 -2396 3520 3520 3520 -45862 -45860 -45860 165713 165711 165711 76757 76759 76758 13256 41375 141346

SYSTEM: BKS

[A:]

Actuate the F1 key to confirm the modifications and the new coordinates are displayed on the screen:

CARL CLOOS SCHWEISSTECHNIK ROTROL V 07.00, 13.05.01 SYSTEM: BKS Point no.

-L -L -L -R -R -R

EXT1

-R

ADJUSTMENT T1

; TCP: -26 -46 4549; LIN:[0.1MM]; ROT:[0.001 GRD]; PRG: P110 43

STATUS SPEED A1-A4 X Y Z ALPHA BETA GAMMA

[A:]

PTP PTP 100 100 0000 0000 12881 13134 0 -1943 3520 3520 -45861 -45862 165712 165711 76757 76758

PTP PTP 100 100 0000 0000 13320 13445 -1600 -1972 3520 3520 -45861 -45862 165712 165712 76759 76758

PTP 100 0000 13821 -1860 3520 -45862 165713 76757

PTP 100 0000 13657 -2210 3520 -45860 165711 76759

PTP 100 0000 13999 -2396 3520 -45860 165711 76758

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Page 5

Point editor

Block 9 - Options

After selection of a new point range it is also possible to carry out the same modifications for this point range by pressing the F2 key (last operation).

F2 JUMP Jump to a point

Enter here the number of the point to be treated. Confirm with ENTER and the selected point as well as the following seven points appear on the screen.

F3 SYSTEM Selection of coordinate system

Actuate F3 (SYSTEM) and the following line appears. Select now the coordinate system in which the point information should appear: F1-BASIS F2-MACHINE_INCREMENTAL F3-MASCHINE_ANGLE F4-WORKPIECE

After pressing the F1, F2 and F3 keys, the points are displayed in the corresponding coordinate system. Up to ten different workpiece coordinate systems can be defined for each program. The following mask appears on the screen after pressing F4:

CARL CLOOS SCHWEISSTECHNIK ROTROL V 05.03, 13.05.97 [A:] ADJUSTMENT T1 SYSTEM: MKSW ; TCP: -26 -46 4549; LIN:[0.1MM]; ROT:[0.001 GRD]; PRG: P110 WCS-NR.

REFERENCE POINT

POINT ON X-AXIS

PUNKT IN XY-LEVEL

SELECTION OF THE WCS-NO.: F1-DEFINE A WCS F2-DELETE A WCS

Actuate the F1 key (create a Workpiece Coordinate System) and define up to ten different coordinate systems. When pressing the F2 key (remove a Workpiece Coordinate System) a previously defined coordinate system is deleted. Enter the Number of the required coordinate system and actuate the ENTER key to return to the point display. Concerning this subject please refer to chapter "Coordinate systems", Block 3, Programming Manual - Standard. Page 6

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Point editor

F4 DELTE Delete points

After presing F3 enter the point or point range to be deleted. Example: DELETE POINT NUMBERS: 34..38 -

F5 COPYING Copying points

After pressing F5 enter the point or point range to be copied. Confirm with ENTER and indicate the number with which the copied range should start. Example: COPYING;

SOURCE: 22..36

TARGET:

122

F6 RENUMBER Renumbering points

RENUMBER enables you to renumber points so that the distance between the points is the same.

In the example, the points 1, 2, 3 and 31 are to be renumbered at a distance of 20:

CARL CLOOS SCHWEISSTECHNIK ROTROL V 05.02, 25.05.96 [A:] ADJUSTMENT T1 SYSTEM: BKS ; TCP: -26 -46 4549; LIN:[0.1MM]; ROT:[0.001 GRD]; PRG: P110 Point no. STATUS SPEED A1-A4 X -L Y -L Z -L ALPHA -R BETA -R GAMMA -R EXT1 -R RENUMBER;

