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ABB Flexible Automation

ProcessWare

SpotWare Plus On-line

ABB Robotics Products AB DPT / MT S-72168 VÄSTERÅS SWEDEN Telephone: (0) 21 344000 Telefax: (0) 21 132592

• Spot Welding Summary................................................................................................... Page
  • Spot welding features
  • Principles of SpotWarePlus
  • Programming principles
  • Spot welding instructions
  • Spot welding data
• Programming SpotWare..................................................................................................
  • Programming Spotwelding
  • Defining gun closing times.........................................................................................
  • Tip dressing
  • Customising the spotweld instruction.........................................................................
  • Task overview.............................................................................................................
• SpotWarePlus
  • IO configuration
  • Basic setup..................................................................................................................
• SpotML - Spot Welding with multiple guns
  • Arguments
  • Customising
  • Program execution......................................................................................................
  • Program stop and restart
  • Instruction by instruction execution
  • Simulated welding
  • Error handling.............................................................................................................
  • Communication
  • Power failure handling................................................................................................
  • Syntax
  • Related information
• spotmdata - Spot weld data
  • Description
  • Components
  • Structure......................................................................................................................
  • Related information
• gunmdata - Spot weld gun data
  • Description
  • Components
  • Structure......................................................................................................................
  • .Related information
• System Module - SWUSRC............................................................................................. SpotWare Plus
• System Module - SWUSRF
• System Module - SWTOL
• Index..................................................................................................................................

SpotWare Plus spot welding

Spot Welding Summary

The SpotWarePlus package provides support for synchronous welding and full individual monitoring of up to four separate gun equipments.

The SpotWarePlus application provides fast and accurate positioning combined with gun manipulation, process start and supervision of the different gun equipments.

Communication with the welding equipment is carried out by means of digital inputs and outputs.

It should be noted that SpotWarePlus is a package that can be extensively customised. It is intended that the user adapts some user data and routines to suit the environmental situation.

Spot welding features

The SpotWarePlus package contains the following features:

• Fast and accurate positioning
• Handling of up to four on/off guns with two strokes
• Dual/single guns
• Gun pre-closing
• User-defined supervision of the surrounding equipment before weld start
• User-defined supervision of the surrounding equipment after the weld
• User-defined open/close gun and gun supervision
• User-defined pressure setting
• User-defined preclose time calculation
• Monitoring of the external weld timer
• Weld error recovery with automatic rewelding
• Spot counters
• Time or signal dependent motion release after a weld
• Quick start after a weld
• User-defined service routines
• Presetting and checking of gun pressure
• Simulated welding
• Reverse execution with gun control
• Parallel weld timer interface
• Supports both program and start-trigged weld timers.
• SpotML current data information

SpotWare Plus spot welding

Programming principles

Both the robot’s linear movement and control of up to four spot weld processes are embedded in one instruction, SpotML.

Each spot welding process is specified by:

• Spotmdata: spot weld process data
• Gunmdata: spot weld gun data
• The system modules SWUSRF and SWUSRC: RAPID routines and global data for customising purposes. See Predefined Data and Programs ProcessWare.
• System parameters: the I/O configuration. See User’s Guide - System Parame- ters

Spot welding instructions

Instruction Used to: SpotML Control the motion, gun closure/opening and the welding proc- esses. Move the TCP along a linear path and perform a spot welding with up to four gun equipments at the end position.

Spot welding data

Data type Used to define: spotmdata The spot weld process control gunmdata The spot weld gun

spot welding SpotWare Plus

Programming SpotWare SpotWare Plus

Programming spotweld instructions

• Jog the robot to the desired destination position.
• Call up the instruction pick list by choosing IPL1: Motion&Process.
• Select the instruction SpotML.

The instruction will be added directly to the program. The arguments are set in relation to the last spotweld instruction. (See Figur 1).

Figur 1 A spotweld instruction is added directly to the program.

• Change the arguments if necessary.

Testing spotweld instructions

To prevent the spotweld process executing during programming, it is possible to run SpotML in simulation mode.

This can be done by setting sw_inhib_weld TRUE. This will set the output current_enable low and the simulation will be carried out by the weld timer.

If such a signal is not connected the spotweld can be internally inhibited by setting sw_sim_weld TRUE. The simulated weld time is then stored in sw_sim_time. In this simulation mode the start signal is never sent to the welding timer.

Note. The guns will be opened and closed in the normal way.

Running spotweld instructions

In continuous mode the spotweld instructions are by default running in concurrent exe- cution, i.e. the program execution is continuing while welding is in progress, and it will not stop until the next motion instruction.

