Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
KR C2
Release 1.0
for KUKA System Software (KSS) Release 5.2, 5.3
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e Copyright 2005
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Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Brief description of the commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Additional safety instructions for KUKA.ArcTech Analog . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Symbols and icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4.1 Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4.2 Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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5.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.8.2 Types of motion for the ARC OFF command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.8.3 Programming ARC OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.8.3.1 Inline form and parameter lists for ARC OFF, weld and end parameters . . . . . . . . . . . . . . 38
5.8.4 Inline form with TRACK function when sensor is active (KUKA.ArcSense) . . . . . . . . . . . . 40
5.8.5 Parameter lists for weld parameters (W) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.9 Mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.9.1 Weave frequency, weave length, path velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.10 Thermal weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.11 Combined mechanical and thermal weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.12 Ramp function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.13 Extended weld parameter lists for special applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.13.1 Additional weld parameter lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.13.2 Parameter list for the end parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6 Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.1 Starting welding of seam 1 -- ARC ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.2 Ending welding of seam 1 -- ARC OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.3 Moving to seam 2 (PTP) and starting welding -- ARC ON . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.4 Welding seam 2 (up to P8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8 Online optimizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.1 Function overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2 Modification of the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2.1 Modifying the velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.2.2 Velocity modification limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.2.3 Deselecting the online optimizing mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.2.4 Block selection response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.2.5 Modifying the weld voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.2.6 Modifying the wire feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.2.7 Modifying the weave parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.3 Interrupt response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.4 System response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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9 Override for correction motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.1 Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.2 Correction motion override and online optimizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10 Customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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1 Introduction
1 Introduction
1.1 Functions
The KUKA.ArcTech Analog technology package allows the creation of robot--controlled arc
welding applications for weld power sources with an analog reference voltage. The
development of welding robots that are easy and safe to use has been made possible by the
universal adaptation of the user interface and other interfaces to a wide range of
analog--controlled welding equipment, and by the user--friendly handling of the
KUKA.ArcTech Analog technology package.
Fig. 1 shows the basic structure of the KUKA.ArcTech Analog commands. You can see how
the motion and weld commands and the start and end parameters are assigned to the
individual sections of a seam.
4 8 8 8
5 6 6 7
P1 P2 P3
3
1 2
1 Seam section 1
2 Seam section 2
3 Welding torch
4 Initialization
5 Arc start parameters
6 Arc weld parameters
7 Arc end parameters
8 Motion parameters
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G ARC ON
The ARC ON command contains the parameters for moving the welding torch (type of
motion, speed, etc.) from the home position to the start point of the seam, and all the ignition
parameters. ARC ON ends after ignition has been successfully completed.
G ARC SWITCH
The ARC SWITCH command is used where the seam is divided into several sections. It
contains the motion and weld parameters (including mechanical and thermal weaving) for
the current section of the seam.
The set weld parameters are used as a default setting for all of the following ARC SWITCH
commands.
A command from the Motion group is used for moving the welding torch, e.g. from the end
of a seam (ARC OFF) to the home position of a following ARC ON command, and for
reorienting the welding torch.
G ARC OFF
The ARC OFF weld command contains the motion and weld parameters (including
mechanical and thermal weaving) and the end parameters for the seam, or for the last
section of the seam if it is divided into several sections.
ARC OFF ends the welding process by filling the crater and burning back excess wire, so
that the correct free wire length and form are ensured for the ignition process at the start of
the next seam.
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1 Introduction (continued)
This documentation has been created for the User user group. It contains the description
of the graphical user interface of the KUKA Control Panel and illustrates the operator actions
necessary for creating, testing, correcting, altering and optimizing programs of the
KUKA.ArcTech Analog technology. Explanatory information on the technology commands
and the associated parameters is also included.
The functions that are specific to KUKA.ArcTech Analog, the operator control elements, the
menus, and the various inline forms of the KUKA Control Panel are described in Chapter 4 -
Graphical user interface of the KUKA Control Panel.
Chapter 5 - Programming and operation -- contains the description of the individual
KUKA.ArcTech Analog commands together with various tables and information on
programming. The command--specific overviews showing the parameter lists assigned to the
inline forms, together with a brief description of the parameters and of the frequently required
operator control elements, can be useful, especially for less experienced users.
