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Jaguar Land Rover

PAN Projects

Spot Welding Standard

for

FANUC's R30iB Controller

Robot To Spot Welding

Programming

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 2

Issue No.Details of the UpdateAuthor

1.0 Initial Release JP

2.0 Updated 5.12

Robot To Spot Welding

Programming

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 3

Contents

1. Introduction.......................................................................................................................4

2. Safety................................................................................................................................4

3. Robot Configuration..........................................................................................................5

4. IO Interface.......................................................................................................................6

5. SpotTool Instructions ........................................................................................................8

5.1 SPOT Instruction.........................................................................................................8

5.11Start Distance (SD) & End Distance (ED)................................................................8

5.12 Pressure Schedule (P)...........................................................................................9

5.13 SPOT ID (S)...........................................................................................................9

5.14 Example SPOT Command.....................................................................................9

5.2 SET_WELD_DATA......................................................................................................9

5.3 Pressure Motion Command.......................................................................................10

5.4 Thickness Check.......................................................................................................10

5.5 Errors and Fault Recovery.........................................................................................11

5.51 Thickness Check Error.........................................................................................11

5.52 General Weld Fault..............................................................................................11

5.53 Auto Error Recovery.............................................................................................12

6. Tip Dressing....................................................................................................................13

6.1 TIPDRESS_CONTROL.............................................................................................13

6.2 TOOL(No.)_TIP_DRESS...........................................................................................14

7.Tip Wear Compensation ..................................................................................................15

8. Gun Resistance Calibration.............................................................................................16

9. Manual Pressure Check..................................................................................................19

9.Programming ...................................................................................................................21

Appendix 1 - Example Spot Program .................................................................................22

Robot To Spot Welding

Programming

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 4

1. Introduction

This document only specifies the "Robot Spot Welding Programming Standard" within FANUC's R30iB Controller with "EtherNetIP" bus communication. It is only relevant for JLR PAN Project installations and should be used in conjunction with "JLR PAN Robot to PLC Standard" documentation. The document should be read and fully understood by the end user before any commissioning and or programming is started.

IF IN DOUBT ASK

2. Safety

The safety of people is always of primary importance in any situation. When applying safety measures to your robotic system, consider the following: •External devices •Robot(s) •Tooling •Workpiece

Only trained personnel should operate a Robot

For more information refer to the Safety section in the:- •FANUC Corporation SYSTEM R-30iB and R-30iB Mate HandlingTool and LR HandlingTool Setup and Operations Manual MAROBHT8203131E REV C The Robot E-Stop out is wired into some Allen Bradley Safe Point I/O which is then monitored by the Line PLC. The safety of the robot is all run over Ethernet I/P safe and utilises the Robots Safe I/O connect feature. This can make logical decision's on Safe Inputs on whether to issue a robot E-Stop or fence output. Correct PPE must be worn when running the welding software in manual mode (whilst inside the guard line), due to possible sparks or flash off caused by the weld process. All tip dressing operations must be done from outside the guard line (safety gates must be closed). All safety systems must be fully functional without any manual overrides to ensure the end user is fully protected from all hazards.

Robot To Spot Welding

Programming

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 5

3. Robot Configuration

Along with the standard package loaded into every JLR robot, as discussed in the 'Robot to PLC Standard Programming' manual, every Spot Welding Robot will have another package loaded into it. This will contain the following: Spot Welding Teach Pendant (TP) Programs:- These are stored in the TPP memory allocation on the SRAM (non-volatile) memory of the Robot. TP programs are the routines the Robot runs when in automatic to complete a task. All the Spot Welding TP programs will have SPOT selected as their Application Process within the 'Detail' of the program (Program Detail explained later in the manual). Karel Programs are loaded in to the Robot to conduct certain tasks that are unable to be done in TP language. The code for these programs isn't visible and the Integrator/End User are unable to edit these without the source code. Karel programs can be called to run from TP programs just in the same way as any other programs. For Spot Welding all the 'DEBUG_TEXT' and 'DCP_FAULTS' are dealt with within Karel Programs. PMC (Programmable Machine Controller) is ladder logic that runs in the background of the robot and is used to the communicate with the PLC, TP Programs and third party equipment around the cell. Fundamentally PMC is a PLC built into the robot controller as standard. This has been written and proven by FANUC UK Ltd andMUSTnot be changed by the Integrator/End User. As all the robots are configured with FANUC's standard software package "SpotTool+" they are able to be configured to do:-

Spot Welding

Dispensing

Handling

Any robot that is going to be used as a Spot Welding Robot has already been configured in a Controlled Start as a SPOT robot. If the robot has been configured to be a SPOT Robot and a Handling Robot you can Toggle between the 2 Application Tools by:-

FCTN (Key)0(Next)5(Change Appl-Tool)

Robot To Spot Welding

Programming

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 6

4. IO Interface

The fieldbus communication is EthernetIP and the robot acts as the master for the Bosch

Weld Timer and Controller.