Therefore if the running is stopped during welding, the program pointer is normally moved to the next SpotML or motion instruction. It is important to remember this fact when modifying SpotML positions with ModPos.

To avoid problems it is recommended to execute the program in step-by-step mode when positions are modified. In this mode the program pointer corresponds to the robot position. If a strictly sequential execution is also desired in continuous mode the

SpotML p60,vmax\G1:=spot1,tool1;

Program Instr

File Edit View IPL1 IPL

Copy Paste IPLhide (ModPos) Test

WELDPIPE/main Motion&Proc 1(1 ) 1 ActUnit 2 DeactUnit 3 MoveC 4 MoveJ 5 MoveL 6 SearchC 7 SearchL 8 SpotML

SpotWare Plus Programming SpotWare

NoConc argument must be set in the instruction.

Defining gun closing times

The SpotML instruction has a built-in pre-closing of the weld guns, i.e. when approach- ing the position the guns will start to close in advance, in order to save time. The pre_closing relates to closing the guns from the work stroke. Closing the retract stroke should be handled in the user program by a fly-by position or by using the CRetract argument in the instruction.

The gun closing times are defined in the gunmdata array sw_gun{4) in SWUSRC. For each gun equipment it is possible to define one closing time for each gun pressure (max. 4).

The pressure to use in the current SpotML instruction is stored in the spotmdata for the current instruction. It will also pick the accurate closing time.

Note. The pre-closing can be disabled by choosing the \InPos argument in the instruc- tion or by setting sw_inpos TRUE in SWURSF (global disabling).

Defining the closing time manually

• Set SpotML in simulation mode (see above)
• First, make a rough guess and define it in the gunmdata for gun equipment 1.
• Set up the desired pressure in the spotmdata for gun equipment 1
• Run SpotmL forward step-by-step and check the closing. The gun should be just about closed when the robot stops in the position.
• If the result is not OK, execute SpotML backwards.
• Adjust the corresponding closing time.
• Repeat the test until the result is OK.
• Repeat the whole sequence for different pressures and gun equipments until all clos- ing times are defined for all the gun equipments used.

Defining the closing time automatically

It is possible to measure and store the closing times using a RAPID program.

Tip dressing

The gunmdata contains counters for each pair of tips. The counters will be incremented for each spot.

SpotWare Plus Programming SpotWare

Task overview

Task 0 is normally the Main task. Task 1 is always used for process 1. All other tasks will be given the next available task number.

Data trans- fer

MOTION

close_time

sw_event

sw_event2_time

sw_event3_time

sw_start

Reset Start

sw_open_gun sw_check_open

START SIGNAL

READY SIGNAL

Cleanup Release MOC

Hold MOC Set Start

PROCESS CYCLE

Kernel actions

User hooks

sw_close_gun sw_check_close

sw_set_pressure sw_preweld_sup

sw_event

EXTERNAL PROCESS CYCLE

Set progno

sw_postweld_sup

Programming SpotWare SpotWare Plus

Program memory: task 0 (Main) Program

System module SWUSRC

Main module

Main routine

Program data

System modules Data

Routines

Routines

System module SWUSRF

Data

Routines

Program memory: task 1 (Process 1) System module SWUSRC

Data

Routines

Program memory: task 2..5 (Supervision, Process 2..4) System module SWUSRC

Data

Routines

spot welding:system parameters SpotWare Plus

Start and monitoring of the weld

Weld program number

N.B. Signals in the same group must be connected to physical signals in sequence on the same board.

Gun control

Pressure setting and supervision

The SpotWarePlus can set and supervise up to four discrete pressure levels. The pres- sure values are selected in spotmdata.The number of possible pressure levels is defined for each gun by max_pressure in gunmdata. The corresponding output signals g1_ p2_req to g1_p4_req must be defined as consecutive physical outputs. When only one pressure level exists, no pressure request signals need to be connected.