By using the simple examples given in both Chapter 6 - Program example - and
Chapter 7 -- Altering existing programs --, where the individual steps required for creating
and altering programs are illustrated, even less experienced users can quickly familiarize
themselves with programming.
Chapter 8 -- Online optimizing -- contains a description of how to carry out online optimizing.
As a user, you should have adequate knowledge regarding the creation of motion
programs. More detailed information on this can be found in the [Operating Handbook], in
the chapter Motion Programming.
The documentation [KUKA.ArcTech.Analog -- Configuration] contains detailed information
on programming and setting parameters for the Expert user group.
The meaning of the symbols, icons, and particular font conventions is also explained in the
[Operating Handbook], in the chapter About this Documentation.
It is assumed that the robot system has been prepared for production operation and that
the technology package has been loaded. Information on this can be found in the
[Operating Handbook] in the chapter Start--up.
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Unless otherwise stated, settings and changes to the variable values only become active
after the system is restarted. The following procedure is carried out:
G When configuration is complete, save the data on the hard disk.
Menu function: File Save all to floppy
G Once the data have been saved, shut the system down.
G Restart the system.
Configurable options
The following configurable options are available:
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2 Safety
2 Safety
WARNING!
Failure to observe these safety instructions could result in injury or a fatal accident
and/or damage to the robot system or other property!
G All pertinent safety regulations as well as the booklet [Safety and Installation
Instructions] are to be observed when working on the system.
G The KUKA safety chapter [KRC Safety, General] is supplied with the robot system and
must be read and understood before commencing work.
G The safety instructions in the KR C2 Operating Handbook must be observed.
2.2 Liability
The KUKA.ArcTech Analog technology package has been designed, built, and
programmed using state--of--the--art technology and in accordance with the recognized
safety rules. Nevertheless, improper installation of this unit or its employment for a purpose
other than the intended one may constitute a risk to life and limb of operating personnel or
of third parties, or cause damage to or failure of the control cabinet, resulting in damage to
or failure of the entire robot system and other material property.
KUKA.ArcTech Analog may only be used in technically perfect condition in accordance with
its designated use and only by safety--conscious persons who are fully aware of the risks
involved in its operation. Connection and use must be carried out in compliance with this
documentation.
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WARNING!
Exact compliance with these safety warnings is necessary for the prevention of
personal injury.
CAUTION!
Exact compliance with these safety warnings is necessary for the prevention of
damage to property.
2.4.2 Icons
Info
Indicates passages which are of particular significance or are useful for greater under-
standing.
See also
Indicates sections or chapters containing further information and explanations.
NOTE
Indicates sections with additional information on a particular subject and highlights special
features.
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3 Installing the software
3.2 Setup
When performing the setup, a menu appears on the screen for selecting the KUKA.ArcTech
Analog option to be installed.
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4 The graphical user interface -- KUKA Control Panel (KCP)
A basic description of the user interface (HMI) and how to operate it can be found in the
[Operating Handbook -- KUKA System Software], in the chapter Operator Control.
Creating, selecting and altering a program is described in the chapter Program creation
in the [Operating Handbook].
For detailed information on the functions of the KUKA.ArcTech Analog status keys,
see Section 4.2.3.
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The weld commands ARC ON, ARC SWITCH, and ARC OFF are available for selection.
The following types of motion are available for selection:
G PTP, LIN, or CIRC for the weld command ARC ON,
G LIN or CIRC for the weld commands ARC SWITCH and ARC OFF.
In the following example, ARC ON, PTP has been selected.
When the Enter key is pressed, an inline form is opened in the program window:
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4 The graphical user interface -- KUKA Control Panel (KCP) (continued)
The functions of these status keys are only available after they have been configured in
$CONFIG.DAT and the system has been rebooted.
The two status keys HOT/COLD and DRY have a toggle function with reciprocal lockout.
It is not possible to switch directly from HOT (welding on) to DRY and vice versa.
The screenshot on the left shows the status Welding and DRY switched off, which can be
identified by the crossed--out welding torch icons. In this position, only the motions of a
welding program can be executed; actual welding does not take place. The wire feed and
the shielding gas are switched off.