PTP 100 0000 13649 -46 14821 -55955 90000 55960 0

PTP 100 0000 12941 -1959 5411 -45861 165712 76754 0

PTP 100 0000 12957 -1933 3435 -45862 165710 76760 0

SOURCE: 1..31

31 PTP 100 0000 13200 -2031 3435 -45862 165710 76759 0

PTP PTP 100 100 0000 0000 13316 13425 -1779 -2036 3435 3435 -45864 -45864 165709 165709 76759 76761 0 0

PTP 100 0000 13675 -1938 3435 -45864 165707 76762 0

PTP 100 0000 13583 -2182 3435 -45864 165708 76762 0

DISTANCE: 20

Programming Manual ROTROL速 II

Page 7

Point editor

Block 9 - Options

Since the new point numbers 1, 21, 41 and 61 fall into the range where points already exist, the following error message appears: Please reorganize the following point range : [41..61] In this case a renumbering is not carried out. Please take care that after the modification the program sequence (EDI) may be adapted.

F7 MENU2 Config, Zoom and Center Point

After pressing F7 the following menu appears: F1-PRINT -

F2-CONFIG

F3-ZOOM

F4-CENTER POINT

F1 PRINT Printing points

When the point range has been input, these points are printed in the corresponding coordinate system. -

F2 CONFIG Define step widths

Define: TAB / Backspace

Jump width when "scrolling".

+/-

Factor by which the coordinates are modified.

After pressing the F1 key the following mask appears on the screen: CARL CLOOS SCHWEISSTECHNIK ROTROL V 05.03, 13.05.97 [A:] ADJUSTMENT T1 SYSTEM: BKS ; TCP: -26 -46 4549; LIN:[0.1MM]; ROT:[0.001 GRD]; PRG: P110 TABULATOR SIZE

POINT DISTANCE FOR RENUMBERING

SPEED

CARTESIAN LINEAR

100

CARTESIAN ROTATION

1000

INCREMENTAL

500

STEP WIDTHS

Page 8

Programming Manual ROTROL速 II

Block 9 - Options -

Point editor

F3 ZOOM Modification of component sizes After entering the point range to be modified and a reference point, the size of a component can be modified by any factor.

In the example the component size is to be increased by factor 1,5. Reference point is point 3.

POINT RANGE FOR ZOOMING : 3..15

REFERENCE POINT: 3 ZOOM FACTOR: 1.5

If there is no error message after input of the zoom factor, the function is finished.

F4 CENTER POINT Define a reference point for the ZOOM function

If you want to use the ZOOM function with a reference point which is in the center of the component, the center can be defined with the function CENTER POINT. In the example, the center point 200 is to be built out of the points 3-11 and 7-15. Enter the two pairs of points and the center point to be generated into the following display:

Enter two point pairs for the definition of the distances!

CENTER POINT NUMBER:

200

Programming Manual ROTROL速 II

Page 9

Block 10 - Options

Parameter interpolation

Index

Parameter interpolation .................................................................................................. 2

1 Parameter interpolation ...................................................................................... 2 1.1 General .......................................................................................................... 2 1.2 The dialogue field .......................................................................................... 2 1.3 Command structure ....................................................................................... 3 1.4 Examples ....................................................................................................... 3

Programming Manual ROTROL速 II

Page 1

Parameter interpolation

Block 10 - Options

Parameter interpolation 1 Parameter interpolation 1.1 General If the seam conditions change continuously during a contour, e.g. air gap, seam volume or temperature conditions (in the case of aluminium), it is necessary to adapt the parameters to the actual conditions. With the parameter interpolation function it is possible to define the start values in one weld parameter list and the target values in another weld parameter list.

Selection of the dialogue field for the parameter interpolation 1.2 The dialogue field

In the dialogue field you select which of the maximum eight parameters are to be changed. The command LINON_(1,0,0,0,1,0,1,1) is input in the user program and activates the parameter interpolation. This means: With the value=1, the corresponding parameter is to be changed (interpolation), with the value=0 the parameter remains the same during the contour.

