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NX Robot Controller COMARC Training Manual Revised 11/25/05 NOT FOR RESALE November 25, 2005 MOTOMAN 805 Liberty Lane West Carrollton, OH 45449 TEL: (937) 847-6200 FAX: (937) 847-6277 24-HOUR SERVICE HOTLINE: (937) 847-3200 WWW.MOTOMAN.COM The information contained within this document is the proprietary property of Motoman, Inc., and may not be copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman, Inc. ©2004 by MOTOMAN All Rights Reserved

NX Comarc 11-25-05

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Page 1: NX Comarc 11-25-05

NX Robot Controller

COMARCTraining Manual

Revised 11/25/05

NOT FOR RESALE

November 25, 2005

MOTOMAN805 Liberty LaneWest Carrollton, OH 45449TEL: (937) 847-6200 FAX: (937) 847-627724-HOUR SERVICE HOTLINE: (937) 847-3200WWW.MOTOMAN.COM

The information contained within this documentis the proprietary property of Motoman, Inc.,and may not be copied, reproduced ortransmitted to other parties without theexpressed written authorization ofMotoman, Inc.

©2004 by MOTOMANAll Rights Reserved

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PREFACE

PURPOSE OF THIS MANUAL

MOTOMAN TECHNICAL EDUCATION CENTER training manuals are not intended for use asstand alone training tools. This manual is to be used in conjunction with the NXCOMARC course.

WHO SHOULD USE THIS MANUAL

This manual is only issued to attendees of the NX COMARC course.Do not use the manual as a reference tool unless you have attended the course andreceived certification through MOTOMAN TECHNICAL EDUCATION CENTER.

HOW TO USE THIS MANUAL

This training manual has been written according to the daily structure of theNX COMARC course. It is designed to assist students in understanding theCOMARC set-up and tracking functions for the NX100 controller and aMOTOMAN robot. Use this manual as a step-by-step guide through the course.

DISCLAIMER

Information in this manual is based on the assumption that the NX100 controller isin the MANAGEMENT Security Level and is using the EXPANDED Language.Be aware that the keystrokes described in this manual may vary based on othersettings, software versions, and options.

NOTE: This manual is not for resale and will not be sold separately.All training manuals developed by MOTOMAN TECHNICAL EDUCATION CENTER

are copyrighted. Do not copy any portion of these manuals.

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NX ComArc Training Manual T O C - 1 © MOTOMAN

CONTENTS

1.0 COMARC SEAM TRACKING .............................................. 1-1

1.1 Connection Verification ........................................................................ 1-1

1.2 Arc Sensor Function ............................................................................ 1-2

1.3 Setting Up for ComArc Seam Tracking ................................................ 1-4

1.3.1 Program the Path ........................................................................................... 1-4

1.3.2 Registering the ComArc instructions ............................................................... 1-5

1.4 Measurement and Registration of Information ..................................... 1-6

1.4.1 Measurement and Registration of Phase Compensation ............................. 1-7

1.4.2 Measurement and Registration of Sensing Conditions ................................ 1-9

1.5 Testing COMARC .............................................................................. 1-12

1.6 COMARC Condition File ................................................................... 1-13

1.6.1 U/D & L/R Correction Selection................................................................. 1-13

1.6.2 Passover Function .................................................................................... 1-14

1.7 Dead Zone ........................................................................................ 1-15

1.8 COMARCSET ................................................................................... 1-15

1.9 SCOMARC ........................................................................................ 1-15

2.0 SEAMFINDING/ TOUCHSENSING........................................... 2-1

2.1 POSITION VARIABLES....................................................................... 2-1

2.1.1 Access to Position Variable Display ............................................................ 2-1

2.1.2 Establishing Data Type ............................................................................... 2-2

2.2 Programming Motion with Position Variables....................................... 2-3

2.3 Position Variable Functions ................................................................. 2-3

2.3.1 CNVRT ....................................................................................................... 2-3

2.3.2 GETE ......................................................................................................... 2-4

2.3.3 SETE ......................................................................................................... 2-5

2.3.4 GETS ......................................................................................................... 2-5

2.3.5 Reference Points ........................................................................................ 2-5

2.4 SYSTEM VARIABLES ($) ................................................................... 2-6

2.5 Temporary Shift Instruction (SFTON/SFTOF)....................................... 2-7

2.6 Touch jobs ........................................................................................... 2-9

2.6.1 Reference Point Location ............................................................................ 2-9

2.6.2 Touch Jobs ................................................................................................. 2-9

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1.0 COMARC SEAM TRACKING

Seam Tracking is a function of ComArc that uses amperage feedback from the arcto determine the location of the weld joint. It is recommended for fillet joints only, inthe 1F or 2F positions. Out of Position tracking is not recommended. Weaving isrequired.

Most of the ComArc Seam Tracking programming functions can only be performedin the Management Security level.

To access the Management Security Level, perform the following:1. With the MAIN MENU displayed, choose SYSTEM INFO.2. Choose SECURITY.3. Press SELECT, cursor to MANAGEMENT and press SELECT.4. Enter the appropriate password and press ENTER.The security level indicator in the STATUS area should now show ManagementMode.

1.1 Connection VerificationSpecific hardware is required to use the COMARC function. This hardware (theNCP02 card) processes the amperage, or current feedback from the powersource. This information can be displayed and indicates that the board is functioningproperly.

To view the signals being input to the NCP02, perform the following:1. In the PLAY mode, with a welding job selected and the cursor on the NOP,

choose In/Out from the Main Menu.2. Choose NCP02 I/O.The screen in Figure 1 will be displayed.