The HOT/COLD status key always has to be switched on for welding (HOT).
This status key is also used to switch manually between HOT (welding) and COLD (robot
motion only): so--called On/Off switching on the fly.
The DRY status key is locked and deactivated when the HOT status key is switched on.
In Automatic External mode, you first need to switch to HOT as otherwise the functions
of the status keys will not be available.
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When the DRY status key is activated, the robot moves at a higher velocity (in accordance
with the default setting DRY_RUN_Vel Default = 0.15m/s in $CONFIG.DAT). The welding
process, the wire feed, and the shielding gas are then switched off and any mechanical
weaving that has been programmed is not executed.
NOTE:
This speed may not be increased, for reasons of safety!
When the computer starts up, (hot) welding is always deactivated, as indicated by the
crossed--out welding torch icon on the left--hand status key bar. In order to be able to weld,
this status key has to be switched to the HOT position corresponding to the symbol shown
on the left.
The functions of both the Jog mode status key at top left (manual movement of the robot
using the Space Mouse or the right--hand status keys) and the Program run mode status
key beneath it are described in the [Operating Handbook], in the chapter Controller, KCP
Display.
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5 Programming and operation
Only alter variables if you have adequate knowledge of their function, and of the
possible consequences!
The default variables may have to be changed in order to adapt them to the periphery (weld
controller, welding mode, number of analog channels, burnback mode). A brief overview follows.
When the controller is started up, it will be restored to the status it was in when the computer
was last shut down. In order to be able to weld, this status key has to be switched to the HOT
position corresponding to the symbol shown on the left.
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You always need to select the ArcTech template when creating a welding program.
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5 Programming and operation (continued)
After pressing the Technology menu key, you can select options from the menus by means
of the arrow keys. See also Section 4.2.1 of this documentation.
The inline forms contain a series of input boxes, whose designations are freely selectable.
This applies to the following boxes:
P1 Designation of the end point
PDAT1, CPDAT1 Designation of the motion parameters data set
PS or MM Designation of the particular weld mode
S Designation of the start parameters data set
W1 Designation of the weld parameters data set
E Designation of the end parameters data set
Seam1 Comment (max. 24 characters)
The following must always be observed:
-- The designation can consist of letters and numbers. Special characters cannot be
used, except for the underscore _.
-- The first character of a designation always has to be a letter.
-- The designation for the boxes mentioned above may consist of no more than 24
characters.
-- The designation is taken over unchanged as a pure character string into all of the
subsequent program lines.
-- If the last character is a number, the value of this number is automatically incremented
(n +1) in the subsequent commands, e.g. W1, W2 ... Wn or SEAM_FRONT1,
SEAM_FRONT2 ...SEAM_FRONT99.
Please remember that the number of characters increases by 1 when going from 9 to 10.
Should this lead to the designation exceeding 24 characters, which is not permitted, the
remainder of the comment is cut.
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The path cannot be predicted exactly for PTP motions. The motion characteristics of
the robot near obstacles should therefore be checked in a test run.
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5 Programming and operation (continued)
When you select Technology ! ArcTech Analog! ARC ON ! PTP, the inline form
set out in Fig. 4 will appear.
Seam1
Motion
Start Parameter
Only when number
of analog channels
>2
Acceleration Reserved for an
(1 to 100 %) additional analog
channel
Fig. 4 Inline form and parameter lists for the command ARC ON, PTP
In the parameter list Frames, note that external axes can also be set under Base.
The entry EX_AX_DATA [ ] only appears in the window, however, if an external axis is
correspondingly configured in the machine data.
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Brief description of the input boxes of the inline form (from left to right), their functions, and
their range of values where applicable:
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5 Programming and operation (continued)
When you select Technology ! ArcTech Analog! ARC ON ! LIN, the inline form set
out in Fig. 5 will appear.
Seam1
Motion
Fig. 5 Inline form and parameter lists for the command ARC ON, LIN
In the parameter list Frames, note that external axes can also be set under Base.
The entry EX_AX_DATA [ ] only appears in the window, however, if an external axis is
correspondingly configured in the machine data.