Deactivation of the parameter interpolation

Page 2

Programming Manual ROTROL速 II

Block 10 - Options 1.3 Command structure

Parameter interpolation

Example: the sequence of parameters of a standard power source: LINON_(1,0,0,0,1,0,1,1) Pulse voltage Pulse time Base current Oscillating amplitude Height set value Voltage/frequency Wire feed Speed

(13. Parameter of the weld parameter list (12. "" (11. "" (10. "" (7. "" (6. "" (5. "" (4. ""

)* ) ) ) ) ) ) )

* Please pay attention to the appropriate parameters when using different welding technologies and power sources.

1.4 Examples In the following example a straight weld seam (two points) is to be started with the oscillating amplitude of weld parameter list $1 and changed linear to the value from weld parameter list $2 at the end of the weld seam.

LIST 1 = (5211,3,0,50,150,259,70,0,2,16,99,22,330,0,0,0,0,0,0,0,0) LIST 2 = (5211,3,0,50,150,259,70,0,2,34,99,22,330,0,0,0,0,0,0,0,0) MAIN GP_(1,2) $_(1) LINON_(0,0,0,0,1,0,0) GC_(3) This value defines the oscillating amplitude $_(2) GP_(4,1) END | If the values in the command LINON are "0", the command can be shortened from the back. Alternatively, the command used in the above example could be as follows: LINON_(0,0,0,0,1) With an oscillating amplitude increasing towards the seam end the robot performs the following contour for example.

Programming Manual ROTROL速 II

Page 3

Parameter interpolation

Block 10 - Options

Please pay attention that, during a weld seam, the next list (target list) - and not, as usual, the last list called up - appears on the teach pendant PHG after LINON and that this next list is changed. All parameters which are not changed by LINON obtain the values from the corresponding target lists during the contour. For this reason it is recommended that initial and target lists are first created with identical parameters. When using start and end lists, the required parameters between 1. 2. 3.

Start list and initial list (first normal list) Initial list and target list Target list and end list

are interpolated.

LISTS 1=(5211,1,300,55,80,212,0,0,2,0,60,22,330,0,0,0,100,0,0,120,0,0) LISTE 1=(5211,3,0,65,120,205,60,0,2,0,60,22,330,0,0,150,0,0,0,120,0,0) LIST 1 =(5211,3,0,50,150,259,70,0,2,16,99,22,330,0,0,1,0,0,0,0,0) LIST 2 =(5211,3,0,50,150,259,70,0,2,34,99,22,330,0,0,0,1,0,0,0,0) MAIN GP_(1,2) $_(1) LINON_(0,0,0,0,1,0,0,0) GC_(3,4) $_(1) GC_(5) $_(2) LINOFF GP_(6,1) END |

When calling up LINOFF the function Parameter interpolation is switched off.

Tack weld lists are excluded from the function Parameter interpolation.

Page 4

Programming Manual ROTROL速 II

Block 11 - Options

List of commands

List of commands ........................................................................................................... 2

Programming Manual ROTROL速 II

Page 1

List of commands Command

Block 11 - Options

Function

Block Page

Positioning of an external axis Determination of the actual axis state Determination of the input voltage values of the analogue sensor Activate analogue sensor

Block Block Block Block

1 1 6 6

19 20 17 17

CEC CHA CHSYN CIRDEF

Include external axes in the transformation Execution of the Offline Change Funktion Switching the synchronous monitoring of synchronous axes Definition of a centre point referenced circle

Block Block Block Block

4 4 1 5

18 17 26 2

D DCH DEC OFFLEN DEVCL DEVER DEVILR DEVIUPDN DEVOPM DEVOPS DMI DTCP DTOV DTR

Define an Offline Change-Funktion Change the maximum offset number Deactivation of offsets Delete offsets Lateral limitation during seam tracking Vertical limitation during seam tracking Storage of list offsets Storage of single offsets Definition of an offline imaging Definition of an offline TCP transformation Definition of an offline TOV transformation Definition of an offline transformation