The integrator/end user must set the IP address of the Bosch Controller and weld timer with the EtherNetIP settings within the robot. This should be done in accordance with the JLR Standard and Controls Department allocation Sheet. Follow the procedure below to set the IP address for the Controller/Timer unit within Fanuc's EtherNetIP settings:-

1. Press the Menu Key

2. Cursor down to I/O (5) and Press Enter

3. Press F1 (Type) and Select EtherNetIP

4. Cursor Down to the Bosch Weld Controller or Timer you want to setup, it will be

commented up as Bosch CT or Bosch WT, then cursor across to the Enable Column

Press F5(False)

5. Cursor back onto the Description Column and Press F4(Config)

6. Press Enter on the IP Address and enter in the correct IP address using the Key pad

on the Teach Pendant followed by enter,

7. Press the previous key on the Teach Pendant, cursor back to the enable column of

the Bosch WT or Bosch CT and press F4(True) The interface for the Weld Controller is made up of 18 Bytes of Input Data and 4 Bytes of Output Data, all these signals are pre-defined and should not be altered by the integrator/End User. The interface for the Weld Timer is made up of 8 Bytes of Input Data and 8 Bytes of Output Data, all these signals are pre-defined and should not be altered by the integrator/End User. Within the SpotTool+ software there are also some pre-defined digital IO groupings:-

Cell Interface

Weld Interface

Spot Config

Dispense

Cell interface is used as the generic signals with the cell that aren't specific to one particular process. These will be setup by FANUC UK and will not need modifying by the integrator/end user. Weld Interface is used for Spot Welding robots, digital IO signals can be entered here and then the SPOT commands with the TP programs will have control over the IO.

Robot To Spot Welding

Programming

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 7 The interface also interacts with the PLC via the Robots PMC so that the process is monitored and decisions can be made as and when necessary.

PLC Inputs

DI[97: Weld ON]

DI[98: Tip Dress In Cycle Ped 1]

DI[99: Tip Dress In Cycle Ped 2]

DI[100: Mid Cyl Tip Cmb]

DI[103: First Dress]

DI[104: Reset Tip Dress Cntrs]

DI[105: Rst Weld Tmr Tip Counts]

DI[109: Water Off 1]

DI[110: Run Mill Motor 1]

DI[112: Tip Dress 1 Swing Arm Bck]

DI[113: Tip Dress 1 Swing Arm Fwd]

DI[114: Tip Dress 1 Swing Arm Intd]

DI[118: Water Off 2]

DI[119: Run Mill Motor 2]

DI[121:Tip Dress 2 Swing Arm Bck]

DI[122:Tip Dress 2 Swing Arm Fwd]

DI[123:Tip Dress 2 Swing Arm Intd]

DI[124:First Dress]

PLC OutputsDO[97:Timer Ready]

DO[98:Weld Fault]

DO[99:Manual Weld Selected]

DO[100:Weld Contactor Fdback]

DO[101:Tip Dress Required]

DO[102:Tip Dress Pre-Warning]

DO[103:Tip Change Required]

DO[105:Tip Dress Supply CB Ok]

DO[106:Shunt Trip Operated]

DO[107:Servo Gun 1 Open]

DO[108:Do Not Mon Water Flow 1]

DO[109:Water Flow 1 Ok]

DO[110:Tip Dress 1 Contr Ok]

DO[111:Weld Transformer 1 Temp]

DO[112:Tip Dress 1 Swing Bck]

DO[113:Tip Dress 1 Swing Fwd]

DO[114:Tip Dress 1 Swing Int]

DO[115:Without Weld Monitoring]

DO[116:Servo Gun 2 Open]

DO[117:Do Not Mon Water 2 Flow]

DO[118:Water Flow 2 Ok]

DO[119:Tip Dress Contr ok]

DO[120:Weld Transformer 2 Temp]

DO[121:Tip Dress 2 Swing Bck]

DO[122:Tip Dress 2 Swing Fwd]

DO[123:Tip Dress 2 Swing Int]

DO[124:Weld On From Timer]

DO[125:Servo Gun 3 Open]

DO[126:Ok for Tip Change]

DO[127:At Tip Dress Position]

Robot To Spot Welding

Programming

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 8

5. SpotTool Instructions

The following instructions are specific to Spot Welding and will be what the integrator/end user will be using when programming the robots. Other Programming instructions that are standard to the FANUC controller can be found in the SpotTool+ Manual.