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Brief description of the input boxes of the inline form (from left to right), their functions, and
their range of values where applicable:
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5 Programming and operation (continued)
When you select Technology ! ArcTech Analog! ARC ON ! CIRC, the inline form
set out in Fig. 6 will appear.
Seam1
Wire Feed
Wire feed rate
(0 to 20 m/min)
Motion
Only when number
Start Parameter
of analog channels
Acceleration >2
(1 to 100 %) Reserved for an
additional analog
channel
Fig. 6 Inline form and parameter lists for the command ARC ON, CIRC
In the parameter list Frames, note that external axes can also be set under Base.
The entry EX_AX_DATA [ ] only appears in the window, however, if an external axis is
correspondingly configured in the machine data.
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Brief description of the input boxes of the inline form (from left to right), their functions, and
their range of values where applicable:
For the remaining parameters, see the description for the command ARC ON ! LIN
in this section.
Start Time
Start time
(delay of weld start)
0 to 1.5 seconds
Voltage
Start voltage
*)
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5 Programming and operation (continued)
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KUKA.ArcTech Analog -- Operation
Frames Motion
Tool coordinate
Acceleration
system (1...16 or
(1 to 100%)
NULLFRAME)
Base coordinate
system (1...16 or
NULLFRAME)
Fig. 9 Inline form and parameter lists for the command ARC SWITCH, LIN
In the parameter list Frames, note that external axes can also be set under Base.
The entry EX_AX_DATA [ ] only appears in the window, however, if an external axis is
correspondingly configured in the machine data.
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5 Programming and operation (continued)
Brief description of the input boxes of the inline form (from left to right), their functions, and
their range of values where applicable:
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When you select Technology ! ArcTech Analog! ARC SWITCH ! CIRC, the inline
form set out in Fig. 10 will appear.
Frames Motion
Tool coordinate
system (1...16 or Acceleration
NULLFRAME) (1 to 100%)
Base coordinate
system (1...16 or
NULLFRAME)
External TCP True
or False
Fig. 10 Inline form and parameter lists for the command ARC SWITCH, CIRC
In the parameter list Frames, note that external axes can also be set under Base.
The entry EX_AX_DATA [ ] only appears in the window, however, if an external axis is
correspondingly configured in the machine data.
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5 Programming and operation (continued)
Brief description of the input boxes of the inline form (from left to right), their functions, and
their range of values where applicable:
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The part of the inline form and the parameter lists for the weld parameters of the ARC
SWITCH command are set out in Fig. 11.
Weave Type
Weave Length
Weave amplitude
(1 to 15 mm)
Weave Angle
Degrees
Weave angle
(--180 to +180
degrees)
Fig. 11 Inline form and parameter lists for ARC SWITCH, weld parameters
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5 Programming and operation (continued)
Brief description of the input boxes of the inline form (from left to right), their functions, and
their range of values where applicable:
Information on the Weld parameters parameter list and details regarding mechanical
and thermal weaving can be found in Sections 5.9 and 5.10.
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Frames Motion
Base coordinate
system (1...16 or
NULLFRAME)
Fig. 12 Inline form and parameter lists for the command ARC OFF, LIN
In the parameter list Frames, note that external axes can also be set under Base.
The entry EX_AX_DATA [ ] only appears in the window, however, if an external axis is
correspondingly configured in the machine data.
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5 Programming and operation (continued)
Brief description of the input boxes of the inline form (from left to right), their functions, and
their range of values where applicable:
When you select Technology ! ArcTech Analog! ARC OFF ! CIRC, the inline form
set out in Fig. 13 will appear.
After selecting the command ARC OFF -- CIRC, the inline form shown below is opened:
Frames Motion
Tool coordinate
system (1...16 or Acceleration
NULLFRAME) (1 to 100%)
Base coordinate
system (1...16 or
NULLFRAME)
External TCP True
or False
Fig. 13 Inline form and parameter lists for the command ARC OFF, CIRC
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In the parameter list Frames, note that external axes can also be set under Base.
The entry EX_AX_DATA [ ] only appears in the window, however, if an external axis is
correspondingly configured in the machine data.
