ServogunSetupUsersManual v1.0

GMNA Controls, Conveyors, Robotics & Welding

Servo Gun Setup Manual Fanuc SpotTool+ 7.20 with GRS4 Customization

October 10, 2007

Rev 1.0

DOCUMENT MANAGEMENT INFORMATION

Authors:

Andrew Buckland: General Motors CCRW Chad Lare: Extreme Automation Prateek Mishra: General Motors CCRW Lloyd Steed: Fanuc Robotics N.A. Rob Totten: General Motors CCRW

Sponsoring group:

General Motors -Controls, Conveyors, Robotics and Welding, CCRW

Forward questions, comments and/or revisions to:

General Motors Corporation Controls, Conveyors, Robotics & Welding 30300 Mound Road 109 Mail Code 480-109-266 Warren, MI 48090 Attn: Prateek Mishra Phone #: (810) 602-8295

Document revisions:

Date Revision By Revision History 10-Oct-07 1.0 PM Clarifications and corrections and remove Draft.

Remove section on Tip Dress. Refer tip dress manual.

7-Dec-06 0.14 RLT First Draft 10-31-2005 0.10 RLT Start of Rework to convert SpotTool+ 6.40 Manual

to SpotTool+ 7.20

Servogun Setup Users Manual for Fanuc SpotTool+ 7.20 with GRS4 Customization

i General Motors Corporation. All Rights Reserved.

-UNCONTROLLED WHEN PRINTED-

TABLE OF CONTENTS

Section Description Page

1. GENERAL ............................................................................................................................................ 1 1.1 SCOPE.............................................................................................................................................. 1 1.2 PURPOSE.......................................................................................................................................... 1 1.3 INTENDED AUDIENCE....................................................................................................................... 1 1.4 BACKGROUND ................................................................................................................................. 1 1.5 SETUP FLOW.................................................................................................................................... 2

2. GUN INSTALLATION........................................................................................................................ 3 2.1 GUN MOUNTING.............................................................................................................................. 3

3. WIZARD SETUP ................................................................................................................................. 4 3.1 GETTING STARTED .......................................................................................................................... 4 3.2 EXAMPLE: SINGLE CARRIED SERVO GUN........................................................................................ 4 3.3 HELPS AND HINTS ........................................................................................................................... 6

3.3.1 Re-Running the wizard to correct for an incorrect response during initial setup .................. 6 3.3.2 Re-Running the wizard to add a feature ................................................................................. 6

4. ESTABLISHING PULSE ON SERVO GUN MOTORS .................................................................. 7 4.1 RESETTING BZAL (BATTERY ZERO ALARM) .................................................................................. 7 4.2 ESTABLISHING PULSE...................................................................................................................... 7

4.2.1 GSWA and SW-Series Motors................................................................................................. 7 4.2.2 HT-Series Motor ..................................................................................................................... 7

5. MASTERING THE GUN .................................................................................................................... 8 5.1 SETTING GUN CLOSE DIRECTION .................................................................................................... 8 5.2 MASTERING THE GUN AND SETTING AXIS LIMITS........................................................................... 9

5.2.1 Single Gun per Equipment...................................................................................................... 9 5.2.2 Dual Guns on One Equipment (Typically Dual Carried or Dual Pedestal) ......................... 11

5.3 AUTOTUNING ................................................................................................................................ 13 5.3.1 Running................................................................................................................................. 13 5.3.2 Help and Hints...................................................................................................................... 15

6. PRESSURE CALIBRATION............................................................................................................ 17 6.1 EQUIPMENT ................................................................................................................................... 17 6.2 PERFORMING CALIBRATION .......................................................................................................... 17 6.3 HELP AND HINTS ........................................................................................................................... 21

7. THICKNESS CHECK CALIBRATION.......................................................................................... 22 8. TIP WEAR COMPENSATION ........................................................................................................ 24

8.1 SETUP............................................................................................................................................ 24 8.1.1 Enabling Tip Wear Compensation........................................................................................ 24 8.1.2 Running Tip Wear Compensation Setup Program(s) ........................................................... 26 8.1.3 Wear Ratios .......................................................................................................................... 26

8.2 VIEWING TIP WEAR VALUES ......................................................................................................... 26 8.3 TIP WEAR UPDATING .................................................................................................................... 28

8.3.1 Tip Wear Routines ................................................................................................................ 28 9. SET GUN CLOSE DIRECTION ...................................................................................................... 29

9.1 CARRIED +Z ................................................................................................................................. 29


ii General Motors Corporation. All Rights Reserved.


9.1.1 Single Gun ............................................................................................................................ 29 9.1.2 Dual Gun Single Equipment ................................................................................................. 30

9.2 PEDESTAL +Z ................................................................................................................................ 30 9.2.1 Single Gun ............................................................................................................................ 31 9.2.2 Dual Gun Single Equipment ................................................................................................. 31

10. PRESSURE SCHEDULES ............................................................................................................ 33 10.1 BACKGROUND ............................................................................................................................... 33 10.2 ELEMENTS..................................................................................................................................... 33

10.2.1 Weld Force ........................................................................................................................... 34 10.2.2 Part Thickness ...................................................................................................................... 34 10.2.3 Gun Sag ................................................................................................................................ 35

10.2.3.1 Enabling........................................................................................................................ 35 10.2.3.2 Setup ............................................................................................................................. 36

10.2.4 Pushing Depth ...................................................................................................................... 37 10.2.5 Contact Speed ....................................................................................................................... 38

11. BACKUP SCHEDULES ................................................................................................................ 40 12. DISTANCE SCHEDULES ............................................................................................................ 41 13. PROGRAM LISTINGS ................................................................................................................. 42

13.1 STYLE TEMPLATES ........................................................................................................................ 42 13.1.1 Carried Servo Gun................................................................................................................ 42 13.1.2 Single Pedestal Servo gun No Tip Dress .............................................................................. 43 13.1.3 Dual Pedestal Servo Gun No Tip Dress ............................................................................... 44 13.1.4 Single Pedestal Servo gun With Tip Dress ........................................................................... 45 13.1.5 Dual Pedestal Servo Gun With Tip Dress............................................................................. 46

13.2 MISCELLANEOUS SERVO GUN MACROS ........................................................................................ 47 13.2.1 Stepper Check ....................................................................................................................... 47 13.2.2 CAP_WEAR.......................................................................................................................... 48 13.2.3 Number of Guns.................................................................................................................... 49 13.2.4 TW_GUNS ............................................................................................................................ 50 13.2.5 Tip Reset ............................................................................................................................... 51 13.2.6 Cap Select ............................................................................................................................. 52

14. RECOVERY ................................................................................................................................... 53 14.1 RECOVERY FROM LOSS OF MASTERING......................................................................................... 53

14.1.1 Mastering the Gun from the Master/Calibrate screen.......................................................... 53 14.2 CAP CONFIGURATION CHANGE ...................................................................................................... 54

14.2.1 Re-Run the wizard ................................................................................................................ 54 14.2.2 Mastering the Gun and Setting Axis Limits .......................................................................... 54 14.2.3 Running Tip Wear Setup....................................................................................................... 54 14.2.4 Completing Pressure Calibration......................................................................................... 54 14.2.5 Path Touch up....................................................................................................................... 55

14.3 MOTOR REPLACEMENT ................................................................................................................. 55 15. VARIABLE LISTING ................................................................................................................... 56 16. COMMON ERRORS ON SERVO GUN ERRORS .................................................................... 57

16.1 SRVO-023: SERVO STOP ERROR EXCESS (G:%D A:%D)............................................................. 57 16.2 SRVO-024: SERVO MOVE ERROR EXCESS (G:%D A:%D)........................................................... 57 16.3 SRVO-069: SERVO CRCERR ALARM (GRP:%D AX:%D)........................................................... 57 16.4 SRVO-062: SERVO BZAL ALARM (GROUP:%D AXIS:%D)......................................................... 57 16.5 SRVO-068: SERVO DTERR ALARM (GRP:%D AX:%D).............................................................. 57 16.6 SVGN-023: INCOMPLETE PRESSURE CALIBRATION ...................................................................... 57 16.7 SVGN-024: INCOMPLETE WEAR DOWN CALIBRATION ................................................................. 58


iii General Motors Corporation. All Rights Reserved.