Block Block Block Block Block Block Block Block Block Block Block Block

4 6 6 6 6 6 6 6 4 4 4 4

16 14 14 14 8 8 14 14 9 13 13 6

Indirect workpiece drive Definition of the kinematic chain of external axes Circles with external axes Definition of external axes Switching the control stopper Switch off the orientierung synchronisation Switch off a synchronous movement Switch on a synchronous movement

Block 1 Block 1 Block 1 Block 1 Block 1 Block 1 Block1 Block 1

28 6 10 3 28 9 3 8

Fast contact sensor function Generation of a filling run for multi-layer welding

Block 3 Block 2

5 5

Switch off an online TCP transformation Switch on an online TCP transformation

Block 4 Block 4

12 12

Determine weld pattern geometry for the weld groove section Numeric oriented multi-layer definition Point oriented multi-layer definition Switch off parameter interpolation Switch on parameter interpolation

Block 2 Block 2 Block 2 Block 10 Block 10

10 8 8 4 2

A ADRIVEAX ADRVSTAT ANAIN ANASENS

E ENCRATIO EXTCHAIN EXTCIR EXTDEF EXTOFF EXTORIOFF EXTSYNOFF EXTSYNON

F FASTSENS FILL

G GUNCHAOFF GUNCHAON

L LAYACT LAYDEFNUM LAYDEFPNT LINOFF LINON

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Programming Manual ROTROL速 II

Block 11 - Options Command

List of commands

Function

Block Page

Manual movement external axis Definition of Master - Slave robot Definition of Master - Slave robot Switch off an online imaging Switch on an online imaging Execute an offline imaging Manipulation of point information external axes

Block Block Block Block Block Block Block

1 1 1 4 4 4 1

17 24 24 8 8 8 11

Activate the vertical set value measurement Definition of an online TCP transformation Switch off pre-transformation of path points

Block 6 Block 4 Block 6

10 10 12

Definition of an oscillating pattern Cycles of the oscillating pattern

Block 7 Block 6

3 3

Selection of the point editor Define weld groove sections Liest ein Datenbyte von der durch DB und DW bestimmten Adresse Liest ein Datenbyte von der durch DB und DW bestimmten Adresse aus dem Ausgabefeld aus. Schreibt ein Datenbyte von der durch DB und DW bestimmten Adresse Synchronisieren angegebener Partner beim Profibus

Block 9 Block 2 Block 8

2 8 11

Block 8 Block 8 Block 8

12 12 12

Change the preset resolution of external axes Program text edition for multi-layer welding End of a root definition for multi-layer welding Start of a root definition for multi-layer welding

Block Block Block Block

1 2 2 2

27 2 2 2

Software Referencing Measurement of the vertical set value on the path beginning Determination of the search speed Determination of the measuring points for seam tracking Determine measuring points of freely defined oscillating patterns Synchronisation instructions for Master/Slave Synchronisation instructions for Master/Slave

Block Block Block Block Block Block Block

1 6 6 7 6 1 1

10 10 5 3 11 23 23

Definition and execution of an online transformation Switch off an online transformation Switch on an online transformation

Block 4 Block 4 Block 4

7 3 3

Block 1

Block 3 Block 3

3 6

M MANAX MASTEROFF MASTERON MIRROFF MIRRON MIRROR MPE

N NEWOFFS NEWTCP NSTYPE

O OSCDEF OSCVEC

P PED PICTURE PLCGET PLCPEEK PLCSET PLCSYNC

R RESTORP ROOTCPY ROOTOFF ROOTON

SOFTREF SSMOFFS SSPD STCLK SYNCOFF SYNCON

T TRAN TROFF TRON

W WAITONAX Wait for positioning of an external axis WHEN_IN(..)_DURING_GC(..)_THEN_............ Parallel shifting with a sensor WHENPAR Presettings for the sensor routine