5.1 SPOT Instruction

Spot instructions tell the robot to spot weld. This section describes each spot welding instruction. This instruction is entered on the enter of a Robot FINE move, therefore becoming linked to that move and is executed once the robot has finished the move. The robot is configured with a servo controlled spot welding gun therefore the following instruction will be valid.

SPOT[SD=**, P=**, S=**, ED=**]

SD = Start Distance

P = Pressure Schedule

S = SPOT ID

ED = End Distance

For Start/End Distance and Pressure there are inbuilt Schedules within the robot that are used within the SPOT Command. These can be found in the Data Menu inside the Fanuc iPendant. The numbers that are entered into the SPOT Command will point at which schedule needs to be used.

5.11Start Distance (SD) & End Distance (ED)

The value in theStart Distance(SD) andEnd Distance(ED) relate to the Distance Schedule that is to be used on that SPOT. Distance schedules hold values in millimetres of how far the each tip of the Gun should be away from the Part. The notation used for each tip is GUN and Robot, where GUN is the moving tip of the Gun (How far the Gun needs to move away from the part) and Robot is the static tip of the gun (how far the robot needs to move away from the part). This motion is co-ordinated so the gun and robot move together to achieved the required distances.

Robot To Spot Welding

Programming

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 9

5.12 Pressure Schedule (P)

The value in thePressure Schedule(P) relates to the schedule number to be used on this SPOT. The pressure schedules hold a pressure in Newton's. As the Bosch is the master to the robot and it will send out the required pressure it is not necessary to have multiple pressure schedules for production programs as the robot will automatically write in the pressure sent by the Bosch. This will be written into the pressure schedule define in the 2nd argument of SET_WELD_DATA. Therefore it is suggested thatPressure Schedule 1 is

ALWAYS usedfor production programs.

5.13 SPOT ID (S)

The value enter in theSPOT ID(S) is the SPOT ID within the Bosch Controller, when the SPOT instruction is executed the SPOT ID is sent to the BOSCH Controller in a 32bit Group ID.

5.14 Example SPOT Command

L P[1] 200mm/sec FINE SPOT[SD=1, P=1, S=12345, ED=2]

Start Distance (SD) = Distance Schedule 1 Used

Pressure (P) = Pressure Schedule 1 Used

End Distance (ED) = Distance Schedule 2 Used

5.2 SET_WELD_DATA

The SET_WELD_DATA program needs to be called before every SPOT command. This program is used to retrieve the Thickness and Pressure expected for the following SPOT command from the Bosch Weld Controller. It then writes the thickness and pressure into Pressure Schedule that will be used on the following SPOT. There are 3 Arguments that are passed into this program:-

Argument 1 = Spot ID(String)

Argument 2 = Pressure Schedule to be used on following SPOT Argument 3 = Thickness Tolerance (mm) for this Spot(Optional)

Robot To Spot Welding

Programming

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 10 The third argument is optional, if a value is used in the third argument the thickness tolerance in the thickness check is altered to this amount. If this argument isn't used/specified then the robot uses the global thickness tolerance that can be specified in

Register 19 (R[19:Global Thk Tol]).

Example

CALL SET_WELD_DATA(1-151234567,1,2)

L P[1] 500mm/sec FINE SPOT[SD=1, P=1,S=151234567, ED=2] In the Example above you can see that the Pressure schedule used in the argument for SET_WELD_DATA matches the Pressure Schedule used in the following SPOT. Also the Spot ID matches as well. In this example the third argument has been used and set to 2, this means that the thickness tolerance that will be used on this spot will be 2mm

5.3 Pressure Motion Command

In built into the SpotTool software is a pressure motion command, PRESS_MOTN. This command works in a very similar way to a SPOT Command just without welding. The command is used after a tip change to Press the new tips firmly into place before continuing with welding.

Example

PRESS_MOTN[SD=**,P=**] (SD=Start Distance, P=Pressure) When this command is ran the gun will close the tips together to the pressure specified in the requested pressure schedule, using the Start Distance schedule as the position the gun drives to before activating the pressure.