JOBDOUTMOVEEND

IN/OUT

In Out

SYSTEM INFO

VARIABLE

B001

ROBOT

CF

FD/CF

EDIT DISPLAY UTILITYDATA

Short CutMain Menu

ARC WELDING

NCP02 I/O STATUSBOARD : NCP02#1NO. A/D (IN) (OUT)

12345678

-327680000000

PARAMETER

SETUP

Figure 1-1 NCP02 I/O Status Screen

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Start the weld job and verify the A/D (analog to digital) data on channel NO. 01shows positive values. If there is no change or if the data is a negative value, thereis a misconnection.

1.2 Arc Sensor FunctionAn understanding of weld characteristics helps the understanding of COMARC.Amperage in the arc is dependent on many variables. Some of these are:

1.Wire diameter

2.Wire type

3.Base metal type

4. Base metal thickness

5. Shielding gas type

6. Welding Equipment (power source and wire feeder)

7. Wire feed speed

8. ESO (Electrical Stick Out)

Changes to any of these will cause the amperage to vary. Since the first six (6) ofthese variables are not frequently changed, the amperage variances are normallycaused by the Wire Feed Speed and the Electrical ESO (ESO) changes. Wire feedspeed is controlled by the Amperage settings in the Arc Start Files, and can beconsidered fixed in this situation. Now the only variation to the amperage/current isdue to changes in ESO. Figure 2 shows the relationship.

Figure 1-2 Electrical Stick Out (ESO)

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As the robot weaves across either a groove weld or a T-joint, the ESO will vary asit passes from the deeper part of the joint to the edges of the joint. If the path is inthe middle of the joint, the ESO on either side will be equal as shown in Figure 3.

Figure 1-3 Equal ESO on Both Sides of the Weld Joint (normal)

If the robot path is not in the center of the weld joint, there will be inequality of theESO at the sides of the weave, and therefore different amperages as shown inFigure 4.

Direct ion of pathcorrect ion

Direct ion of pathcorrect ion

Figure 1-4 Electrical stickout when the path is offset

Because of the inequality of ESO (and related amperage) the path should be shiftedin a Left or Right direction.

There may also be deviation in the path caused by the height of the parts. In thissituation, the path requires a shift either Up or Down as shown in Figure 5.

Figure 1-5 Offset path (vertically)

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1.3 Setting Up for ComArc Seam Tracking

The weldment must be a fillet joint. Groove joints may be tracked if the joint designprovides deep grooves and the joint is not completely filled. ComArc SeamTracking requires that the ESO changes as the wire passes from the center of theweld to the toe of the weld. Fully filled groove welds are NOT recommended.

1.3.1 Program the Path

Path programming is normally performed with the part in the nominal position.Proper ESO is essential while programming.

Start

Pullout (Departure)

Finish

Safe Point

Decel (Approach)

Figure 1-6 Fillet programming

The Job will also have a normal ARCON ASF#(X) and ARCOF AEF#(X) (or anyother technique for weld programming) in the proper locations. Weave instructionsmust be programmed in this initial job. Use a normal WVON and WVOFinstruction referencing the appropriate file. Test and PLAY the job to ensure goodarc characteristics and a proper weld bead with no undercut is deposited. The Jobshould appear as in Figure 6.

Note: To achieve proper results, the length of the test weld should be at least8 inches and the amplitude of the weave should be at least 2.5 mm.

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JOBDOUTMOVEEND

IN/OUT

In Out

SYSTEM INFO

VARIABLE

B001

ROBOT

CF

FD/CF

EDIT DISPLAY UTILITYJOB

Short CutMain Menu

ARC WELDING

JOB CONTENTJOB NAME : TESTCONTROL GROUP : R1

STEP NO : 002TOOL : 00

MOVJ VJ=50.00ARCON AC=200 AVP=100 T=0.30WVON WEV#(1)MOVL V=80MOVL V=80WVOFARCOF AEF#(1)MOVJ VJ=50.00MOVJ VJ=50.00

000200030004000500060007000800090010

=> MOVJ VJ=50.00

PARAMETER

SETUP

Figure 1-7 Job with ARCON instruction

CAUTION! Weave settings should be the same for both the test and theproduction part weld. Changes can be made to the Amplitude, butchanges to the Weave Frequency will cause the system to nottrack the part.

1.3.2 Registering the ComArc instructions

The ComArc instructions (COMARCON and COMARCOF) must be in theprogram after the ARCON and before the ARCOF. The COMARCONinstruction will take the place of the WVON instruction. The COMARCOFinstruction will take the place of the WVOF instruction. The ComArc instructionsare in the INFORM LIST under the SENSOR selection.

The COMARCON will need to be edited for the proper data. Use the DETAILEDIT screen for this procedure by pressing SELECT with the cursor on theCOMARCON instruction in the input line. There are at least three (3) and up tofour (4) pieces of information included on the COMARCON instruction line. Theseavailable choices are:

1a. Weave File- the same as used in the original set-up job

or

1b. Set AMP for amplitude and FREQ for frequency of the weave

2. Set the U/D (for the amperage/stickout)

3. Set the L/R (for offset leg lengths)

4. (optional) identify the COMARC File

NOTE: When weaving conditions are set by AMP, FREQ, and ANGL on theCOMARC line, the weaving mode is “single oscillation” .

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The COMARCOF instruction is programmed without any tags and will instruct thecontroller to both stop tracking and stop weaving.