16.8 SVGN-032: TIP INCREASED ERROR............................................................................................... 58 16.9 SVGN-118: MAX WEAR EXCEEDED .............................................................................................. 58 16.10 SVGN-020: PRESSURE SHORTAGE ............................................................................................ 58 16.11 HOW TO CHECK GUN IMPEDANCE: ............................................................................................. 59


1 General Motors Corporation. All Rights Reserved.


1. General 1.1 Scope

The following documentation is intended to be a reference document to aid in the setup and installation of the robotic servo weld guns for all project using servo guns and Fanuc SpotTool+ 7.20 with the GRS4 Customization. This documentation is intended to detail the steps necessary to install a Tolomatic servo weld gun on to a Fanuc R-2000iB R-30iA robot. The steps outlined in this manual will allow the intended audience to install the weld gun, calibrate and tune, and program/touchup weld paths. 1.2 Purpose

The steps outlined in this manual will help to ensure that all servo weld guns are integrated and setup in the same fashion so that the system is easily maintained and is fully functional to all RS specifications as well as GCCS-2, and GCCH-1. This document is not intended to replace servo gun manuals from Fanuc, but to simply document specific setup criteria specific to General Motors applications, using Fanuc SpotTool+ 7.20 with the GRS4 Customization. 1.3 Intended audience The intended audience for this document is, the robot programmers, engineers, and skilled trades that will be responsible for setting up the servo gun robots at integration, and maintaining the equipment once it is installed into the production environment. 1.4 Background The servo guns that are being utilized use a Tolomatic motor that incorporates a Fanuc encoder, and connectors that allow it to be controlled by the Fanuc robot. There are 5 different motor sizes.

1. HT-12, which is capable of generating 1200 lb of force 2. HT-23 which is capable of generating 2300 lb of force 3. SW-44 that is capable of 2500 pounds of force 4. GSWA-101(Global C-Gun Actuator) that is capable of 2500 pounds of force 5. GSWA-102(Global Pinch Gun Actuator) that is capable of 2500 pounds of force 6. GSWA-103(Global X-Gun Actuator) that is capable of 2500 pounds of force

Note: The GSWA-102 and GWSA-103 are electrically identical, and only vary on there mounting features. Therefore they share the same parameters in the robot.

All motors are driven by the same 40 amp auxiliary amplifier in the robot, as an integrated robot axis. The basic setup has the robot arm as motion group 1, and the servo guns as group 2, and group 3 if necessary. The control of the servo gun is integrated into the robot system, such that I/O is not necessary to control the gun functionality, such as backup or equalization.




1.5 Setup Flow

The following flow chart is a process of the steps necessary to setup a servo gun robot

Mount & ConnectGun

RunWizard

ResetPulse code

Faults

Master & SetLimits

Auto Tune

PerformPressure Calibration

Confirmconnectorsare clear

GSWA-101GSWA-102GSWA-103

SetGun Close Direction

SetupPressure Schedules

SetupBack up Schedules

Teach-Touch upPath

Tip DressSetup

New Caps

Enable / DisableDesiredSchedules withinGun Range

TouchtoMetal

New caps

SetupTip Wear

Gun - MoveableRobot - Stationary

SetupApplication

T1100%

Run Tip WearSetup Macro

Carried: +ZPedestal: +Z

Done in TestCell Prior toIntegration if

Possible

Section2

Section3

Section4

Section5

Section6

Section7

Section8

Section9

Section10

Section11

Section12

Perform Cold Start

ControlledStart

Menu Utilities

PerformThickness Calibration




2. Gun installation 2.1 Gun Mounting

When mounting the gun to the robot faceplate, care should be given to the way the connectors for the motor will route. There are 2 connectors that are used to control the Tolomatic motor from the robot. The first is the power cable and the second is the encoder cable. These should be positioned such that the cables and connectors are in the safest location relative to projected path. If there is an interference, it is possible to rotate the motor end cap +- 90. See motor documentation on rotating the connectors on the end cap.




3. Wizard Setup

The wizard allows the robot software to be configured for the specific application. The programmer needs only answer a few questions and the software configures itself based on the answers chosen by the programmer. This functionality has been further enhanced to include setting up of the servo gun applications, including group and axis data that previously needed to be done manually before running the wizard. This presented some complexity issues and has been remedied by adding the necessary functionality to the wizard.

3.1 Getting Started

Before running the wizard there are a few things that need to be known about the robot and

application. They are as follows: 1. Robot software version.

Must be 7.20/P19 with GRS4 Customization dated 01/06/2007 or later. An update will be necessary if the software is not up to this level.

2. Information about the application that the robot performs Carried or Pedestal Process

3. Information about the servo guns Motor Type Maximum Force for the gun (NOT the maximum motor force) Net Gear Ratio (NOT the motor ratio) Maximum gun opening (NOT the maximum motor stroke) Gun type: Pinch/X-style or C-style Auxiliary Amplifier that the servo motor is attached to

4. Information on how the guns are going to be used (If multiple guns exist) Dual gun single equipment Dual gun Dual equipment, 1 or 2 weld controllers

a. Affects tip wear compensation and pressure schedule approach. If the appropriate groups are not present when the wizard is run, the wizard will automatically

add the Servo Gun group and then boot back to controlled start. Once the robot has returned to Controlled start it will be necessary to re-run the wizard to configure the robot application. The following shows the steps necessary to configure a single carried servo gun. Other applications follow a similar setup, and the user should be able to configure for other applications by simply following the provided prompts.

3.2 Example: Single Carried Servo Gun Wizard Execution: (Single Carried Servo Gun)

1. Perform Controlled Start 2. Place a full load memory card with the AP1 directory into the controller

This will allow the wizard to load a Servogun Axis as group 3 for multi equipment configurations.

3. Scroll to item 1[Setup Wizard] and press [F4: ENABLED] 4. Answer [YES] to the prompted question HAS THE I/O BEEN BACKED UP? 5. At the GRS4 CUSTOMIZATION menu, press [1: START SETUP WIZARD], then press

[ENTER]. 6. At the Select Manufacturing Area, Press [1:Bodyshop] 7. Press [1: SPOTWELDING], then pre1ss [ENTER]. 8. Press [1: ONE WELD CONTROLLER], then press [ENTER]. 9. Press [1: EthernetIP], then press [ENTER]. 10. Press [1: ROBOT HELD GUN], then press [ENTER]. 11. Press [1: YES], then press [ENTER], when asked if the gun is a servo gun.




12. The wizard will then ask what motor type is attached to the servo gun Answer [1: Tolomatic SW 44] then [ENTER] for the SW/44 motor. Answer [2: Tolomatic HT 23] then [ENTER] for the HT/23 motor. Answer [3: Tolomatic HT 12] then [ENTER] for the HT/12 motor. Answer [4: SWGA C-Type] then [ENTER] for the Global C-motor. Answer [5: SWGA X/P Type] then [ENTER] for the Global X/P-motor. See motor tag for motor type

13. The wizard will then ask to enter the Gear Ratio for the gun Enter the gear ratio of the gun (mm/rev) from the GUN tag, not the motor tag and

then [ENTER]. 14. The wizard will then ask to enter the maximum weld gun force for the servo gun

Enter the maximum weld pressure (N) of the gun from the GUN tag, not the motor tag and then [ENTER].

15. The wizard will then ask to enter maximum gun opening distance for the servo gun Enter the maximum opening distance of the gun (mm) from the GUN tag and then

[ENTER]. 16. The wizard will then ask what style the servo gun is

Answer [1: C Gun Type] then [ENTER] if the gun is a C-style gun. Answer [2: X Gun Type] then [ENTER] if the gun is an X-style gun.

17. The wizard will then ask what amplifier the servo gun is attached to. The servo gun will typically be attached to amplifier #2

Guns 1 and 2 are typically on Amplifier #2 Guns 3 and 4 are typically on Amplifier #3

Enter [2] then [ENTER] (May be 3 for robots with more than 2 guns) 18. The wizard will then ask if transformer overtemp is used for the gun

Answer [1: YES] then [ENTER] if the transformer has an overtemp switch wired in .

Answer [2: NO] then [ENTER] if the transformer does NOT have a transformer overtemp wired in.

19. The wizard will then ask if the gun has a tip dresser. Answer [1: YES] then [ENTER] if there is a tip dresser for the gun. Answer [2: NO] then [ENTER] if there is no tip dresser.

20. If you answered yes to the question of does the gun have a tip dresser, you will be prompted for the tip dresser motor starter model

Answer [1: ECS 1085/1086] then [ENTER] for legacy motor starters Answer [2: ARMORSTART] then [ENTER] for Global Motor Starters

21. If you answered yes to the question of does the gun have a tip dresser, you will be prompted if you want to tip dress after a cap change

Answer [1: YES] then [ENTER] if you want to tip dress after a cap change. Answer [2: NO] then [ENTER] if you do not want to tip dress after a cap change. The plan is to predress the new global weld caps, so the answer should always be

Yes. 22. You will then be prompted if you have a Tool Changer.