Programming Manual ROTROL速 II

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ANHANG / APPENDIX / ANNEXE Adressenliste CLOOS-Vertreterbezirke List of addresses of CLOOS representatives Liste d'adresses des représentants CLOOS Werksvertretungen Inland: Representatives at home: Représentants en Allemagne: Gerhardt Schweißtechnik Hohenrohter Straße 11 35759 Driedorf-Mademühlen Tel.: (02775) 95 31 33 Fax: (02775) 95 31 34 e-mail: gerhardt-schweisstechnik@t-online.de Paul Görmiller Schweißtechnik Im Burggraben 5 88486 Kirchberg Tel.: (0 73 54) 18 02 Fax: (0 73 54) 22 26 e-mail: pg-schweisstechnik@t-online.de Hoh Schweißtechnik GmbH Julius-Bauser Str.8 72186 Empfingen Tel: (07454) 9 80 52 56 Fax: (07454) 92565 e-mail: hoh-metallbearbeitung@t-online.de http://www.hoh-metallbearbeitung.com Carl Lixfeld GmbH & Co. KG Flurstraße 3-5 57076 Siegen Tel.: (02 71) 48932-0 Fax: (02 71) 48932-32 e-mail:info@lixfeld.net http://www.lixfeld.net Carl Lixfeld GmbH & Co. KG Niederlassung West Melmesfeld 8 47647 Kerken Tel.: (0 28 33) 57 30 75 Fax: (0 28 33) 57 30 76 e-mail:Lixfeld.west@lixfeld.net http://www.lixfeld.net Autogen Morgenstern Schutterwälder Str. 16 01458 OIttendorf-Okrilla Tel.: (035205) 402-0 Fax: (035205) 402-90 e-mail: info@autogen-morgenstern.de http://www.autogenmorgenstern.de Pascoletti Schweisstechnik Sperbersloher Str. 128 D-90530 Wendelstein Tel.: (0 91 29) 28 96 40 Fax: (0 91 29) 28 96 42 e-mail: info@pascoletti.com http://www.pascoletti.com Philippe Schweißtechnik Industrieanlagen Max-Planck-Straße 12 66271 Kleinblittersdorf Tel.: (0 68 05) 94 13 -0 Fax: (0 68 05) 94 13 -13 e-mail: info@philippe-schweisstechnik.de http://www.philippeschweisstechnik.de

SCHWABE Elektromaschinenbau Reißiger Str. 10 08525 Plauen Tel.: (03741) 22 44 46 Fax: (03741) 22 44 48 Stiftstraße 4 08228 Rodewisch Tel.: (03744) 3 31 76 Fax: (03744) 3 31 78 e-mail: info@ema-schwabe.de http://www.ema-schwabe.de 24-h-Hotline: (0172) 3 72 11 21

DIWA-Schweißtechnik GmbH Edisonstraße 4 04319 Leipzig-Engelsdorf Tel.: 0341 – 65974-10 Fax: 0341 – 65974-90 e-mail: info@diwa-leipzig.de http://www.diwa-leipzig.de

SB Schweißgeräte GmbH Am Bleichbach 11 85452 Moosinning Tel.: (0 81 23) 27 43 + 27 46 Fax: (0 81 23) 43 15 e-mail: sb@sb-schweissgeraete.de http://www.sb-schweissgeraete.de Johann Steinbeck GmbH & Co. KG Paul-Lincke-Straße 4 33659 Bielefeld Tel.: (05 21) 4 90 21 / 23 Fax: (05 21) 49 38 84 + 49 48 33 e-mail: info@johann-steinbeck.de http://www.johann-steinbeck.de Schweißtechnik Schwalbach GmbH Große Seestraße 42-H 60486 Frankfurt/Main Tel.: (0 69) 97 98 90-0 Fax: (0 69) 7 07 37 56 Telex: 41 46 83 e-mail: info@schweisstechnikschwalbach.de http://www.schweisstechnikschwalbach.de Engelking Schweißtechnik Ehlbeek 5 30938 Burgwedel Tel.: (05 139) 957 06-0 Fax: (05 139) 957 06-22 e-mail: info@engelkingschweisstechnik.de Ing. Grimm Schweisstechnik GmbH König-Georg-Stieg 6 21107 Hamburg Tel.: 040 - 75 60 36 – 0 Fax: 040 – 75 60 36 – 26 e-mail: info@grimm-schweisstechnik.de http://www.grimm-schweisstechnik.de Verges-Schweißtechnik GmbH Leipziger Str. 50 34260 Kaufungen-Papierfabrik Tel.: (05 61) 58 30 82 Fax: (05 61) 58 28 41 e-mail: info@verges.de http://www.verges.de