Brief description of the input boxes of the inline form (from left to right), their functions, and
their range of values where applicable:
5.8.3.1 Inline form and parameter lists for ARC OFF, weld and end parameters
The part of the inline form and the parameter lists for the weld and end parameters of the
ARC OFF command are set out in Fig. 14.
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5 Programming and operation (continued)
Primary Weld
Travel Speed
Weld velocity Ramp function 4/5 Ramp function 2)
(0 to 2 m/min)
Voltage
Weld voltage Ramp length
Volts (13 to 39 V) (0 to 25 mm)
Burnback Time
Burnback time*
(0 to 1.5 sec)
Crater Time
Weave Length Crater time
Weave length
(1.5 to 12 mm) (0 to 1.5 sec)
Weave Type
Weave type End Set Seam--specific
burnback data
Voltage
Post Flow Time
Weld voltage Gas postflow time
(0 to 39 V) (0 to 1.5 sec)
Wire Feed
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Brief description of the input boxes of the inline form (from left to right), their functions, and
their range of values where applicable:
5.8.4 Inline form with TRACK function when sensor is active (KUKA.ArcSense)
The inline form illustrated in Fig. 15 also contains the selection box TRACK. The TRACK
function is only available if the KUKA.ArcSense sensor has been installed and activated
(A50_OPTION=#ACTIVE).
Once TRACK has been selected, another box, T, is added.
If box T has the focus, the Tracking Conditions parameter list is opened in the status
window offering the option of adjusting the settings for the through--the--arc sensor.
Tracking Conditions
For detailed information on the functions and configuration of the KUKA.ArcSense through--
the--arc seam tracking sensor, see the [KUKA.ArcSense] documentation.
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5 Programming and operation (continued)
Primary Weld
This page (see Fig. 16) contains the parameters for the weld voltage and the wire feed rate. If
the Thermal weaving option is selected (see also Section 5.10), the values for the weld voltage
and the wire feed rate that are set in this parameter list are the maximum values for each.
The maximum and minimum values are dependent on the welding rectifier and must be
adapted accordingly in the registry.
More detailed information about making modifications in the registry can be found in the
documentation [KUKA.ArcTech Analog -- Configuration].
Only carry out modifications in the registry if you know exactly what you are doing!
Otherwise, contact KUKA Roboter GmbH.
Wire Feed
Wire feed rate
*)
Burnback time
Burnback Time
0 to 1.5 seconds
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Mechanical Weaving
Mechanical weaving
Weave Type
Weave type
Figure Without weaving (No Weave),
10 patterns as per table,
2 freely definable patterns
Weave Length
Weave length*)
1.5 to 12 mm
Weave amplitude
Weave amplitude
Half of the total weave width, from peak to 0.
1 to 15 mm
Weave Angle
Weave angle
Degrees --180 to +180 degrees
*) Information about applications in which
thermal and mechanical weaving are combined
can be found in Section 5.11.
In the case of mechanical weaving, the effective weld velocity (travel speed) is greater than
the path velocity, due to the weave amplitude and weave length.
Weave width
Weave length
*) Weave amplitude = half the weave width
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5 Programming and operation (continued)
Fig. 19 and Fig. 20 show the weave patterns available. Trapezoidal, spiral and figure--eight
weave patterns result in a non--uniform effective weld velocity. This can vary during one
period between the set path velocity and a multiple of it, depending on the relation of the
lateral deflection (amplitude) to the weave length.
s
Weave amplitude
Weave length
Direction of welding
s
No weave
Triangle
Double triangle
Trapezoid
Double trapezoid
Unsym. trapezoid
Spiral
Double 8
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Edge weave
bottom Weave length
Direction of welding
z x
s
y
Direction of welding
With the weave patterns Edge weave bottom und Edge weave top shown in Fig. 20, the
weave angle changes within one weave length.
With the Edge weave bottom pattern, the torch is deflected laterally (direction y) in the first
half according to the weave amplitude defined [s] and vertically in the second half
(direction z). With the Edge weave top pattern, the deflection is vertical (z) in the first half
and lateral (y) in the second half.
The lateral deflection (amplitude), the weave length (the length over which a pattern is
executed) and the angle of the torch to the welding plane can be set for each weave pattern.