5.4 Thickness Check

As standard this feature will be turned on in all JLR Spot Welding robots with the tolerances set at ±1mm (Register 19 as mentioned in 5.2). As explained in section 5.2 the thickness is read from the Bosch weld timer and written into the Pressure schedule that is going to be used on the next Spot. When the Spot command is ran the first thing the robot does it check the feedback in the servo gun to compare the requested thickness against the actual thickness. If these fall outside the predefined tolerances a DCP fault is displayed with the following screen.

Robot To Spot Welding

Programming

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 11 The recovery for this fault and other examples can be found in section 5.5 Errors and Fault

Recovery.

5.5 Errors and Fault Recovery

During the cycle of the Robot there are going to be instances where we get faults during Spot Welding, whether these be Thickness Errors (Thickness detected is out of tolerance to the supplied thickness from Bosch), Failure to read data from the Weld Timer or a General Weld Fault. To display and recovery from these errors a mixture of the Fanuc Software Auto Error Recovery is used alongside the JLR standard DCP faults.

5.51 Thickness Check Error

In section 5.4 a thickness check error was explained and demonstrated. There are 2 possible ways to resolve this fault, these are to Retry the Weld or Ignore.

Ignore:-

In this instance if ignore is selected the robot will initiate the weld again but it will temporally disable the thickness checking just on this weld and then re-enable it afterwards. Therefore with the thickness check disable the robot will try and weld as normal. Retry:-In this instance the robot will try to weld again and re-detect the thickness, if the thickness falls into tolerance the robot will weld otherwise the same DCP fault will be displayed again.

5.52 General Weld Fault

A general weld fault usually occurs when the robot has tried to weld, even has managed to weld but no weld complete is issued by the weld controller therefore the FANUC spot tool times-out.

Robot To Spot Welding

Programming

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 12

Retry:-

The robot will initiate the weld again and wait for the weld complete. If it times-out again the same screen will appear.

Ignore:-

In this instance the weld will be skipped, no attempt to weld this spot will be made.

5.53 Auto Error Recovery

Auto Error Recovery is a piece of FANUC software that has been loaded into all JLR robots. Auto Error Recovery allows a recovery program to be activated under certain conditions (Alarm Codes, Digital Inputs etc) and pause the main program where it is and return to it once the Auto Error Recovery program has been executed. For the welding it is setup to monitor for the following system alarms on the Robot:-

1. SVGN-040 Thickness out of Tolerance - Code = 30040

2. SPOT-008 Weld Complete Timeout - Code = 23008

Up to 10 Monitored alarm codes can be used and FANUC can add more in if required. This is not to be modified by the Integrator/End User. The Command RESUME_PROG[1]=SPOT_ERROR is used within the SET_WELD_DATA program, this instructs the robot that from this point if any of the monitored alarm codes are detected the SPOT_ERROR program is to be started and the current program to be paused. As the monitored alarm codes would normally make the robot fault and stop when the RESUME_PROG[] command has been issued these alarms will no longer make the robot fault, only activate the SPOT_ERROR program. Once the last spot of the welding program has been completed the integrator/end user needs to insert the command CLEAR_RESUME_PROG. This then deactivates the error recovery program. See Appendix 1.

Robot To Spot Welding

Programming

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 13

6. Tip Dressing

The Tip Dressing is controlled via the Bosch Weld Controller, this keeps track of how many welds the Gun has done since the last tip dress. The amount of welds between each tip dress is set internally via the Bosh Software which will be the responsibility of Bosch and

JLR to setup.

Once the tip dress interval has been reach DI-[778] Tip Dress Request is turned on to the Robot. This signal will be checked at the end of every weld program and if the signal is high program 'TIPDRESSS_CONTROL' will be executed.

6.1 TIPDRESS_CONTROL

Used to interrogate the Weld Controller to find out which gun/electrode requires a tip dress.

Program Name:- TIPDRESS_CONTROL

TP usage/notation:- CALL TIPDRESS_CONTROL

Associated I/O:- DO[779], DI[778]

Other Programs used:- GETWELDDATA(1-1234567,1)Argument 1 = Spot ID/.Program No. Argument 2 = Pressure schedule to be used. In this case always 1.

Argument 3 = Thickness Tolerance for this Spot

The TIPDRESS_CONTROL program is called when the Bosch Controller is issuing DI-778 (Tip Dress Request) to the robot. The program then interrogates the weld controller to determine which gun/electrode needs to be dressed. First the Karel Program 'GETWELDDATA' is used to select program 1 in the weld controller:-

GETWELDDATA(1-1,1,2) Type

Program 1 using Type 1 is actually selecting Electrode (Gun) 1 in the Bosch controller to be queried. Then by turning DO-[779] On (Request Electrode Status) the Weld Controller will either turn off DI-[778:Tip Dress Request] if this electrode isn't the one requiring a tip dress or leave it on if it does. If it is requiring a tip dress the TP Program will then call TOOL1_TIP_DRESS. Otherwise it will do the same process but query electrode 2, electrode

3 and so on.