JOBDOUTMOVEEND

IN/OUT

In Out

SYSTEM INFO

VARIABLE

B001

ROBOT

CF

FD/CF

EDIT DISPLAY UTILITYJOB

ShortCutMain Menu

ARC WELDING

JOB CONTENTJOB NAME : TESTCONTROL GROUP : R1

STEP NO. : 002TOOL : 00

000200030004000500060007000800090010

=> MOVJ VJ=50.00

MOVJ VJ=50.00ARCON AC=200 AVP=100 T=0.30COMARCON WEV#(1) U/D=200 L/R=10.0MOVL V=80MOVL V=80MOVL V=80COMARCOFARCOFMOVJ VJ=50.00

PARAMETER

SETUP

Figure 1-8 Job Structure with ComArc instructions

NOTE: There will only be tracking between the COMARCON andCOMARCOF instructions. Any welding after the ARCON and beforethe COMARCON (line 0004 in Figure 1-8) or after the COMARCOF andbefore the ARCOF (line 0009 in Figure 1-8) will not be using the seamtracking function.

1.4 Measurement and Registration of InformationTwo tests must be performed when setting up a COMARC weld. The first is aPhase Compensation test. The second is a Sensing Test.

The information fed back to the controller as A/D data is delayed from “real time”based on the length of the cables and harnesses.

Weaving motion

Welding current wave form

Welding current peak value

Both ends of weaving motion

Figure 1-9 Phase Difference

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Phasing differs as the Weave frequencies change. To get accurate tracking results,this time delay information must be registered in a controller parameter. Whensetting up for tracking, PC (phase compensation) tests are made for each of theweave frequencies that will be used while tracking.

NOTE: Once a weld is set-up for tracking, changes in the Weave frequency willcause the system not to track properly.

1.4.1 Measurement and Registration of Phase Compensation

After a job has been created to properly weld the example weld joint, a single weldis made to accumulate the Phase Compensation data.

NOTE: This test may not establish good data if only run a single time. Iftracking fails, run the test multiple times (up to 10 may be required) anduse either the Mean data or the Median number.

This weld will be made in the same location as the original but without the “top”plate.

Original Joint PC Test Joint

weave direction weave direction

Figure 1-10 PC Test Joint

This wide variation of ESO allows the controller to recognize the time delay, or thePhase Compensation required. This measurement will be in milliseconds.

To measure and register phase compensation value, set the parameter SxE197 to avalue of “1”. This setting instructs the controller to calculate the PhaseCompensation value.

To place the controller in the Measurement Mode, perform the followingkeystrokes:

1. Select the Job for measurement.2. Select PLAY.3. In the MENU area, choose UTILITY.4. Choose SETUP SPECIAL RUN.5. Cursor down to COMARC MEASURE MODE and press SELECT.

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SPECIAL PLAY

LOW SPEED STARTSPEED LIMITDRY-RUN SPEEDMACHINE ROCKCHECK-RUNWEAV PROHIBIT IN CHK-RUNCOMARC MEASURE MODE

INVALIDINVALIDINVALIDINVALIDINVALIDINVALID

VALID

Figure 1-11 Setup Special Run Screen

This should make the Measure Mode “VALID” and display a message on theMessage Line “COMARC MEASURE MODE”. Run the job.

1. From the MAIN MENU, choose JOB.2. In the sub menu, choose JOB.3. Execute the job (weld).

To display the results of the test, perform the following:1. Select the TEACH mode.2. On the Menu Line, choose UTILITY.3. Choose COMARC COND MODIFY.

The screen for the Phase Compensation will be displayed as shown in Figure 1-12.Note the parameter number and the Phase Comp value.

COMARC PHASE COMP

JOB NAME

PARAMETER NO.PHASE COMP

SENSOR SL 1

63286 msec

TEST

Figure 1-12 COMARC Phase Compensation Screen

To record the results of the PC test, perform the following:1. From the Main Menu, choose PARAMETER.2. Choose SxE.3. With the cursor on the Parameter numbers (left side) press SELECT, enter the

parameter number from the above test and press ENTER.4. Cursor to the Value side (right side), press Select, enter the value of the Phase

Comp and press ENTER.

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1.4.2 Measurement and Registration of Sensing Conditions

To get accuracy for the actual amperages used for the Up/Down and Left/Right(U/D and L/R) shifting , measurement of the nominal weld must be made.

Walldirection

Horizontaldirection

UP

RIGHT

LEFT

DOWN

Figure 1-13 Up/Down and Left/Right directions

This test is performed with both plates in position (i.e. a full fillet).

Original Joint Sensing Test Joint

weave direction weave direction

Figure 1-14 Sensing Test Joint

To perform this test, perform the following keystrokes:1. Cursor/Select to SxE 197 and reset this measurement parameter to “0”.

NOTE: Parameter SxE197 sequences the COMARC COND MODIFY screen.This will allow the display the Phase Comp display (value of 1) or theComArc Cond Modify display (value of 0).

2. Select the Job for measurement.3. Select PLAY.4. In the Menu Area, choose UTILITY.5. Choose SETUP SPECIAL RUN.

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6. Cursor down to COMARC MEASURE MODE and press SELECT.7. This should make the Measure Mode “VALID” and display a message on the

Message Line “COMARC MEASURE MODE”.

NOTE: This setting may be VALID from previous testing. Tracking can not beperformed when the Measurement Mode is ON (VALID).