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ANHANG / APPENDIX / ANNEXE

Werksvertretungen im Ausland: Foreign Representatives: Représentants à l'étranger Argentina DI-TE-SO S.R.L. Neuquen 954 Barrio Providencia 5000 Córdoba Tel.: (00 54) 351 4744829 Fax: (00 54) 351 4713850 e-mail:cloosdts@arnet.com.ar

Austria CARL CLOOS SCHWEISSTECHNIK GmbH Rheinboldtstr. 15 A-2362 Biedermannsdorf Tel.: (00 43) 22 36 / 62298-0 Fax: (00 43) 22 36 / 62298-41 e-mail: office@cloos.co.at http://www.cloos.co.at/

Brasilia DEUMA do Brasil Ltda. Rua Presidente Juscelino, 274 Caixa Postal 1314 CEP 89252-050 Jaraguá do Sul-Santa Catarina Tel.: (00 55) 47-371 90 46 Fax: (00 55) 47-275 06 37 e-mail: honig@deuma.de

Bulgarien Rapid EOOD 54, Gorski Patnik Str. BG-1421 Sofia Tel.: (+3592) 963 1668 Fax: (+3592) 963 3666 e-mail: cloos@mail.orbitel.bg

Dänemark A.H. INTERNATIONAL A/S Essen 10 6000 Kolding Tel.: (+45) 7550 11 00 Fax: (+45) 7550 20 21 E-mail: ahi@ahi.dk http://www.ahi.dk

France (à l'exeption des dep. 57-67-68) Sté. SANA Parc d'Activités Rue de l'Épinoy B.P. 8 F-59175 Templemars / France Tel.: (00 33) 3 20 18 30 80 Fax: (00 33) 3 20 95 38 10 e-mail: lille@sana.tm.fr http://www.sana.fr

(seulement dep. 57-67-68) Philippe Schweißtechnik Industrieanlagen Max-Planck-Straße 12 66271 Kleinblittersdorf Tel.: (0 68 05) 94 13 -0 Fax: (0 68 05) 94 13 -13 e-mail: info@philippe-schweisstechnik.de http://www.philippe-schweisstechnik.de

Finnland MEURO-TECH Kehräsaari A 206 33200 Tampere Finnland Tel.: +358 40 579 1211 Fax: +358 3 260 7134 e-mail: ismo.meuronen@meuro-tech.fi http://www.meuro-tech.fi

Greece CONNEKT - TASSOPOULOS KOSTOPOULOS COMPANY 69 G.GENNIMATA STR. GLYFADA 165 62 ATHENS GREECE Tel.: (00 30) 210 960 24 18 Fax: (00 30) 210 961 09 29 e-mail: info@connekt.gr http://www.hec-agelidis.gr

Hungary Crown International KFT. Vámosgyörk utca 30 H - 1163 Budapest Tel.:(00361) 4 03 53 59 Fax:(00361) 4 03 22 43 e-mail: info@cloos.hu http://www.cloos.hu

Israel Adler & Stern Ltd. Hahistadrut 206, P.O.B 10799 26119 IL-Kiryat-Haim Tel.: (0 09 72) 4-841 38 59 Fax: (0 09 72) 4-841 42 13 e-mail: ast93@netvision.net.il