Answer [1: YES] then [ENTER] if the robot has a tool changer Answer [2: NO] then [ENTER] if the robot does not have a tool changer

23. You will then be prompted if you would like to set up the pressure and backup tables for the gun.

Answer [1: YES] then [ENTER] if this is the first time the robot has been setup. This will load the default servo gun pressure schedules, but will not overwrite the actual pressure values.

Answer [2: NO] then [ENTER] if you have made changes to the servo gun pressure schedules and do not want them overwritten with the defaults.

24. You are now back at the GRS4 CUSTOMIZATION SCREEN. Press [2: Set Cell I/O to PLC] then [ENTER] to launch the SET CELL I/O functionality.




25. Press [1: EthernetIP], then press [ENTER] twice. 26. You are now back at the GRS4 CUSTOMIZATION SCREEN. Press [4: Exit] then [ENTER]

twice to close the wizard. 27. Press [FCTN] -> [ENTER], to Cold Start the robot.

3.3 Helps and Hints 3.3.1 Re-Running the wizard to correct for an incorrect response during initial setup If a mistake was made in the initial setup of the wizard, the easiest way to recover is to re-run the wizard. This will allow the robot to automatically reconfigure for the change. There is no need to reboot back to controlled start if you are currently at controlled start. Simply re-run the wizard making sure to take your time. It is necessary to set Cell I/O every time the wizard is run as the robot resets the cell interface to default when the wizard is launched. 3.3.2 Re-Running the wizard to add a feature If it is necessary to add a feature such as a tip dresser or Transformer Over Temp, it is not necessary to re-run the wizard completely. It is necessary however to Boot to Controlled start and launch the Wizard, selecting Item #3 Add to Configuration. This will allow the user to add the necessary items, without having to run through the entire wizard. Prior to adding a feature, it is best to back up the robot, incase an error occurs. A backup all is sufficient

1. Perform a Backup All of the controller 2. Perform a Controlled Start 3. Start the wizard

a. Select Option #3 Add to Configuration i. Follow the prompts as necessary

4. Perform a cold boot 5. Query any new DeviceNet nodes as necessary.




4. Establishing Pulse on Servo Gun Motors Once the groups and axis are configured, and the wizard run, it is necessary to master the guns. This procedure is critical, and must be followed as outlined below. The steps outlined below need to be followed for each configured servo gun. 4.1 Resetting BZAL (Battery Zero Alarm)

As is the case any time a motor is installed on the robot it will be necessary to clear the BZAL alarm that indicates that the system has lost communication with the encoder.

The steps necessary for clearing the BZAL alarm:

1. Press [MENUS] -> [NEXT] -> [SYSTEM] -> [Master/Cal] 2. Press [FCTN] ->[3: CHANGE GROUP] (Select the Servo Gun group, either 2 or 3) 3. Press [F3: RES PCA] 4. Select [F4: YES] when prompted to Reset pulse coder alarm? 5. Repeat steps 2 and 3 for all servo gun groups. 6. Cycle the power on the robot controller. 7. SRVO-075 Pulse not established will be displayed in the fault log upon power up.

4.2 Establishing Pulse

Before the Gun can be mastered it is necessary to establish pulse with the Fanuc Encoder that is mounted in the Tolomatic motor.

4.2.1 GSWA and SW-Series Motors

The method used to establish pulse on the SW series motor is identical to the method used to master a standard Fanuc motor.

1. Select Group 2 for equipment 1, Group 3 for equipment 2

a. Press [FCTN] b. Item [3: Change Group]

2. Jog Servo Gun axis until pulse is established. (The robot may indicate on the teach pendent that 'Pulse has been Established')

a. Jog the axis in both the +X and -X direction until 'Pulse is established'

b. For a second gun on that equipment jog the second axis in the +Y and -Y direction until 'Pulse is established'.

4.2.2 HT-Series Motor

For the HT-series motors, because they are 4-pole rather than an 8-pole require an additional step to establish pulse with the encoder. It is not possible to immediately jog the axis without manually rotating the motor by hand. To establish pulse on the HT-Series motors it is necessary to perform the following for each gun:

1. Locate the manual override key/gear on the servogun actuator. 2. Loosen the cover and slide out of the way. (Do not remove completely) 3. Using a screwdriver carefully rotate gear one complete revolution. 4. Attempt to jog the gun.

i. If successful, the gun will move, and the gun can then be mastered ii. If unsuccessful, the robot will still indicate a pulse not established alarm.

Repeat step 3 and 4 until successful. 5. Replace cover on manual override access .




5. Mastering the Gun

This is the recommended method to master the weld gun, because it calibrates the axis automatically and sets the servo gun limits to the limit defined in the Wizard setup at controlled start. This method also verifies that the gun close direction is correct such that there is commonality among all guns and for the capability to download simulations.

To access the Gun Setup and Autotuning screen :

Press [MENUS] -> [Utilities] -> [TYPE] -> [Gun Setup]

5.1 Setting Gun Close Direction The first step in calibrating the gun is to set the gun close direction. This is to set the robot up such that +X on the teach pendent closes the gun. Follow the directions and then proceed to the next step.

1. Select [Set Gun Motion Sign], and follow instructions

The following steps must be completed in order.




Note: For all GM servo guns we want +X to close the gun tips and -X to open the gun (+Y/-Y for the second gun on an equipment). If this is not the case, as with reverse parallel guns, it will be necessary to go into controlled start and to change the motion sign under the axis configuration from False to True. This should only be the case on reverse parallel guns. 5.2 Mastering the Gun and Setting Axis Limits 5.2.1 Single Gun per Equipment

1. Select [Set Gun specs, master gun]

2. Answer [YES] When prompted if you know the guns tip displacement of the gun (Gear Ratio from the gun tag)




3. Answer [YES] When prompted if you know the guns stroke limits (Gear Ratio from the

gun tag) 4. Follow the directions to master the gun and set limits

Close the Gun until the caps are touching and Press [F4:Closed] Enter the Tip Displacement (This is the Value that was entered in the Wizard at

controlled start)

5. Enter the Open and Closed limits for the weld gun.

The open limit is the value that was entered at controlled start. The closed limit is 20mm for all guns

6. Press [F3:COMP] when complete

This will actually master and calibrate the gun at once, allowing you to jog the gun open to the axis limit that was set off the gun tag at controlled start.




7. It is now necessary to Autotune the motor.

5.2.2 Dual Guns on One Equipment (Typically Dual Carried or Dual Pedestal)

Because of the way Fanuc handles Dual guns on 1 equipment, it is necessary to master both guns together even thought they each have their own Servo Gun Tune screen. The following will outline the steps necessary to Setup dual guns as a single equipment.

1. Select [Set Gun Specs, Master Gun] for Gun 1

2. Answer [YES] When prompted if you know the guns tip displacement of the gun (Gear Ratio from the gun tag)

The INDEX button is used to switch between guns on the same equipment

The EQUIP button is used to switch between guns on different equipment




3. Answer [YES] When prompted if you know the guns stroke limits (Gear Ratio from the gun tag)

4. Follow the directions to master the gun and set limits with the following changes Both guns associated with the active equipment must be mastered together

Jog both guns closed before selecting F4 at step 1. Enter the Tip Displacement and Limits

5. Repeat steps 1 - 3 for the other gun on the active equipment. Use the Index button to switch between guns on the same equipment

Jog both guns associated with the active Equipment to the closed position. Then F4 is pressed it will master and calibrate both guns associated with the Equipment, not just the active gun




This is necessary to get the gun 2 screen to indicate that everything is set. This is easily accomplished by using the backup keys and closing the backups

to 0mm before mastering for gun 2.

6. Once both guns are mastered, proceed to autotuning. 5.3 Autotuning

The purpose of Autotuning is to have the robot calculate certain properties of the weld gun

that are necessary for proper operation. This operation must be completed prior to pressure calibration, tip wear setup, or any of the following sections. Autotune must be run for each servo gun separately. It will be necessary to cycle power after running Autotune before the next gun can be tuned. All guns should be mastered prior to Autotuning any gun. 5.3.1 Running

1. Select [3: Auto Tune] and Press [Shift] & [F3:EXEC] Put robot in T2 mode 100% override




2. Select [YES] to Begin




3. Select [OK] and continue to hold [Shift] and the Deadman

4. After Auto Tuning completes, it will be necessary to cycle power for the new parameters to take effect.

5. Repeat above steps for all configured servo guns 5.3.2 Help and Hints

If autotuning fails there are a number of possible reasons. The following are a list of the faults that can occur as well as some possible remedies to these faults. 1. Collision detection alarm

The axis limits may be swapped. The axis limits are not set correctly. The gun may not be mastered correctly.