SPECIAL PLAY

LOW SPEED STARTSPEED LIMITDRY-RUN SPEEDMACHINE ROCKCHECK-RUNWEAV PROHIBIT IN CHK-RUNCOMARC MEASURE MODE

INVALIDINVALIDINVALIDINVALIDINVALIDINVALID

VALID

Figure 1-15 Setup Special Run Screen

Run the job.1. From the Main Menu, choose JOB.2. From the Sub Menu, choose JOB.3. Execute the job (weld) with both plates in position.

To record the results of this test, perform the following:1. Select the TEACH mode.2. In the Menu Area, choose UTILITY.3. Choose COMARC COND MODIFY.

DOUTMOVEEND

IN/OUT

In Out

SYSTEM INFO

VARIABLE

B001

ROBOT

CF

FD/CF

EDIT

Short CutMain Menu

ARC WELDING

COMARC COND. MODIFYJOB NAME : TEST!!! SENSOR SL1 STEP CURRENT OFFSET-CURRENT

030405

239236238

0.00.00.0

DATA DISPLAY UTILITY

MODIFY COMARCCOND

PARAMETER

SETUP

Figure 1-16 COMARC COND MODIFY screen

This is the information that the COMARC function has “seen” as compared to theinformation initially programmed into the COMARCON instruction.

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To register this information into the COMARCON instruction in the job,perform the following keystrokes:

1. In the Menu Area, choose DATA.2. MODIFY COMARC COND will be the only “pull down”.3. Choose or SELECT to register the U/D and L/R information in the

COMARCON instruction in the job.U/D data is the actual amperage that the controller recorded as the Sensing Testwas performed. This should be close to the ARCON data if the Power SourceCondition File is set for Amperage. If the Power Source Condition File is set forWire Feed Speed, there will be no correlation between the ARCON and the U/Ddata.

L/R data is the difference between the Upper Leg amperage and the Lower Legamperage. Values other than 0 technically indicate that the weld is not equal leglength.

NOTE: Manually changing the U/D data will either increase or decrease the“stickout”. Changing the L/R data will create an offset fillet weld. Oneleg will be shorter than the other. If the weld is currently offset,modification of the L/R data can be used to force the equalization of thefillet legs.

To turn off all Measurement Modes:

1. Display the current job and put the system back in the PLAY mode.2. In the Menu Area, choose UTILITY.3. Choose SETUP SPECIAL RUN.4. Cursor to COMARC MEASURE MODE.5. Press SELECT to make this INVALID.

SPECIAL PLAY

LOW SPEED STARTSPEED LIMITDRY-RUN SPEEDMACHINE ROCKCHECK-RUNWEAV PROHIBIT IN CHK-RUNCOMARC MEASURE MODE

INVALIDINVALIDINVALIDINVALIDINVALIDINVALIDINVALID

Figure 1-17 Measurement Mode INVALID

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1.5 Testing COMARCAll information for COMARC Seam Tracking has now been collected andrecorded. Checking the COMARC function and current set-up is performed bywelding using the COMARCON/COMARCOF instructions with the part in thenominal position. A second weld is made with the part shifted horizontally at theARCOF end of the weld.

NOTE: By default, the COMARC correction values are between 100 and 150microns (.100mm to .150 mm) per weave cycle. If the controller cannotcorrect enough to follow the joint, the tracking may appear not to work.Changing the parameter for correction amount may allow the controllerto properly track the joint.

A third weld is made with the part shifted vertically at the ARCOF end of the weld.A fourth weld is made with the part shifted both horizontally and vertically at theARCOF end of the weld. More testing may be performed. If it is not feasible toshift the parts, the same scenario may be created by modifying the taught pointsaway from the part.

NOTE: Incorrect tracking of the offset part may indicate the need to perform theset-up tests again or correction of COMARC parameters.

The amount of correction applied by the COMARC function can be viewedby performing the following:1. From the Main Menu choose Arc Welding.2. Choose COMARC CORRECT.The following screen will be displayed.

IN/OUT

In Out

SYSTEM INFO

VARIABLE

B001

ROBOT

EDIT

Short CutMain Menu

ARC WELDING

CORRECTING LISTNO. OF STEPS : 3 STEP SENSOR : SL1 STEP VAR-U VAR-D V AR-L VAR-R

003004005

DATA DISPLAY UTILITY

PARAMETER

JOBDOUTMOVEEND CF

FD/CF

SETUP

0.00.00.0

0.00.00.0

0.00.00.0

0.00.00.0

Figure 1-18 COMARC Correcting List

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1.6 COMARC Condition FileAnother available tag on the COMARC instruction is the COMARC File. This tagis in addition to the Weave data, U/D data, and L/R data, all of which are required.The specification of the file will allow use or non-use of the U/D data, the L/R data,or the Pass Over feature.

COMARCCOND NO. : 1 / 16

CORRECTION SELECT<PASS OVER MONITOR>

CONDITIONVERTICAL MONITORHORIZONTAL MONITORNO.

U/D & L/R

ALARM 0.0 mm 0.0 mm 1 time(s)

Figure 1-19 COMARC File

1.6.1 U/D & L/R Correction Selection

There are 16 COMARC files that are able to be specified in any COMARCONinstruction. These are viewable through the use of the PAGE key, or through theDirect Open key from the job.

The first item in the file is the Correction Select. This can be selected as:

Table 1-1 COMARC Condition Correction Select

Setting Function

U/D & L/RCorrects the path in the Up, Down

and Left, Right directions

L/R

Corrects the path in the Left andRight directions only (Up and

Down directions are notcorrected).

U/D

Corrects the path in the Up andDown directions only (Left and

Right directions are notcorrected).