Ostslowakei Weldex-Arena s.r.o. Vajanského 9 SK-08001 Presov Tel.: 00421-51-7722836 Fax: 00421-51-7732105 e-mail: info@weldex.sk http://www.weldex.sk

Switzerland Italy Hebutec AG Saldotecnica Busan S.R.L. Via Gagliani 2 Schweisstechnik I-40069 Zola Predosa (BO) Gallusstr. 16 Tel.: (00 39) 051 75 23 54 Postfach 615 Fax: (00 39) 051 75 86 28 CH-9500 Wil e-mail: saldotecnica@ Tel.: (00 41) 71 911 77 11 saldotecnicabusan.com Fax: (00 41) 71 911 01 27 http://www.saldotecnicabusan.com e-mail: info@schweissen-schleifen.ch http://www.hebutec.ch/ Saldobraz Engineering S.R.L. schweisstechnik/ Via Fausto Coppi Nr. 11 I-10043 Orbassano (To) Tel.: (00 39) 011 901 90 30 Tschechische Republik Fax: (00 39) 011 901 90 27 (Südböhmen) e-mail:saldobraz@saldobraz.it KVK GmbH http://www.saldobraz.it Zahradni 203 332 02 St. Plzenec-Sedlec Tel.: 00420-37-7966304 Romania Fax: 00420-37-7966304 ROBCON TM. S.R.L. E-Mail: weldkvk@atlas.cz Str. Eneas Nr.10 P.O.B.26 RO-300479 Timisoara (Südmähren) Tel.: (0040) 256 22 09 20 SIP Fax: (0040) 256 49 01 02 Schweißtechnik CLOOS GmbH e-mail: office@robcon.ro Nr. 180 http://www.robcon.ro 592 21 Skrdlovice Tel.: (00420) 566 659 259 Fax: (00420) 566 659 144 Russland E-Mail: sip@sipzr.cz IPC Handels GmbH http://www.sipzr.cz Ul. Viatskaya 27 127015 Moskau Tel.: (007) 095 9167236 (Nordmähren) Fax: (007) 095 9167236 Ferier s.r.o. e-mail:ipconsult@sojuz.ru Slavikova 6143 IPC Handels GmbH IZ-NÖ Süd Strasse 7, Obj. 58,B8 A-2355 Wiener Neudorf Tel.: 0043 (0)2236/ 379 599-13 Fax: 0043 (0)2236/ 379 599-15

Slowakische Republik Westslowakei Elektro Plus s.r.o. Cukrovarská 186 SK-92600 Sered Tel.: 00421-31-7895977 Fax: 00421-31-7896753 e-mail: elektroplus@elektroplus.sk http://www.elektroplus.sk

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708 00 Ostrava Poruba Tel.: 00420-59-6923372 Fax: 00420-59-6923372 E-Mail: ferier@ferier.cz http://www.ferier.cz

ANHANG / APPENDIX / ANNEXE

Verkaufs- und Beratungsbüros: Sales and advice offices: Bureaux de consultation et des ventes: Carl Cloos Schweißtechnik GmbH Verkaufs- und Beratungsbüro Matthias Zughorst Hindenburgstr. 52 71696 Möglingen Tel.: (0 71 41) 48 13 55 Mobil (01 75) 930 79 49

Werksniederlassungen: Branches: Filiales: Carl Cloos Schweißtechnik GmbH Niederlassung Berlin Volmer Str. 9b 12489 Berlin Tel.: (0 30) 722 50 35 o. 67806780 Fax: (0 30) 678067825 e-mail: cloos-berlin@cloos.de

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ANHANG / APPENDIX / ANNEXE

Tochterunternehmen: Subsidiaries: Sociétés: Belgium Cloos Belgium N.V. Grijpenlaan 24 B-3300 Tienen Tel.: (00 32) 16 39 55 00 Fax: (00 32) 16 40 03 45 e-mail: info@cloos.be http://www.cloos.be