2. Stop Excess Error The axis limits may be swapped.




Gun close direction may be incorrect. Should be Plus. +X should close the gun, if it opens the gun then the motion sign under NoBot

setup at Controlled start needs to be changed. The gun may not me mastered correctly.

3. Autotune cannot start Verify that the robot is in T2 mode with 100% override active.

4. Pressure Shortage Verify Mastering

o Make sure tips are touching Verify Servo Gun setup at controlled start under Maintenance.




6. Pressure calibration

Once the servo weld gun has been mastered and Auto Tuned, it is necessary to perform a pressure calibration on the system such that the robot can determine the relationship of motor torque to tip force. Pressure calibration will need to be carried out for each servo gun.

6.1 Equipment

To perform pressure calibration you will need the following items.

1. Calibrated Pressure Gauge set to Peak force rather than tracking. 2. Force gauge holder assembly

a. This allows for one person pressure calibration by fixing the force gauge to the stationary gun arm so that the operator has both hands free to run the pressure calibration from the teach pendent.

b. It is not recommended to run pressure calibration without this assembly because it is too cumbersome to hold the force gauge and execute the pressure commands from the teach pendent

NOTE: Because the weld gun is an additional axis to the robot, this task must be performed with servo power available to all robot axis.

6.2 Performing Calibration

Pressure calibration is to be performed in T1 mode at 100% override. This is possible because the force calibration takes place at 50mm/s, which is less than 250mm/s. The following are the steps necessary to calibrate the weld pressures on a servo gun:

1. Press [MENUS] -> [Setup] -> [Servo Gun] 2. Select under General Setup

3. Select under Pressure Cal: (Should show INCOMP)




4. Select [F4:Yes] when prompted to start pressure calibration 5. Select [F4:OK] to acknowledge the torque limit note 6. Verify the following settings

[Pressuring Time (sec)] = 2.0 [Thickness of Gauge (mm)] = 13.0 [Pushing Depth (mm)] = 8.0 [Gun Open Value (mm)] = 20.0

7. Verify or Add the following Pressure Targets

These settings are for the standard Sensor Development Force Gauge

Verify




8. Attach force gauge to the stationary arm of the weld gun such that the gauge face is resting on the stationary tip.

9. Enter initial torque % for first pressure calibration test.

10. Verify that the speed is 50mm/s 11. With the robot servos reset press SHIFT-[F3: Pressure] to have the robot close the gun at

whatever torque was specified. (Cursor must be on the line for the requested torque) 12. Adjust Torque (%) up or down until the desired force is achieved.

Enter Torque percentage here Start off at a low torque to get an idea of how the gun will perform ~5% starting torque

Verify or Add the following pressure targets up to the rated force of the gun

Verify




13. Repeat steps 9 - 12 for each of the pressures in the table up to the maximum rated force of the gun. Make sure not to exceed the rated force for the gun. The motors are stronger than the guns.

If the necessary torque required to reach a required force exceeds the

allowed torque (Max Gun Toque (%)), it will be necessary to exit pressure calibration by setting pressure calibration complete, and accepting/updating the torque limits when prompted. This will update the over-torque limits. To complete pressure calibration simply restart pressure calibration and the limits will have been increased, allowing for the completion of pressure calibration.

14. When torque values have been entered for all valid pressures in the table, change the

Calibration Status to complete.

15. Select [F4:COMP] to enable new parameters

Cursor up to INCOMP when complete with pressure calibration

Press F4:COMP to complete pressure calibration

Torque can be adjusted in 0.1% increments




16. Select [F2:END] to complete Pressure Calibration

6.3 Help and Hints

The majority of the issues that will occur during pressure calibration are errors that have to do with the pressure calibration settings.

1. Move Error Excess

Make sure pushing depth is set less than the gauge thickness Verify that Tryout mode is not active, because the robot assumes all thicknesses to

be 0mm, regardless of what is specified when in Tryout mode. 2. Stop Excess Error

Verify that Tryout mode is not active, because the robot assumes all thicknesses to be 0mm, regardless of what is specified when in Tryout mode.

Verify gauge thickness o When error occurs, select [POSN] if faulted position is -13.01 to -13.99,

change thickness to 14 mm. 3. Collision guard alarm

Make sure that the gauge thickness is set correctly 4. Pressure gauge shows radically different pressures

Increase Pressuring time 5. Requested Torque exceeds limit and Pressure calibration cannot be performed

This occurs when attempting to calibrate a torque that is greater than that specified under Max Gun Toque (%). This can occur because the values that Fanuc defaults to are conservative and assume full mechanical advantage.

1. To allow calibration to use torques greater than max torque it is necessary to exit pressure calibration by setting pressure calibration complete, and accepting/updating the torque limits when prompted. This will update the over-torque limits.

2. Restart Pressure calibration and the limits will have been increased, allowing for the completion of pressure calibration.




7. Thickness check calibration Once Pressure calibration is complete it is necessary to go back to gun setup and perform the Thickness Check Calibration. This allows for the gun to more accurately calculate part thickness with the gun at force. 1. Press [MENUS] -> [Utilities] -> [TYPE] -> [Gun Setup] 2. Cursor down to item 4 Thickness Check Calibration and press [Shift F3:EXEC] with the

dead man in and robot reset (T2 100% Override)

3. Select [YES] when prompted Are you sure you want to do this:

4. Select [Ok] when prompted




5. When calibration is complete, the teach pendent will indicate Complete.

6. Perform steps 1-5 for all configured servo guns.




8. Tip Wear Compensation

Because the GM Global weld guns do not include equalizers, it is necessary to program the stationary tip touching the metal. As the stationary tip wears through welding and tip dress, it is necessary to determine the amount of tip wear present on each tip, and to offset the robot path to keep the stationary tip in contact with the part throughout the life of the cap. To enable this, the robot has certain macros that setup the tip wear compensation, and other macros that will calculate the wear throughout the life of the cap.

There are a few things that must be remembered when running with tip wear compensation enabled. First is that after changing the caps on the robot, it is necessary to update the tip wear, telling the robot that it has new tips. If this is not done, the robot may bend the flange with the stationary tip, causing damage to the part, gun, or causing collision alarms.

8.1 Setup

To setup Tip Wear Compensation it is necessary to enable compensation under Servo Gun Setup, and to run the respective setup program for the configured servo guns. For dual guns on a single equipment tip wear compensation is enabled or disabled for both guns

8.1.1 Enabling Tip Wear Compensation

To enable Tip Wear compensation go to the Servo Gun Setup Menu for the respective gun and enable Tip Wear Compensation.


3. [Enable] Tip Wear Down Comp




Note: For dual guns Tip Wear compensation is Enabled/Disabled for both guns.

Tip Wear Standard will show COMP when setup program is run

ENABLE

For 2 guns on 1 Equipment, Tip Wear Comp, Gun Sag and robot close direction are under Dual Gun Common




8.1.2 Running Tip Wear Compensation Setup Program(s)

To run the tip wear setup program, simply select the appropriate setup program and run the program from the teach pendent. Be sure that new caps are firmly seated on the gun before running the tip wear setup routine.

The setup programs (macros) are as follows:

TW_SETG1.TP for Gun 1 TW_SETG2.TP for Gun 2 TW_SETG3.TP for Gun 3 TW_SETG4.TP for Gun 4

8.1.3 Wear Ratios The wear ratio is the ratio of wear between the stationary tip and moveable tip. It is set relative to the stationary tip. Therefore a wear ratio of .4 is 40% of total wear is relative to the stationary tip and 60% to the moveable tip. Each gun has its own wear ratio, and they are set via registers for ease of use. By default all ratios are set to .5, or equal wear for each tip. Based on metal stack-up and coating they can be adjusted to better reflect the actual wear ratio. The tip wear ratio registers are as follows:

R[5: TW Ratio fix G1] = .5 for Gun 1 R[6: TW Ratio fix G2] = .5 for Gun 2 R[7: TW Ratio fix G4] = .5 for Gun 3 R[8: TW Ratio fix G4] = .5 for Gun 4

8.2 Viewing Tip Wear values To view the tip wear amounts :


ENABLE




3. Select under Tip Wear Standrd

Shows complete when tip wear setup has been complete

The actual measured tip wear will show up here. It will show 0.00 immediately after tip wear setup is complete. After a wear update, or a cap change this value may be non zero. All measurements are based relative to the setup. The values may not be zero after a cap change, as all caps are slightly different in length