It will be down to the Integrator/End user to make sure that when the program has determined what Electrode is to be dress that the right program is called, as it is possible that Electrode 1 could be 'Tool 2'

Example

LBL[1: Electrode 1]

DO[779: Bosch Req Elect Stat] = OFF

CALL TOOL_2_TIP_DRESS

Robot To Spot Welding

Programming

Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 14

6.2 TOOL(No.)_TIP_DRESS

Program Name:- TOOL(No.)_TIP_DRESS

TP Usage/Notation:- CALL TOOL1_TIP_DRESS

Associated I/O:- DO[127,778,781], DI[110,778,825]

Other Programs used:- SET_WELD_DATA, GETWELDDATA, RESETSPOTMEM,

TIP_WEAR

There are tip dress programs for each Electrode/Tool that the robot uses, e.g. Dual Spot Welding Gun. To complete a Tip Dress the robot must activate the correct program within the Bosch Weld Controller. These programs are as follows:-

Electrode 1:

60 = Short circuit weld

61 = Tip Dress

62 = Tip Change/First dress

63 = Polish dress

64 = Fast open(only used for pneumatic guns)

65 = Resistance calibration

248 = Current check

249 = Force check

Electrode 2:

160 = Short circuit weld

161 = Tip Dress

162 = Tip Change/First dress

163 = Polish dress

164 = Fast open(only used for pneumatic guns)

165 = Resistance calibration

246 = Current check

247 = Force check

Electrode 3:

250 = Short circuit weld

251 = Tip Dress

252 = Tip Change/First dress

253 = Polish dress

254 = Fast open(only used for pneumatic guns)

255 = Resistance calibration

244 = Current check

245 = Force check

For a standard Tip Dress that will be executed within these programs (TOOL(No.)_TIP_DRESS) the following sequence is used:-

Example Tool 1

1. Move into the Tip Dressing position

2. Turn on DO-[127: At Tip Dress Position] and Wait DI-[110: Motor Running]

Robot To Spot Welding

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Jaguar Land Rover : Robot to Spot Welding Standard for FANUC's R30iB Controller 15

3. Call SET_WELD_DATA set Type to '1', program No. to 61 (Tip Dress) and pressure

schedule to 98. a. SET_WELD_DATA('1-61',98) i. Pressure Schedule 98 can be changed by the integrator/end user if the Pressure for tip dressing needs to be altered.

4. A FOR LOOP is executed for a predefined number of loops (set in the Manual Fctns

Spot Setup Page) in which a PRESS_MOTN command is used to close the gun into the tip dresser and pressurise to Pressure Schedule 98.

5. Call SET_WELD_DATA set Type to '1', program No. to 63 (Polish Dress) and

pressure schedule to 96 a. SET_WELD_DATA('1-63',96) i. Pressure Schedule 96 can be changed by the integrator/end user if the Pressure for Polish dressing needs to be altered.

6. A FOR LOOP is executed for a predefined number of loops (set in the Manual Fctns

Spot Setup Page) in which a PRESS_MOTN command is used to close the gun into the tip dresser and pressurise to Pressure Schedule 96.

7. After the 2 dressing sequences the gun then performs a short Circuit weld

a. Using SET_WELD_DATA('1-60',1) program 60 Short Circuit Weld for Tool 1 is selected within the Bosch Weld Controller. b. Then a standard SPOT instruction is executed i. L P[1] 500mm/sec FINE SPOT[SD= ,P= ,S= ,ED= ]

8. Finally the robot will acknowledge the completed tip dress sequence by setting the

Tool Number to the Weld Controller using:-

a. GETWELDDATA('1-1',1) b. DO-[778: Ack Tip Dress] = ON c. WAIT DI-[778: Tip Dress Request] = OFF d. DO-[778: Ack Tip Dress] = OFF e. CALL RESETSPOTMEM f. CALL TIP_WEAR i. TIP_WEAR is the tip wear compensation program used to alter the TCP position based on the amount of wear seen on the tips.

7.Tip Wear Compensation

Built in to the Fanuc Robot SpotTool+ are 2 methods for the robot to detect and calculate the Tip Wear on the servo Gun. There is the 1 and 2 step method, the 2 setup method requiresquotesdbs_dbs7.pdfusesText_13

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