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1.6.2 Passover Function

The second item in the file is the Pass Over information. This information sets aboundary around the original taught path. If the TCP passes out of this boundary,the controller can be made to react in four (4) ways. These are:

ALARM An alarm occurs, and the manipulator stops.

TEACHING POSITION

Sensing stops, and the manipulator returns to the taught position and continues weld-ing.

CORRECTION RETAIN

The taught position just after the occurrence of pass-over. The manipulator restarts welding from a position adjusted for the amount of shift from the taught position just before the occurrence of the pass-over.

NOT MONITOR

The pass-over is not monitored.

Pass-overmonitor value

Pass-over occurred,and the manipulatorstops. Actual welding line

Taught line

= Taught position

Pass-over occurred

Sensing stops, and the manipulator returns to the taughtposition.

Restarts sensing from the taught position

Pass-overoccurred

Sensing restarts at a new, adjusted position.The distance between this new position and thetaught position is equal to the amount of shiftfrom the taught position just before the pass-over.

Amount of shift fromthe taught position

Taught position just beforethe occurrence of pass-over

Taught position just afterthe occurrence of pass-over

The Vertical Monitor sets the pass-over monitor value for the up/down directions.When set to 0.0, the up/down direction is not monitored. The range is 0.0 to 25.5.

The Horizontal Monitor sets the pass-over monitor value for the left/rightdirections. When set to 0.0, the left/right direction is not monitored. The range is0.0 to 25.5.

No. is the number of times the manipulator passes outside the vertical and/orhorizontal limits. The range is 1-10.

NOTE: The COMARC Condition File is optionally used for the seam trackingfunction.

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1.7 Dead Zone

Figure 1-20 Tee Joint with Tack

The Dead Zone sets the initial sensitivity for the correction. If minor currentfluctuations occur (i.e. a tack weld), a set amperage value can be registered for UP/DOWN or LEFT/RIGHT sensitivity. Variations within this range will be ignored.As the robot welds over tacks, the raised area of the tack weld causes a shorterElectrical Stick Out, which raises the current. If seam tracking this joint, the robotwould correct away from the tack, then once past it, track back into the joint. Thisoften causes small nuisance voids in the welds. With the use of Dead Zones, theseminor variations would be ignored and no corrections would take place.Adjustment of the Dead Zone is found in the SxE parameter list.

1.8 COMARCSETCOMARCSET is an instruction that will change the COMARC function. Thisallows the changing of the weave data, the weave file, the U/D data, the L/R data,and/or the COMARC file #. This instruction is programmed between theCOMARCON and the COMARCOF instructions. The controller will start usingthe new data at the point of the instruction.

1.9 SCOMARCSCOMARC is the tracking function/Instruction that is used with systems usingCoordinated Motion. As the controller is coordinating motion between a robot anda positioner (normally), it must also coordinate the COMARC tracking. The set-upis performed the same as in the previous section. The Instruction is available in theInform List, when applicable.

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SxE Parameters

Parameter No.

Contents UnitInitial Value

Setting Range

0 Application designation - - -

1~19 Not used - - -

20Analog signal input channel

-SL1: 1SL2: 2SL3: 1

1 to 8

21Compensation value for conversion of an AD value to a current value

[%] 100 0 to 100

22Number of times that correction was prohibited at COMARCON

- 4 0 to 10000

23Number of times that correction was prohibited at MIN: correction prohib-ited current

- 0 -

24Correction prohibited minimum cur-rent

[0.1A] 500 0 to 10000

25Correction prohibited maximum cur-rent

[0.1A] 10000 0 to 10000

26 Not used - - -

27 Dead zone U/D [0.1A] 50 0 to 10000

28 Dead zone L/R [0.1A] 50 0 to 10000

29 Not used - - -

30Correction amount Y+(Weaving frequency less than 2.0 [Hz])

[µm] 150 0 to 10000

31Correction amount Y-(Weaving frequency less than 2.0 [Hz])

[µm] 150 0 to 10000

32Correction amount Z+(Weaving frequency less than 2.0 [Hz])

[µm] 150 0 to 10000

33Correction amount Z-(Weaving frequency less than 2.0 [Hz])

[µm] 150 0 to 10000

34Correction amount Y+(Weaving frequency 2.0 [Hz] or more, less than 3.0 [Hz])

[µm] 150 0 to 10000

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35Correction amount Y-(Weaving frequency 2.0 [Hz] or more, less than 3.0 [Hz])

[µm] 150 0 to 10000

36Correction amount Z+(Weaving frequency 2.0 [Hz] or more, less than 3.0 [Hz])

[µm] 150 0 to 10000

37Correction amount Z-(Weaving frequency 2.0 [Hz] or more, less than 3.0 [Hz])

[µm] 150 0 to 10000

38Correction amount Y+(Weaving frequency 3.0 [Hz] or more, less than 4.0 [Hz])

[µm] 100 0 to 10000

39Correction amount Y-(Weaving frequency 3.0 [Hz] or more, less than 4.0 [Hz])

[µm] 100 0 to 10000

40Correction amount Z+(Weaving frequency 3.0 [Hz] or more, less than 4.0 [Hz])

[µm] 100 0 to 10000

41Correction amount Z-(Weaving frequency 3.0 [Hz] or more, less than 4.0 [Hz])

[µm] 100 0 to 10000

42Correction amount Y+(Weaving frequency 4.0 [Hz] or more)

[µm] 100 0 to 10000

43Correction amount Y-(Weaving frequency 4.0 [Hz] or more)

[µm] 100 0 to 10000

44Correction amount Z+(Weaving frequency 4.0 [Hz] or more)

[µm] 100 0 to 10000

45Correction amount Z-(Weaving frequency 4.0 [Hz] or more)

[µm] 100 0 to 10000

46~49 Not used - - -

50 Sampling interval [msec] 2 1 to 10

51~59 Not used - - -

60~179 Phase compensation value [msec] - -

180~196 Not used - - -

197Measurement mode (1: Phase com-pensation value measurement)

- 0 0,1

198,199 Not used - - -

SxE Parameters

Parameter No.