8.3 Tip Wear Updating Once tip wear setup has been completed, the robot will periodically update the tip wear value by running a tip wear routine that will close the gun and determine the total amount of wear. It will then apply the tip wear ratio in splitting the wear between the moveable and stationary tips. The standard software is configured to update one gun every cycle. For a single gun case, it will update every cycle, and for a four gun case it will update each gun every 4 cycles. There is a register in the robot that keeps track of the last gun updated and indexes to the next gun automatically. 8.3.1 Tip Wear Routines There are 4 different programs that are run to perform the necessary tip wear functionality. For the most part the operator will need to do nothing with these routines as they are 'baked' into the code, but are listed here for completeness. TW_GUNS This program is run whenever the steppers are reset, or whenever new cap are placed on the robot. This routine calls TW_UPDCC(x) for every configured servo gun. CAP_WEAR This program is run every cycle to update the tip wear on one of the servo guns. This routine is typically run on the way home after entering segment 63 (clear of transfer) or during a drop-off for a pedestal application. This routine will only update a single gun every cycle because of the time involved ~ 4 seconds. That said, each gun will update every 4 cycles worst case. TW_UPDT(x) x= gun number This is the routine that Cap_Wear calls to update the wear on a specific gun. This routine is also called outright to update a specific gun by the tip dress routines. When this routine is run it will close the selected gun and measure the tip wear from the original position that was recorded when Tip Wear Setup was done. This routine expects that each successive measurement will show increased wear. This routine will allow the caps to grow by a small amount (configurable) in case of a 'Cling-On' during a tip dress. TW_UPDCC(x) x= gun number This is the routine that TW_GUNS calls to update the wear on each gun. When this routine is run it will close the selected gun and measure the tip wear from the original position that was recorded when Tip Wear Setup was done. This routine expects the caps to grow, as expected with new caps.




9. Set Gun Close Direction The gun close direction defines direction the tips move to close and weld. For the

moveable tip which the Fanuc software refers to as Gun, should be set to PLUS, indicating that the positive displacement of the moveable tip closes the gun. For the Stationary tip, which the Fanuc software refers to as Robot, needs to be set to indicate the direction that the TCP must move to bring the stationary tip to the workpiece. This setting is critical, because it determines the direction the robot will move to place workpiece on the stationary tip as it goes through the motions that encompass a weld with a servo gun.

9.1 Carried +Z

For Carried spot welding applications, the gun Close direction (Robot) shall be

relative to the Utool of the gun and shall be +Z, for the tool as defined in RS-3.

9.1.1 Single Gun

UT: UTOOL Should be set to UT for Carried Applications

1 (UTOOL #) This is the Utool to use for Close Gun Direction (Robot)

+Z The direction the robot moves relative to the UTOOL to bring the stationary tip to the metal




9.1.2 Dual Gun Single Equipment

9.2 Pedestal +Z For Pedestal spot welding applications, the gun Close direction (Robot) shall be

relative to the UFrame of the gun and shall be -Z, for the tool as defined in RS-3.

UT: UTOOL Should be set to UT for Carried Applications

1 (UTOOL #) This is the Utool to use for Close Gun Direction (Robot)

+Z The direction the robot moves relative to the UTOOL to bring the stationary tip to the metal

Select [Detail] to look at Dual Gun Common Items




9.2.1 Single Gun

9.2.2 Dual Gun Single Equipment

UF: FRAME(RTCP) Should be set to UT for Carried Applications

+Z The direction the robot moves relative to the UFRAME to bring the stationary tip to the metal

1 (UFRAME #) This is the UFrame to use for Close Gun Direction (Robot)




+Z The direction the robot moves relative to the UFRAME to bring the stationary tip to the metal

UF: FRAME(RTCP) Should be set to UT for Carried Applications

1 (UFRAME #) This is the UFrame to use for Close Gun Direction (Robot)

Select [Detail] to look at Dual Gun Common Items




10. Pressure schedules

General Motors has standardized on the Pressure Schedules that are to be used for all servo welding applications. They include 2 schedules for each of the approved weld forces, with the only difference being the part thickness set under pressure schedule detail. These 10 pressure schedules are not to be modified, because they include the best compromise between speed, performance and complexity. If a need arises that requires a unique pressure schedule, it will be necessary to add a schedule. However this will require buy-in from the lead robot and welding engineers due to the fact that it affects the weld spot verification process, and leads to uniqueness, and added complexity. 10.1 Background

The pressure schedules in the robot controls more than the weld pressures; they also controls the way the robot approaches a weld and departs after a successful weld. There are 99 pressure schedules available for each gun. The elements listed below are available for each of the 99 schedules.

To access the pressure schedules in the robot:

1. Press [Data] 2. Press [F1: Type] -> [Pressure]

10.2 Elements

There are 9 elements to each pressure schedule that need to be set correctly for the servo guns to operate in an efficient and effective manner.

1. Weld Force The amount of force the gun will apply before welding.

2. Part Thickness The expected thickness of the part (stack up) that is to be welded.

3. Gun Sag The amount of deflection (flex) on the stationary tip that is caused by closing the gun

to the prescribed pressure. 4. Pushing Depth

1. Setting Manual=True will cause the specified schedule to appear in the select list when the [Gun] key is pressed by the user

2. Pressing [Gun] (non-

shifted) will select the next Pressure Schedule in the list that is set TRUE

3. Pressing [Shift] -

[Gun] will cause the weld gun to move to close at the defined pressure

Verify These are the

default pressure schedules for all robots. Only the forces up to the max rated force of the gun will be present




The maximum distance that the robot will push to build pressure. 5. Contact Speed

The speed at which the welding electrodes will contact the workpiece. 10.2.1 Weld Force

The weld pressure is the tip force (weld pressure) the robot will apply before initiating the weld controller. To access the a pressure schedule in the robot :

1. Press [Data] hard key 2. Press [F1: Type] - > [5: Pressure] 3. Cursor to select desired schedule 4. Select [F4: Detail] 5. Cursor to Weld Pressure to modify

NOTE: Because the robot does not initiate the weld before the gun is at pressure minimal squeeze time is necessary in the welder control.

10.2.2 Part Thickness The part thickness must be set in order for the robot to quickly perform the weld, and can also be used to detect that the correct / all parts to be welded are present. The part thickness needs to be set reasonably close to the actual thickness of the part(s) to be welded because the robot uses this thickness to determine when to switch from positional to torque mode. If this value is too large the robot will switch to torque mode to early, and will have to search (at a slower speed) until it detects the part. If this value is too small it is possible that the tips could touch the part while still in positional rather than torque mode. This could lead to collision alarms, and some part deformation. To access the a pressure schedule in the robot:

1. Press [Data] hard key




2. Press [F1: Type] - > [5: Pressure] 3. Cursor to select desired schedule 4. Select [F4: Detail] 5. Cursor to Part Thickness to modify

10.2.3 Gun Sag

The servo gun has the ability to compensate for gun deflection as the weld force increases,

allowing the stationary tip to remain in the same position as the force increases. This is especially important on C-Guns where the stationary/fixed gun arm wants to deflect under load. By setting up gun sag, the robot can move the stationary/fixed tip in the opposite direction of deflection, allowing for a consistent weld location without the use of an equalizer. This is especially important because the C-Guns for the GMT-966 project do not incorporate pneumatic or spring equalization, with the exception of dual guns and hard automatic fixture guns.

10.2.3.1 Enabling

The Gun Sag Compensation must be enabled for the robot to compensate for gun deflection. 1. Press [MENUS] -> [Setup] -> [Servo Gun] 2. Select under General Setup

Part Thickness of 3.3mm for pressure schedule # 1




3. Select Enable under [Gun Sag Compensation]

10.2.3.2 Setup

1. Make sure that Gun Sag Compensation is enabled 2. Verify that the gun sag values are not 0.0mm in the pressure schedule detail page. [Gun

Sag Comp Value (mm)] will be calculated automatically from data taken during Autotuning, and will be automatically filled into the pressure schedules once pressure calibration is complete.




10.2.4 Pushing Depth

The pushing depth indicates how far the robot will move past where it expects to build pressure, before it faults with a pressure shortage. If the part thickness is set to 3mm, the robot expects to build force when the tips are 3mm apart. The pushing depth feature allows the robot to search past this point to build pressure so that minor variations in part thickness to not cause nuisance faults. This is also useful in that we want to have a single pressure schedule for a given force, and to have the part thickness set to the thickest of the stack-ups that are going to use that force. Given this plan, the default pushing depth for all pressure schedules is 6mm. To access the a pressure schedule in the robot:

1. Press [Data] hard key 2. Press [F1: Type] - > [5: Pressure] 3. Cursor to select desired schedule 4. Select [F4: Detail] 5. Cursor to pushing depth to modify

This value is calculated automatically after Auto Tuning and Pressure Calibration are completed




10.2.5 Contact Speed

Contact speed indicates the speed at which the welding electrodes will contact the workpiece. This value by default is the speed that was used during the pressure calibration of the servo gun. This value should not be adjusted except for certain applications such as tip dress that a higher or lower contact speed is desired for the process.