Czech Republic CLOOS Praha S.R.O. Videnska 352 Vestec u Prahy CZ-252 42 Jesenice Tel.: (00 420) 2-44 91 03 55 Fax: (00 420) 2-44 91 30 29 e-mail: info@cloos.cz http://www.cloos.cz

China Cloos GmbH - Beijing Office Bailian Mansion Room No. 308 No. 17 Jianhua Road (S) Jianwai Street, Chao Yang District, Beijing 100022 Tel.: (0086)10-65667296 (0086)10-65667297 Fax: (0086)10-65667298 e-mail: service@cloos.cn http://www.cloos.cn/ Cloos Shanghai Room 2109, 500 Xiangyang Nanlu, Shanghai P.R. China Tel.: (0086)-21-21-6145 7281 Fax: (0086)-21-6145 7306 e-mail: cloos_shanghai@163.com http://www.cloos.cn/

Indien CLOOS INDIA WELDING TECHNOLOGY PVT LTD, Central Marketing Office., M-69, LOWER GROUND FLOOR, GREATER KAILASH, PART - II, NEW-DELHI :- 110048. INDIA. Tel.: (0091) 11 2921 2931 , 2450 2829, 3252 2930 Fax: (0091) 11 2921 2930 e-mail: info@cloos.in http://www.cloos.in

Great Britain CLOOS UK Ltd. Wulfrun Trading Estate Units 2 + 3 Stafford Road GB-Wolverhampton WV 10 6 HR Tel.: (00 44) 1902-71 12 01 Fax: (00 44) 1902-71 13 76 e-mail: sales@cloos.co.uk

Mexico CLOOS ROBOTIC DE MEXICO Puerto Mazatlan 242-E col. La Fe MX-San Nicolas de los Garza, NL CP 66477 Mexico Tel.: (+52) 8 2992090 Fax: (+52) 8 2992091 e-mail: info@cloos.com.mx

Türkei CLOOS Türkei Mr. Hasan Ülker Esenevler Mah. Selvi Sokak Nr. 12 Zemin Kat, TR-16300 Yildirim, Bursa Tel. 0090-224-3423672 Fax: 0090-224-3426152 E-Mail: hasan.ulker@cloos.de

USA CLOOS Robotic Welding Inc. 911 Albion Avenue USA-Schaumburg, Illinois 60193 Tel.: (00 1) 847-923-9988 Fax: (00 1) 847-923-9989 e-mail: info@cloos-robot.com http://www.cloos-robot.com

Netherlands CLOOS Nederland B.V. Palmpolstraat 94 NL-1327 CJ Almere Tel.: (0031) 36 5240670 Fax: (0031) 36 5240680 e-mail: info@cloos.nl http://www.cloos.nl

Poland CLOOS Polska sp.z o.o. ul. Stawki 5 PL58-100 Swidnica / Polen Tel.: (0048) 74 - 851 8660 Fax: (0048) 74 - 851 8661 e-mail: firma@cloos.pl http://www.cloos.pl

South Korea CLOOS KOREA #101-1101 Poonglim iwant, 309 Bagchon-dong, Gyeyang-gu Incheon 407-330 KOREA Tel.: (0 82) 325534757 Fax: (0 82) 325494757 e-mail:clooskorea@hanafos.com

Spain / Portugal Cloos Espana S.A. C/ Jacint Verdaguer, 116-118 08205 Sabadell - Barcelona Tel.: (0034) - 93 720 91 00 Fax: (0034) - 93 720 90 99 e-mail: Cloos.Millan@terra.es

Switzerland CLOOS Engineering S.A. Jambe-Ducommun 8b CH-2400 Le Locle Tel.: (0 41) 32-931 74 74 Fax: (0 41) 32-931 74 78 e-mail: cloos@cloos.ch http://www.cloos.ch

GT-D / PM\ALLGEM\V-Verzeichnis.P65 - 07.08

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