Contents UnitInitial Value

Setting Range

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NOTES

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2.0 SEAMFINDING/ TOUCHSENSING

Touch Sensing for seam finding is based on the controller recognizing where therobot TCP is located when a circuit has been completed. A comparison is donebetween the TCPs current position and the location of a previously taughtReference Point. Offset data is calculated and then applied as a temporary Shift tothe programmed path.

2.1 POSITION VARIABLESThe NX controller has 128 Position Variable addresses, #P000-P127, that can beused for storing position and shift data.

2.1.1 Access to Position Variable Display

To access the Position Variable display, complete the following steps:1. From MAIN MENU; choose VARIABLE.2. Choose POSITION (ROBOT).3. Touch “PAGE” on the Position Variable display screen, enter the desired

address number, then press ENTER.or

Use the PAGE key to go to the next address; use SHIFT + PAGE keys to goto previous address.

orChoose EDIT, choose SEARCH, enter desired address number, then pressENTER.

DATA EDIT DISPLAY UTILITY

Main Menu ShortCut !Turn on servo power

POSITION VARIABLE

NAME: TOOL: **

#P000 :S L U R B T

*************

Figure 2-1 Position Variable (default, [*******] data type)

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2.1.2 Establishing Data Type

To delete data and/or change the data type of the displayed variable address,complete the following steps:

Cursor to highlight the existing data type; press SELECT. Cursor to YES forthe “CLEAR DATA?” question; press SELECT.

orChoose DATA; Choose CLEAR DATA; press SELECT.

NOTE: The desired data type (PULSE, ROBOT, BASE, USER, or TOOL) mustbe established for each address to be used.

DATA EDIT DISPLAY UTILITY

Main Menu ShortCut !Turn on servo power

POSITION VARIABLE

NAME: TOOL: 00

#P000 :S L U R B T

PULSE0000

-8000027000

DATA EDIT DISPLAY UTILITY

Main Menu ShortCut !Turn on servo power

POSITION VARIABLE

NAME: TOOL: 00

<TYPE> FRONT S<180 UP R<180 FLIP T<180

#P000 R1:X Y Z Rx Ry Rz

ROBOT330.000

0.000-10.000

0.000.000.00

DIRECT PAGE

Figure 2-2 Position Variable formats

Typically, Position Variables set as Pulse Type are used when the robot is to moveto that position. Position Variables set as XYZ type are used for offset data.

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2.2 Programming Motion with Position Variables

To program a motion step into a job using a previously stored positionvariable location, complete the following steps:1. Display the job in TEACH with the cursor on the address side.2. Press the INFORM LIST key, choose MOTION.3. Choose the motion type desired (MOVJ, MOVL, MOVC, or MOVS).4. Cursor onto the existing address on the edit buffer line; press SELECT.5. Enter the desired Position Variable address (0-127); press ENTER.6. Place the cursor on existing velocity for V or VJ; press SELECT.7. Enter the desired Control_point_speed= or Joint_speed=; press ENTER.8. Press ENTER to put the entire MOV_ instruction into the job.

NOTE: If no speed is desired, cursor to the MOV_ and press SELECT. Choosethe V or VJ area of DETAIL EDIT and select UNUSED.

Job Example:

LINE INSTRUCTION0001 MOVJ P000 VJ=25.000002 MOVJ VJ=100.000003 MOVL P018 V=760004 MOVL P126 V=220 PL=0

NOTE: Editing of Position Variables, whether with servo power or number key,can only be performed from the Position Variable screen. Modificationof position variables cannot be done from the Job Content screen.

2.3 Position Variable Functions

2.3.1 CNVRT

The CNVRT instruction converts a Position variable from Pulse or any XYZ Frameto only an XYZ type ( BF, RF, UF, or TF). The converted data may be stored inthe same address or another designated Position variable address.

Examples:

CNVRT PX003 PX003 RF (Converts data of P003 into RF type)

CNVRT LPX004 LPX005 UF#(24) (Converts data of LP005 into UF type inLP004)

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CNVRT PX[B006] PX000 BF (Converts data of P000 into BF type in P

address determined by B006)

CNVRT LPX[I007] LPX[B009] TF (Converts data of LP addressdetermined byB009 into TF type and stores in LP address

determined by I007)

stores status results in B000)

2.3.2 GETE

GET ELEMENT gets the single designated element of a Position variable andstores the value in a D-variable address. In PULSE data the elements 1-6correspond to SLURBT; for XYZ data type the elements 1-6 correspond to X, Y,Z, RX, RY, & RZ respectively.

DATA EDIT DISPLAY UTILITY

Main Menu ShortCut !Turn on servo power

POSITION VARIABLE

NAME: TOOL: 00

#P001 :S L U R B T

PULSE12956

2000

4591427

DATA EDIT DISPLAY UTILITY

Main Menu ShortCut !Turn on servo power

POSITION VARIABLE

NAME: TOOL: 00

<TYPE> FRONT S<180 UP R<180 FLIP T<180

#P000 R1:X Y Z Rx Ry Rz

ROBOT330.000

0.000-10.000

0.000.000.00

DIRECT PAGE

1st2nd3rd4th5th6th

Figure 12-1 Position Variable Elements

NOTE: The X, Y, & Z elements are stored as thousandths of a millimeter(microns), and the Rx, Ry, & Rz elements are stored as hundredths of adegree.