Note: Increasing the contact speed higher than that used for calibration can lead to a higher force deviation from that calibrated.

To access the a pressure schedule in the robot:

6. Press [Data] hard key 7. Press [F1: Type] - > [5: Pressure] 8. Cursor to select desired schedule 9. Select [F4: Detail] 10. Cursor to Contact Speed percentage to modify

Pushing depth is 6mm for schedules 1-16




Calibrated speed for all schedules by default is 50mm/s




11. Backup schedules

The robot has the ability to program backup positions that specify how much the gun is to open when the specified Backup schedule is called. This offers a simplified method of programming gun open positions, without requiring the user to Jog the weld gun axis. The backup command can be added to the standard SPOT instruction, or executed as a manual function using the Backup Key.

There are 30 backup schedules that can be programmed for each gun.

To locate the Backup Data:

1. [DATA] -> [F1:TYPE] -> [6:Backup]

The Backup Schedules are pre-defined in 10mm increments. This will allow for easy assignment of Backup Schedules without referring to the backup data. I.e. Backup No. 1 is 10mm, BU #2 is 20mm, BU# 15 is 150mm and so on. This table can be adjusted as necessary for specific applications, but should be fine as is, with the operator setting Manual = True for those positions that they want to access from the Backup Key.

1. Setting Manual=True will cause the specified gun open distance to appear in the select list when the [BACKUP] key is pressed by the user

2. Pressing [BACKUP] (non-

shifted) will select the next Backup position in the list

3. Pressing [Shift] -

[BACKUP] will cause the weld gun to move to the currently selected Backup position




12. Distance Schedules

The robot has the ability to program distance schedules that specify how close the gun is to be to the workpiece as it approaches a weld. The associated parameters are for Gun (Moveable) Robot (Stationary) tips. These distance schedules are used in the SPOT instruction to determine the position the robot moves the caps to prior to and after a weld. All values are in addition to the part thickness. So if you are calling a SPOT instruction with a pressure schedule that is 3mm, and you use SD(Start Distance)=4, the tips are 11mm apart. 4mm above the part, and 4mm below the part. The same applies for ED(End Distance), which is where the robot will move the gun to after the weld.

17:L P[2] 1500mm/sec CNT100 : SPOT[SD=4,P=1,S=1,ED=4] ;

There are 99 distance schedules that can be programmed for each gun.

To locate the Backup Data:

2. [DATA] -> [F1:TYPE] -> [Distance]

The Backup Schedules are pre-defined in 1mm increments for distances 1 thru 15 This will allow for easy assignment of Distance Schedules without referring to the distance data. I.e. Distance 1 is 1mm, Distance 10 is 10mm and so on.




13. Program listings 13.1 Style templates

The following templates are unique to servo gun applications and are listed here so that the

differences can be explained and documented.

13.1.1 Carried Servo Gun /PROG STYLE01 1: !ECHO STYLE AND OPTION ; 2: GO[2:ManualStyle]=1 ; 3: ECHO OPTION ; 4: MAINT_PROG=MOV_REPR ; 5: ; 6: CALL POUNCE ; 7: ; 8: CALL STPR_CHK ; 9: ; 10: CALL S01PROC1 ; 11: ; 12: RUN CAP_WEAR ; 13: ; 14: MOVE TO HOME ; 15: WAIT (F[1]) ; /POS /END

STPR_CHK This routine checks for caps changed from all configured weld controllers and will perform a tip wear update automatically if the steppers are reset. If only 1 of the steppers on a 2 weld controller setup are reset, the robot will prompt to reset all steppers, or to abort the style

CAP_WEAR This routine performs a tip wear update for the gun as the robot is moving home. Needs to be placed after the robot has entered segment 63(clear of transfer) and is moving home

WAIT (F[1] This wait allows for the tip wear update to complete prior to the style aborting




13.1.2 Single Pedestal Servo gun No Tip Dress /PROG STYLE01 1: !ECHO STYLE AND OPTION ; 2: GO[2:ManualStyle]=1 ; 3: ECHO OPTION ; 4: MAINT_PROG=FFRPROC1 ; 5: ; 6: ! FFR HANDLER ; 7: IF $IN_FFRCVRY=1,JMP LBL[10] ; 8: ; 9: CALL POUNCE ; 10: ; 11: CALL STPR_CHK ; 12: ; 13: CALL PICKUP_1 ; 14: ; 15: LBL[10] ; 16: CALL S01PROC1 ; 17: ; 18: ! FFR HANDLER ; 19: IF DO[43:FFRActive]=ON,JMP LBL[99] ; 20: ; 21: RUN CAP_WEAR ; 22: ; 23: CALL DROPOFF1 ; 24: ; 25: MOVE TO HOME ; 26: WAIT (F[1]) ; 27: LBL[99] ; /POS /END


CAP_WEAR This routine performs a tip wear update for one gun while the robot is dropping the part off. (This requires that the Group masks be set correctly. I.e. DROPPOFF1 must not have Group 2 Mask enabled) For Ped applications with Tip Dress this Cap Wear is replaced with a Pedestal tip dress check (TD_P1_CK) that will either tip dress or do an update

WAIT (F[1]) This wait allows for the tip wear update to complete prior to the style aborting




13.1.3 Dual Pedestal Servo Gun No Tip Dress /PROG style01 1: !ECHO STYLE AND OPTION ; 2: GO[2:ManualStyle] = 1 ; 3: ECHO OPTION ; 4: !FFR HANDLER ; 5: IF $IN_FFRCVRY=1,JMP LBL[R[160]] ; 6: CALL s01pounc ; 7: CALL STPR_CHK ; 8: CALL s01pick1 ; 9: LBL[10] ; 10: R[160]=10 ; 11: MAINT_PROG=MOV_FFRPROC1 ; 12: CALL s01proc1 ; 13: !FFR HANDLER FOR PROCESS 1 ; 14: IF DO[43:FFRActive] = ON, JMP LBL[99] ; 15: LBL[20] ; 16: R[160]=20 ; 17: MAINT_PROG=MOV_FFRPROC2 ; 18: CALL s01proc2 ; 19: !FFR HANDLER FOR PROCESS 2 ; 20: IF DO[43:FFRActive] = ON, JMP LBL[99] ; 21: RUN CAP_WEAR ; 22: CALL s01drop1 ; 23: MOVE TO HOME ; 24: WAIT (F[1]) ; 25: LBL[99] ; /POS /END


CAP_WEAR This routine performs a tip wear update for one gun while the robot is dropping the part off. (This requires that the Group masks be set correctly. I.e. S01DROP1 must not have Group 2 Mask enabled) For Ped applications with Tip Dress this Cap Wear is replaced with a Pedestal tip dress check (TD_P1_CK, or TD_P2_CK) that will either tip dress or do an update

WAIT (F[1]) This wait allows for the tip wear update to complete prior to the style aborting




13.1.4 Single Pedestal Servo gun With Tip Dress /PROG STYLE01 1: !ECHO STYLE AND OPTION ; 2: GO[2:ManualStyle]=1 ; 3: ECHO OPTION ; 4: MAINT_PROG=FFRPROC1 ; 5: ; 6: ! FFR HANDLER ; 7: IF $IN_FFRCVRY=1,JMP LBL[10] ; 8: ; 9: CALL POUNCE ; 10: ; 11: CALL STPR_CHK ; 12: ; 13: CALL PICKUP_1 ; 14: ; 15: LBL[10] ; 15: CALL TDDMPCHK(21) 16: CALL S01PROC1 ; 17: ; 18: ! FFR HANDLER ; 19: IF DO[43:FFRActive]=ON,JMP LBL[99] ; 20: ; 21: CALL TD_P1_CK ; 22: ; 23: CALL DROPOFF1 ; 24: ; 25: MOVE TO HOME ; 26: WAIT (F[1]) ; 27: LBL[99] ; /POS /END


TD_P1_CK This routine checks to see if a tip dress is necessary for the guns on Pedestal 1 and if so will tip dress the necessary guns while the robot is dropping of the part. (This requires that the Group masks be set correctly. I.e. DROPOFF1 must not have Group 2 Mask enabled) If a tip dress is not necessary, the robot will perform a cap wear update

WAIT (F[1]) This wait allows for tip wear update, or tip dress to complete prior to the style aborting