In the Expert user group, two further weave patterns can be defined with the designations
User def. pattern 1 and User def. pattern 2 in the Arc_weave.src file, and existing
patterns can be modified. Detailed information on this can be found in the documentation
[KUKA.ArcTech Analog -- Configuration].
In order to generate a circular or spiral weld pattern, the amplitude must be half the weave
length.
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5 Programming and operation (continued)
Of significance for correct functioning of the robot is the weave frequency, which results
from the programmed weld velocity (travel speed) and the weave length. The following
relationships exist between these parameters:
These relationships are depicted graphically in the nomogram shown in Fig. 22.
0
.1 .2 .3 .4 .6 .7 .8 .9 .1 .2 .3 .4 .6 .7 .8 .9
0 0.5 1.0 1.5 2.0
Weld velocity v m/min
For weave frequencies > 3 Non--permissible range
Hz, see explanation in text.
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The maximum weave frequency for mechanical weaving is influenced by several factors
depending on the robot type concerned, for example by the resonant frequency of the
robot/tool mechanical unit. Weave frequencies of up to 3 Hz (corresponding, for example,
to a weave length of 3.33 mm at a travel speed of 0.6 m/min) are possible without causing
problems according to previous experience.
With higher weave frequencies, undesirable effects are liable to result under certain
circumstances (depending on the tool design and/or tool orientation). With weave
frequencies > 3 Hz, the motion characteristics of the robot should therefore be individually
tested in each case.
Mechanical Weaving
Weave Angle
Degrees
Torch Torch
Weave plane
Weave plane
Component
plane
Weave angle degrees Weave angle 0 degrees
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5 Programming and operation (continued)
If the sensor (KUKA.ArcSense) is being used, it is not possible to change the angle of the
weave plane; the angle is permanently 0 degrees!
In order to achieve the correct distribution of heat, the torch must then be positioned at an
angle.
In the event of a TRACK command, the weave angle is permanently set to 0 degrees.
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In conventional welding processes, the values for the weld voltage and the wire feed rate
remain constant. Thermal weaving is an option for use with certain applications (e.g. for
reducing the welding distortion).
It involves periodic alteration of the weld voltage and the wire feed rate. The result is a seam
with weld metal that varies periodically in relation to these changes.
The robot--specific Thermal weaving mode has nothing in common with the Pulsing option
offered by welding equipment.
A precondition for displaying the Thermal weaving parameter list is that the variable
A_TH_WEAVE_OPT is set to the value TRUE.
Weave Type
Weave type
No weave
Triangle
Triangle
Tri..
Trapezoid
Voltage Weld voltage
Volts *)
Wire Feed
Wire feed rate
20 *)
The Thermal weaving parameter list shown in Fig. 24 is only displayed if the value of the
variable A_TH_WEAVE_OPT has been set to TRUE.
The distribution of heat can be moved from one side of the metal sheet to the other by
rotating the mechanical weave pattern through 180 degrees.
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5 Programming and operation (continued)
The functions of these parameters are only available once they have been configured in
$CONFIG.DAT and the system has been restarted.
Two patterns (triangle and trapezoid) are predefined by the manufacturer, as shown in Fig. 25.
Thermal weaving
*)The maximum values for weld voltage and wire feed are normally entered in the Primary
Weld parameter list, page 1, and the minimum values in the Thermal weaving parameter
list.
Applications in which mechanical and thermal weaving are combined are described in the
next section 5.11.
Detailed information on thermal weaving can be found in the documentation
[KUKA.ArcTech Analog -- Configuration].
In order to ensure synchronization between mechanical and thermal weaving, the variable
$TECH_ANA_FLT_OFF[3]=TRUE has to be set in STEU\$CUSTOM.DAT.
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The precondition for synchronization is that the values for the thermal weave length
(Thermal weaving parameter list) and the weave length in the Mechanical weaving
parameter list are identical.
You can also shift the phase of the thermal weave curve by 180 in relation to the mechanical
weave curve without difficulty. This is done by entering the maximum values for the voltage
and wire feed in the Thermal weaving parameter list, and the minimum values in the
Primary Weld parameter list, page 1.
As can be seen in the following diagram, the weld voltage and the wire feed rate are, again
in this example, greater on the side of the thicker sheet than on that of the thin sheet.