Examples:

GETE D099 P007 (3) (Gets third element of P007 and stores value inD099)

GETE LD000 P[I005] (B099) (Gets element, determined by B099, of Paddress, determined by I005,and store value in LD000)

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2.3.3 SETE

SET ELEMENT sets the designated element in a Position variable equal to aconstant or a value stored in a D-variable address.

Examples:

SETE P007 (1) 500000 (Sets constant into first element ofP007)

SETE P007 (5) -4500 (Sets constant into fifth element ofP007)

SETE LP005 (B002) LD[B002] (Sets data from LD address determinedby B002 into LP005’s element alsodetermined by B002)

2.3.4 GETS

GET THE SYSTEM VARIABLE has the controller find the status of theidentified System Variable and store the result. This may be the result of a touch, orthe location of a Reference Point.

2.3.5 Reference Points

Reference Points are taught positions. The controller does NOT move the robot tothese positions, rather uses the locations for reference information. This may be theorientation of a part for a Weave instruction, or the nominal location of a part forTouch Sensing.

To program a Reference Point, perform the following:

1. Jog the robot to the location desired.2. With the cursor on the Address Side, press the number 0 key to bring REFPT

into the buffer line.3. Cursor to the Reference Point number and press SELECT.4. Enter the desired Reference Point number, press ENTER to enter it into the

buffer line, and INSERT and ENTER to enter it into the job.

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2.4 SYSTEM VARIABLES ($)System variables are storage locations of information that the controller “sees”. Asindicated below, this could be things such as the robot’s current position (both inPulse and XYZ), the status of a “touch” or search, or the position of ReferencePoints.

There are 6 types of System Variables used with the XRC. All are designated bythe “$” symbol. The four ARITHMETIC types $B, $I, $D, & $R, and theCONTROL GROUP AXES POSITION type $PX, are “fetched” using the GETSArithmetic Function and stored in the corresponding User type. The $C-type isused only in Concurrent I/O programming. Each System Variable address isdedicated for a specific use. Some samples for dedicated use are included intable 4-1:

Table 2-1 System Variables

SELBAIRAVMETSYS EPYTRESU ESUDETACIDED

epyt-B$ epyt-BnoitcurtsniHCRSrofedocnruteR=200B$noitcurtsniNESHrofedocnruteR=600B$

noitcurtsniTRATSYSrofedocnruteR=800B$

epyt-XP$epyt-XP

)epyt-PfospuorG(

noitisophtapdetalopretnitnerruC=000XP$rometsys1RrofESLUPniatad

metsys2R+1Rfoevals

noitisophtapdetalopretnitnerruC=100XP$noitisophtapdetalopretniro1Rrof)FB(ZYXni

2R+1RforetsamrofESLUPniatad

noitisopESLUPKCABDEEFlautcA=200XP$metsys2R+1Rfoevalsrometsys1Rrofatad

)FB(ZYXKCABDEEFlautcA=300XP$ESLUPKCABDEEFlautcaro1Rrofnoitisop

.2R+1Rforetsamrof

esluP1PFER=110XP$esluP2PFER=210XP$esluP3PFER=310XP$esluP4PFER=410XP$esluP5PFER=510XP$esluP6PFER=610XP$esluP7PFER=710XP$esluP8PFER=810XP$esluP1PFERS=120XP$esluP2PFERS=220XP$esluP3PFERS=320XP$esluP4PFERS=420XP$esluP5PFERS=520XP$esluP6PFERS=620XP$esluP7PFERS=720XP$esluP8PFERS=820XP$

epyt-C$ ylnoO/I.C REMIT510C$-000C$ )7206#-0106#dnarepO((RETNUOC130C$-610C$ )7406#-0306#dnarepO

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2.5 Temporary Shift Instruction (SFTON/SFTOF)The Shift Function provides the ability to transfer (shift) a single or group ofprogrammed positions by a specified distance and orientation. It uses positionvariables for offsets in the X, Y, Z, RX, RY, and RZ directions. The shift value is thedifference of X, Y, or Z in the specified coordinate system between the programmedposition, the shifted position, and the tool displacement of degrees RX, RY, and RZ.Shifts may also be performed using PULSE data type position variables.

By using the Shift Function, a minimal number of robot positions are programmed inorder to provide execution at multiple locations. This simplifies and reduces thetime required to teach a job. This function is extremely useful for palletizing,stacking, loading/unloading, and other applications that perform repeated functionsat multiple locations.

The Shift Function is activated by programming a SFTON (shift on) instruction andspecifying a position variable and relative coordinate frame tag. If no coordinateframe is specified, then it is defaulted to the Base Frame upon execution of thatprogram line.

NOTE: The shift data in the position variable may be set up in advance bymanual editing, by using the CNVRT instruction, or it may be calculatedusing the MSHIFT instruction.

When the SFTON is executed, programmed positions are shifted by the dataindicated in the specified position variable. The Shift Function will affect servorecorded Command Positions and motion programmed with position variables. Ifa CALL JOB or JUMP JOB instruction is executed during SFTON section of ajob, the positions is these child jobs will also be shifted. The SFTON instructionremains active until the SFTOF instruction is executed.