13.1.5 Dual Pedestal Servo Gun With Tip Dress /PROG style01 1: !ECHO STYLE AND OPTION ; 2: GO[2:ManualStyle] = 1 ; 3: ECHO OPTION ; 4: !FFR HANDLER ; 5: IF $IN_FFRCVRY=1,JMP LBL[R[160]] ; 6: CALL s01pounc ; 7: CALL STPR_CHK ; 8: CALL s01pick1 ; 9: LBL[10] ; 10: R[160]=10 ; 11: MAINT_PROG=MOV_FFRPROC1 ; 12: CALL TDDMPCHK(21) 12: CALL s01proc1 ; 13: !FFR HANDLER FOR PROCESS 1 ; 14: IF DO[43:FFRActive] = ON, JMP LBL[99] ; 15: CALL TD_P1_CK ; 16: LBL[20] ; 17: R[160]=20 ; 18: MAINT_PROG=MOV_FFRPROC2 ; 12: CALL TDDMPCHK(24) 19: CALL s01proc2 ; 20: !FFR HANDLER FOR PROCESS 2 ; 21: IF DO[43:FFRActive] = ON, JMP LBL[99] ; 22: CALL TD_P2_CK ; 23: CALL s01drop1 ; 24: MOVE TO HOME ; 25: WAIT (F[1]) ; 26: LBL[99] ; /POS /END

TD_P2_CK This routine checks to see if a tip dress is necessary for the guns on Pedestal 2 and if so will tip dress the necessary guns while the robot is dropping of the part. (This requires that the Group masks be set correctly. I.e. S01drop1 must not have Group 2 or 3 Mask enabled) If a tip dress is not necessary, the robot will perform a cap wear update WAIT (F[1]) This wait allows for tip wear update, or tip dress to complete prior to the style aborting


TD_P1_CK This routine checks to see if a tip dress is necessary for the guns on Pedestal 1 and if so will tip dress the necessary guns while the robot is performing S01proc2. (This requires that the Group masks be set correctly. I.e. S01proc2 must not have Group 2 Mask enabled). This allows the robot to tip dress the guns on pedestal 1 (Fanuc Equipment 1, Nobot group 2) while welding with Pedestal 2 (Fanuc Equipment 2, NoBot group 3) If no tip dress is necessary, the robot will not perform a cap wear, that will be done in TD_P2_CK. In this case the Run Cap Wear needs to be removed from TD_P1_ck




13.2 Miscellaneous Servo Gun Macros 13.2.1 Stepper Check

This routine is called at pounce by all servo gun applications. It checks if the Steppers are reset, and if so performs a tip wear update automatically. This is critical if the steppers were reset from the DEP, or through some means that did not do a tip wear update. This routine does not check if an update was done, but simply performs an update on all configured Servo Guns. This routine will also check that all configured steppers are reset and prompt the user to reset all or abort if it detects only one of two steppers reset. This is because it is critical for dual guns on one equipment that they are capped out together, because of the tip wear compensation and the lack of equalizers. /PROG STPR_CHK 1: !******************************** ; 2: !THIS MACRO RUNS TIP WEAR UPDATE ; 3: !IF IT DETECTS THAT STEPPERS ARE ; 4: !RESET ; 5: !IT CHECKS FOR ALL CONFIGURED SCR ; 6: !******************************** ; 7: ; 8: IF $SPOTCONFIG.$NUM_WD_CTLS=1,JMP LBL[10] ; 9: IF $SPOTEQSETUP[2].$STUDWELDER=1,JMP LBL[10] ; 10: JMP LBL[20] ; 11: ; 12: LBL[10] ; 13: IF DI[205:diSW1StepReset]=ON,JMP LBL[40] ; 14: JMP LBL[99] ; 15: ; 16: LBL[20] ; 17: IF DI[205:diSW1StepReset]=ON AND DI[221:diSW2StepReset]=ON, : JMP LBL[40] ; 18: IF DI[205:diSW1StepReset]=ON AND DI[221:diSW2StepReset]=OFF, : JMP LBL[30] ; 19: IF DI[205:diSW1StepReset]=OFF AND DI[221:diSW2StepReset]=ON, : JMP LBL[30] ; 20: JMP LBL[99] ; 21: ; 22: LBL[30] ; 23: !******************************** ; 24: !PROMT USER FOR DIRECTION ; 25: !IF ALL CONFIGURED STEPPERS ARE ; 26: !NOT RESET ; 27: !******************************** ; 28: ; 29: DO[48:Process1Fault]=ON ; 30: CALL PROMPTYN(3,40) ; 31: ; 32: DO[48:Process1Fault]=OFF ; 33: IF R[40:PROMPT Y/N REG]=1,CALL TIP_RST ; 34: IF R[40:PROMPT Y/N REG]=0,CALL ABORTIT ; 35: JMP LBL[99] ; 36: ; 37: LBL[40] ; 38: !If Air gun skip tip wear update ; 39: IF $sgcfg[1].$EQUIP_TYPE=1,JMP LBL[99] ;

BOTH STEPPERS ARE NOT RESET VERIFY THAT ALL CAPS CHANGED SELECT: (YES) TO RESET ALL STEPPERS (NO) TO ABORT STYLE




40: CALL TW_GUNS ; 41: ; 42: LBL[99] ; 43: ; /POS /END 13.2.2 CAP_WEAR

This routine is called either by the style program or by the tip dress check program for pedestal tip dressing robots. For carried guns this routine should be called after the robot is clear of transfer (Segment 63) and on the way home. For pedestal applications this routine should be called before the drop off routine, so that the robot can update a gun while dropping the part off. This routine calls NUM_GUNS which determines the number of servo guns on the robot. It then increments a R15 by 1 and does a wear update on that gun. Once the number of guns limit is reached it sets R15 to 0 and the updating starts back at gun 1. The semaphore allows this task to compete prior to aborting the style program. See style templates for examples /PROG CAP_WEAR 1: F[1] = (OFF) ; 2: IF $SPOTCONFIG.$STROKE_ENBL=0,JMP LBL[99] ; 3: CALL NUM_GUNS ; 4: R[15]=R[15]+1 ; 5: IF R[15]>R[16],JMP LBL[10] ; 6: CALL TW_UPD(R[15]) ; 7: JMP LBL[20] ; 8: LBL[10] ; 9: R[15]=0 ; 10: LBL[20] ; 11: IF R[15]=R[16],JMP LBL[10] ; 12: LBL[99] ; 13: WAIT (F[1]) ; /POS /END




13.2.3 Number of Guns

This routine is called by CAP_WEAR and simply determines the number of servo guns active on the robot. It puts this value in R16.

/PROG NUM_GUNS 1: ; 2: !GUN 1 IS EQ1 GUN 1 ; 3: R[16:NUM SERVO GUNS]=1 ; 4: IF $spoteqsetup[1].$num_guns=1,JMP LBL[30] ; 5: !GUN 2 IS EQ1 GUN 2 ; 6: R[16:NUM SERVO GUNS]=2 ; 7: LBL[30:END EQ1 CHECK] ; 8 : ; 9: IF $SPOTNUMEQ=1,JMP LBL[99] ; 10: IF $SPOTEQSETUP[2].$STUDWELDER=1,JMP LBL[99] ; 11: ; 12: IF $spoteqsetup[1].$num_guns=2,JMP LBL[40] ; 13: !GUN 2 IS EQ2 GUN 1 ; 14: R[16:NUM SERVO GUNS]=2 ; 15: JMP LBL[50] ; 16: ; 17: LBL[40: RESET GUN 3] ; 18: !GUN 3 IS EQ2 GUN 1 ; 19: R[16:NUM SERVO GUNS]=3 ; 20: ; 21: LBL[50: RESET GUN 4] ; 22: IF $spoteqsetup[2].$num_guns=1,JMP LBL[99] ; 23: !GUN 4 IS EQ2 GUN 2 ; 24: R[16:NUM SERVO GUNS]=4 ; 25: ; 26: LBL[99] ; /POS /END




13.2.4 TW_GUNS This routine is called by TIP_RST, after a cap change to run a tip wear update on all configured servo gun. TW_UPDCC(X) is the tip wear program for new caps (Tip Wear Update Caps Changed), where X is the gun number. This routine also makes sure that stroke is enabled, so the robot does not try to update in no stroke.