When supervision of the ordered pressure value is required before welding is allowed to start ( close_request = TRUE in gunmdata for gun equipment 1), this is done on one of the input signals g1_p1_ok to g1_p4_ok depending on the selected pressure value in corresponding spotmdata.

g1_start1 output 7 Start signal to the weld timer (Tip1 if a dual gun is used) g1_weld_ready1 input 7 Ready signal from the weld timer (Tip1 if a dual gun is used)

g1_prog_no_group output 11-16 Weld program number g1_prog_parity output 10 Weld program number parity bit

g1_close_tip1 output 5 Close gun signal. (Tip 1, if a dual gun is used). g1_work_select output 6 Work stroke select. Default functionality: The signal is set according to the Retract and CRetract argument in the instruction if the gun is activated in the instruction.

g1_press_group output 2-4 g1_p2_req-g1_p4_req

nof_plevels output output group

1 none pressure group (simulated outputs) 2 g1_p2_req pressure group (g1_p2_req) 3 g1_p3_req pressure group (g1_p2_req, g1_p3_req) 4 g1_p4_req pressure group (g1_p2_req, g1_p3_req, g1_p4_req)

SpotWare Plus spot welding:system parameters

Gun opening supervision

If open_request = TRUE in gunmdata, a check is made whether or not the gun is open before a motion is released.

Double gun

If a double gun is used it must be selected in gundata by nof_tips = 2. Tip_no in spot- data chooses the tip (tip_no = 12 or 21 closes both tips together).

Process state

The following signals give the information about the state of the SpotWare process:

g1_proc_run sim outputProcess is executing

g1_weld_error sim outputSet when a weld ready timeout has occurred. Reset when re-welding was successful or after skipping the current weld.

g1_tip1_open input 5 The gun (tip 1 if a dual gun is used) is open enough to release the robot motion.

g1_start2 sim output Start signal to the weld timer g1_weld_ready2 sim input Ready signal from the weld timer g1_close_tip2 sim output Close gun request, tip 2 g1_tip2_open sim input Tip 2 is open enough to release the robot motion.

SpotWare Plus SpotML

SpotML Spot Welding with multiple guns

SpotML is used in spotwelding to control the motion, gun closure/opening and the welding processes. The instruction can be used both for single gun and multiple gun applications. SpotML moves the TCP linearly to the weld position and then activates 1-4 gun equipments.

Example

SpotML p100, vmax\G1:= spot10\G2:= spot20, tool7;

This is the only instruction needed to implement a complete welding operation with two gun equipments.

The TCP for tool7 is moved on a linear path to the position p100 with the speed given in vmax. The weld position is always a stop position since the welding is always performed while the robot is standing still. The guns are closed in advance when the robot is moved. The weld processes are started and supervised until finished and the guns are reopened.

Note. The program continues to execute after the weld has started and is not blocked until the next order that contains a robot motion. This may be inhibited by the switch \NoConc (see below).

G1 and G2 tell that gun equipment 1 and gun equipment 2 are activated in posi- tion p100.

Spotmdata spot10 contains parameters for the welding with gun equipment 1 e.g. desired program number and pressure. Spotmdata spot20 contains parameters for the welding with gun equipment 2.

All gun equipments used are defined in the gunmdata array sw_gun{4} in SWUSRC.

Arguments

SpotML ToPoint Speed [\G1] [\G2] [\G3] [\G4] [\InPos] [\NoConc]

[\Retract] [\CRetract] Tool [\WObj]

ToPoint Data type: robtarget

The destination point of the robot and external axes. It is defined as a named position or stored directly in the instruction (marked with an * in the instruction).

Speed Data type: speeddata

The speed data that applies to movements. Speed data defines the velocity for the tool centre point, the tool reorientation and external axes.

SpotML SpotWare Plus

[G1] - [G4] Data type: spotmdata

Spot data that is associated with the weld gun equipment 1 - 4.

[\InPos ] Data type: switch

The optional argument \InPos inhibits the preclosing of the guns. The guns are closed first when the robot has reached the end position. This argument will increase the execution time but is useful in narrow situations.

[\NoConc] Data type: switch

The optional argument \NoConc prevents the program from continuing the exe- cution until the actual weld is finished. It is normally used when the next instruc- tion is a logical instruction.

[\Retract ] Data type: switch

The optional argument \Retract will make all activated guns open to their large gap (retract) after the weld. If the argument is omitted the guns open to their small gap (work). If the instruction is executed backwards the guns open to retract stroke before the motion.

[\CRetract] Data type: switch

The optional argument \CRetract will set all activated guns to work stroke before closing the guns. If the instruction is executed backwards the guns open to retract stroke after the motion.

Tool Data type: tooldata

The tool in use when the robot moves. The tool centre point is the point moved to the specified destination position, and should be the position for one of the electrode pairs when the gun is closed.

[\WObj] Data type: wobjdata

The work object (coordinate system) to which the robot position in the instruction is related.

This argument can be omitted, and if it is, the position is related to the world coor- dinate system. If, on the other hand, a stationary TCP or coordinated external axes are used, this argument must be specified in order to perform a linear move- ment relative to the work object.