In the job example the motions in Lines 0013, 0014, and 0015 will be shifted duringcontinuous operation in Play mode or with INTERLOCK + TEST START inTeach.

LINE INSTRUCTION

0011 MOVJ VJ=25.000012 SFTON P127 UF#(5)0013 MOVJ P000 VJ=100.000014 MOVL V=12500015 MOVL V=12500016 SFTOF0017 MOVJ VJ=100.00

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To program the SFTON instruction, complete the following steps:

1. Display the job in Teach mode with the cursor on the Address side.2. Press the INFORM LIST key and choose SHIFT.3. Choose SFTON.4. Press SELECT with the cursor on SFTON at the Edit Buffer line to access the

DETAIL EDIT screen.5. Cursor to the existing P-VAR ROBOT address, press SELECT, enter the

desired address number; press ENTER.When entered as SFTON PXXX, the shift will be in the Base Frame regardless ofthe coordinate set in the Position variable.

If a different coordinate/Frame is desired:

1. With the cursor on the SFTON in the Edit Buffer Line, press SELECT toaccess the Detail Edit Screen.

2. Cursor to the COORDINATE “UNUSED” and press SELECT.3. Cursor to BF, RF, TF, or UNUSED; press SELECT.

orSelect UF#( ), enter the desired number; press ENTER.

4. Press ENTER to exit the DETAIL EDIT screen.5. Press ENTER.

To program the SFTOF instruction, complete the following steps:

1. Display the job in Teach mode with the cursor on the Address side.2. Press the INFORM LIST key, choose SHIFT.3. Choose SFTOF.4. Press ENTER.

NOTE: The current shift value in the position variable may be monitored whenactive by displaying the SHIFT VALUE screen under the ROBOT iconmenu.

The results of multiple SFTON instructions is not cumulative. Using a secondSFTON with a different Position variable reference simply “changes to” thespecified variable. SFTOF is not required to change from one set of shift data toanother.

CAUTION! If the cursor is placed on a motion step between the SFTON andSFTOF instructions and the TEST/START or the FWD key is used,the NX100 will move the robot to the command position guidingthe TCP for the TOOL No. of the originally recorded step!

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2.6 Touch jobsTouch jobs are frequently provided by Motoman. These provided jobs aredesigned for specific situations. TOUCH1 (or R1-TCH-1) is designed to find boththe vertical and horizontal plates of a fillet weld. There are jobs designed for lapjoints, single direction touches, end search, and corner search. When the logic isunderstood in the provided jobs, development of joint specific jobs can easily bedone.

2.6.1 Reference Point Location

Reference Points are programmed in the weld job. Typical job structure would be:

Placement of Reference Points is critical. These taught locations provide a normalplate location for the offset calculations.

Ref Pt 3

Ref Pt 5

Ref Pt 4

Figure 5-1 Location of Reference Points for Touch 1 Job

2.6.2 Touch Jobs

The Touch job is used as a subroutine.NOPMOVJ VJ=100.00MOVJ VJ=100.00MOVJ VJ=100.00REFP 3REFP 4REFP 5CALL JOB:R1-TCH-1SFTON P001MOVJ VJ=25.00ARCON ASF#(1)

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The contents of a typical Touch job appear as:

NOP'********************************'THIS JOB USES GLOBAL P001 ONLY *'YOUR OFFSET AMOUNT WILL BE *'STORED IN P001 *'********************************GETS LPX001 $PX013GETS LPX002 $PX014GETS LPX003 $PX015'REF POINTS 3 4 5'********************************CNVRT LPX004 LPX001 BFCNVRT LPX005 LPX002 BFCNVRT LPX006 LPX003 BF'CONVERT REF 3 4 5 TO BASE FRAME'********************************MOVL LP001 V=12.5'MOVE TO REF P 3MOVL LP002 V=12.5 SRCH RIN#(1)=ON T=0.10 DIS=25.0'SEARCH TOWARD REF P 4'********************************GETS LB000 $B002'SEARCH DETECTION'********************************JUMP *NG IF LB000=0'TOUCH FAILED IF LB000=0'********************************GETS LPX007 $PX002'GETTING 1ST DETECTION POINT'********************************CNVRT LPX008 LPX007 BFSUB LP008 LP005'CALCULATING 1ST SHIFT AMOUNT'********************************MOVL LP001 V=12.5'MOVE TO REF P 3MOVL LP003 V=12.5 SRCH RIN#(1)=ON T=0.10 DIS=25.0'SEARCH TOWARD REF P 5

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'********************************GETS LB000 $B002'SEARCH DETECTIONJUMP *NG IF LB000=0'TOUCH FAILED IF LB000=0'********************************GETS LPX009 $PX002'GETTING 2ND DETECTION POINT'********************************CNVRT LPX010 LPX009 BFSUB LP010 LP006'CALCULATING 2ND SHIFT AMOUNT'********************************ADD LP008 LP010SET P001 LP008'SETTING GLOBAL SHIFT VARIABLE'********************************SETE P001 (4) 0SETE P001 (5) 0SETE P001 (6) 0'CLEARING ROLLABOUT DATA'********************************MOVL LP001 V=12.5RET*NGSUB P001 P001'RESETTING GLOBAL SHIFT VARIABLEPAUSE'TOUCH FAILED'********************************MOVL LP001 V=12.5END

Final offset amounts are stored in P001 and are used in the parent job as thePosition Variable for the SFTON instruction. If P001 is being used for otherpurposes, or if there are multiple touch routines being performed, use the SETinstruction in the Parent Job to transfer the offset information to another PositionVariable.

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NOTES