/PROG TW_GUNS 1: IF $SPOTCONFIG.$STROKE_ENBL=0,JMP LBL[99] ; 2: !If Air gun skip tip wear update ; 3: IF $sgcfg[1].$EQUIP_TYPE=1,JMP LBL[99] ; 4: !GUN 1 IS EQ1 GUN 1 ; 5: CALL TW_UPDCC(1) ; 6: IF $spoteqsetup[1].$num_guns=1,JMP LBL[30] ; 7: !GUN 2 IS EQ1 GUN 2 ; 8: WAIT .30(sec) ; 9: CALL TW_UPDCC(2) ; 10: LBL[30:END EQ1 CHECK] ; 11: ; 12: IF $SPOTNUMEQ=1,JMP LBL[99] ; 13: ; 14: IF $SPOTEQSETUP[2].$STUDWELDER=1,JMP LBL[99] ; 15: !If Air gun skip tip wear update ; 16: IF $sgcfg[2].$EQUIP_TYPE=1,JMP LBL[99] ; 17: IF $spoteqsetup[1].$num_guns=2,JMP LBL[40] ; 18: !GUN 2 IS EQ2 GUN 1 ; 19: WAIT .30(sec) ; 20: CALL TW_UPDCC(2) ; 21: JMP LBL[50] ; 22: ; 23: LBL[40: RESET GUN 3] ; 24: !GUN 3 IS EQ2 GUN 1 ; 25: WAIT .30(sec) ; 26: CALL TW_UPDCC(3) ; 27: ; 28: LBL[50: RESET GUN 4] ; 29: IF $spoteqsetup[2].$num_guns=1,JMP LBL[99] ; 30: !GUN 4 IS EQ2 GUN 2 ; 31: WAIT .30(sec) ; 32: CALL TW_UPDCC(4) ; 33: ; 34: LBL[99] ; /POS /END




13.2.5 Tip Reset

This routine gets called to reset steppers. This can occur either at a 'Request Continue' with a decision code 14, or as a style 27 'Cap Change'. This routine checks that the watersavers have detected a 'Cap Loss' or are bypassed before allowing the steppers to be reset. If it detects that the configured watersaves are not tripped, or bypassed it will prompt the user to 1. Reset anyway, or 2. Skip Reset. If the watersavers were tripped, or the operator selected reset anyway, the robot will then reset all configured steppers and watersavers, and will then perform a TW_GUNS which will update the wear for all servo guns.

/PROG TIP_RST 1: !******************************** ; 2: !TIP RESET WELD CNTRLS ; 3: !THIS MACRO RESETS STEPPERS ; 4: !FOR ALL CONFIGURED SCRS ; 5: !IF CAP LOSS OR BYPASS DETECTED ; 6: !******************************** ; 7: ; 8: ; 9: IF $SPOTCONFIG.$NUM_WD_CTLS=1,JMP LBL[10] ; 10: IF DI[309:diG1WS_CapLoss]=ON AND DI[317:diG2WS_CapLoss]=ON, : JMP LBL[20] ; 11: IF DI[307:diG1WS_Bypassed]=ON AND DI[315:diG2WS_Bypassed]=ON, : JMP LBL[20] ; 12: IF DI[309:diG1WS_CapLoss]=ON AND DI[315:diG2WS_Bypassed]=ON, : JMP LBL[20] ; 13: IF DI[307:diG1WS_Bypassed]=ON AND DI[317:diG2WS_CapLoss]=ON, : JMP LBL[20] ; 14: JMP LBL[30] ; 15: ; 16: LBL[10] ; 17: IF DI[309:diG1WS_CapLoss]=ON,JMP LBL[20] ; 18: IF DI[307:diG1WS_Bypassed]=ON,JMP LBL[20] ; 19: JMP LBL[30] ; 20: ; 21: LBL[20] ; 22: !RESET STEPPER AND WATER SAVER ; 23: !FOR WELD CONTROLLER 1 ; 24: ; 25: CALL RST_STP1 ; 26: CALL RST_WTR1 ; 27: ; 28: IF $SPOTCONFIG.$NUM_WD_CTLS=1,JMP LBL[40] ; 29: IF $SPOTEQSETUP[2].$STUDWELDER=1,JMP LBL[40] ; 30: !RESET STEPPER AND WATER SAVER ; 31: !FOR WELD CONTROLLER 2 ; 32: ; 33: CALL RST_STP2 ; 34: CALL RST_WTR2 ; 35: ; 36: JMP LBL[40] ; 37: ; 38: LBL[30] ; 39: !******************************** ; 40: !PROMT USER TO RESET ANYWAY IF ;




41: !WATERSAVERS DID NOT TRIP ; 42: !OR WERE NOT BYPASSED ; 43: !******************************** ; 44: ; 45: DO[48:Process1Fault]=ON ; 46: CALL PROMPTYN(2,40) ; 47: ; 48: DO[48:Process1Fault]=OFF ; 49: IF R[40:PROMPT Y/N REG]=1,JMP LBL[20] ; 50: IF R[40:PROMPT Y/N REG]=0,JMP LBL[99] ; 51: ; 52: LBL[40] ; 53: !If Air gun skip tip wear update ; 54: IF $sgcfg[1].$EQUIP_TYPE=1,JMP LBL[99] ; 55: CALL TW_GUNS ; 56: ; 57: LBL[99] ; 58: ; /POS /END 13.2.6 Cap Select

This routine is called at FFR to allow the user to select that the caps were changed, so that the robot can reset the steppers and perform a tip wear update before returning to the style to re-weld the part. /PROG CAP_SELC 1: !******************************** ; 2: !THIS MACRO ALLOWS THE USER TO ; 3: !SELECT IF THE CAPS WERE CHANGED ; 4: !AT FFR ; 5: !STEPPERS ARE RESET IF USER ; 6: !ANSWERS YES TO THE PROMPT ; 7: !******************************** ; 8: ; 9: !******************************** ; 10: !PROMT USER FOR DIRECTION ; 11: !IF CAPS CHANGES AT FFR ; 12: !******************************** ; 13: ; 14: CALL PROMPTYN(4,40) ; 15: ; 16: IF R[40:PROMPT Y/N REG]=1,CALL TIP_RST ; 17: ; 18: LBL[99] ; 19: CALL USERCLR ; 20: CALL USERPAGE ; /POS /END

HAVE THE CAPS BEEN CHANGED? (ALL CAPS MUST BE CHANGED) SELECT: (YES) TO RESET STEPPERS (NO) TO CONTINUE W/ OLD CAPS

WATERSAVERS NOT TRIPPED ARE ALL CAPS CHANGED? SELECT: (YES) TO RESET STEPPERS (NO) TO SKIP STEPPER RESET




14. Recovery

The following are the recommended recovery procedures necessary to recover from the most common and foreseeable errors that will occur once the servo guns are in production. It is anticipated that this section will grow as we garner more information and additional lessons learned. 14.1 Recovery from Loss of Mastering

The steps outlined below are necessary to recover from a loss of mastering, after the robot has been setup and programmed. It is recommended that the caps not be changed before the following procedure, as the wear in the caps are accounted for in the recalibrate routine. 14.1.1 Mastering the Gun from the Master/Calibrate screen

This method is to be used to recover from a loss of mastering after initial setup of the servo gun has been performed.

1. Do not replace the electrodes

The robot will use the existing cap wear to calculate correct position and update the tip wear automatically

2. Press [MENUS] -> [NEXT PAGE] -> [SYSTEM] -> [Gun Master] 3. Select [Select F3:BZAL] to reset the battery zero alarm and cycle power

4. Re-Establish pulse with the encoder 5. Select [NEXT] 6. Jog the welding electrodes (tips) together until they just touch 7. Select [F4:RECALB]

This will master and calibrate the gun, and update the tip wear compensation master position




8. The axis is now mastered 9. Verify the weld path, and touch up if necessary

14.2 Cap configuration change

The steps outlined below are necessary to change from one cap configuration to another due to product or process changes. This includes the change of cap size, say from a #2 short to a #2 long, or change from one shank style to another. It is not recommended to single axis master and update limits on this axis, as this tends not to work, and can cause issues with tip wear. 14.2.1 Re-Run the wizard

To ensure that the transition from the original cap configuration to the new configuration is successful, and straight forward it is necessary to delete the gun axis in question from the group, and to re-enter the axis with the new information, paying close attention to the axis limits. The easiest way to accomplish this is to re-run the wizard and to select YES when prompted to setup the servo gun axis.

14.2.2 Mastering the Gun and Setting Axis Limits

Because the axis information has been updated it is necessary to re-run the gun mastering and axis setup.

See section Mastering the Gun to re-master the gun

14.2.3 Running Tip Wear Setup

Because the mastering information has changed, particularly the master counts with the new caps, it will be necessary to re-run tip wear setup.

See section Tip Wear Compensation to setup tip wear compensation. It may also be

necessary to update the wear ratio when changing cap configurations.

14.2.4 Completing Pressure Calibration

Because the gun setup has changed pressure calibration has changed and should be verified. Most likely the torque to force curve has not changed due to a simple cap change, but should be verified. The values that were recorded during the initial setup

ServogunSetupUsersManual v1.0

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