+ Maximum values for weld voltage
Min. voltage, and wire feed rate are entered in
min. wire feed the Thermal weaving parameter
list.
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5 Programming and operation (continued)
Further information on mechanical and thermal weaving can be found in the documentation
[KUKA.ArcTech Analog -- Configuration].
Ramp length
0 to 25 mm
If the through--the--arc seam tracking sensor (KUKA.ArcSense) is being used, the ramp
function must not be used! In this case, the variable must be set to A_RAMP_OPTION =
FALSE.
If the distances between points are small, it may be necessary for the system to
execute an exact stop.
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--
Wire feed rate
+
--
P4
P3
P2
P1
In the first seam section (ARC SWITCH P1 -- P2) the weld voltage changes, after P1 and
within the ramp length (12 mm), from the value set in the start parameter list to the value (26
volts) set in the weld parameter list (ARC SWITCH). The wire feed changes in the same way.
In the second seam section (ARC SWITCH P2 -- P3) the weld voltage can be seen to change
from 26 volts to 23 volts within the ramp length (5 mm) after P2. The wire feed value changes
from 15 to 8 m/min.
In the third seam section (ARC OFF P3 -- P4), the ramp length value is 0 mm. The switch
from the weld parameters for the second seam section to those for the third occurs at P3
without a transition.
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5 Programming and operation (continued)
The functions of these variables are only available once they have been configured and the
system has been rebooted. Otherwise, the weld parameter list is not displayed.
For more information, see also the documentation [KUKA.ArcTech Analog -- Configuration].
An additional weld parameter list for applications with three analog channels is shown in
Fig. 30. If the number of analog channels is increased further, the number of additional input
boxes, and thus the structure of the parameter lists, is also increased.
Primary Weld, page 2
Primary Weld
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Crater Time
Crater time
0 to 1.5 seconds
*)
*)
Burnback Time
Burnback time 1)
0 to 1.5 seconds
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5 Programming and operation (continued)
The end crater parameters are only effective when the crater fill time (Crater Time) is greater
than zero. If the value for the crater fill time is zero, the burnback parameters for the last
command executed are used.
Further information on end crater filling and burnback can be found in the documentation
[KUKA.ArcTech Analog -- Configuration].
Wire Feed
Wire feed rate *)
0 to 20 meters per minute
Burnback Time
Burnback time
0 to 1.5 seconds
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6 Program example
6 Program example
A simple program example will now be used for a step--by--step demonstration of how the
individual commands available with KUKA.ArcTech Analog can be used. The welded
assembly shown in Fig. 35, consisting of three individual parts, is to be fabricated by means
of two seams.
Welding torch
Start position
ARC ON -- PTP
P8
P1
P7
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Start position
ARC ON -- PTP
P1
Seam 1
When you select Technology ! ArcTech Analog ! ARC ON ! PTP, the following
inline form will appear:
You can also correct your original selection (ARC command/motion command, type of
motion ...) by means of this softkey bar. The inline form changes accordingly when a selection
is made. The Cmd Abort softkey can be used to abort the command without saving data.
Now enter the motion and weld parameters into both the inline form and the corresponding
parameter lists.
An overview of both the inline input boxes and the parameter lists can be found in Section
5.6.3.
For the purpose of positioning the welding torch, move it to the position P1 by means of the
Space Mouse or the jog keys. Information on controlling motions of the robot manually can
be found in the chapter [Jogging the Robot].
You can now press the Touch Up softkey. In this case, press the Yes softkey to confirm
the query Touchup (Y/N)? that is displayed in the message window. Alternatively, press the
Cmd OK softkey or the Enter key. The current robot coordinates are automatically saved.
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6 Program example (continued)
The command is ended by pressing the Cmd OK softkey or the Enter key. If touchup has
not yet been performed for the point P1, the current robot coordinates are now automatically
saved. The information message Point P1 created automatically is displayed in the
message window.
The inline form is then closed and the generated program line is inserted into the program
form. The numbers of the following program lines are automatically updated.
P1
Seam 1
P2
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When you select Technology ! ArcTech Analog ! ARC OFF ! LIN, the following
inline form will appear:
Now enter the motion and weld parameters into both the inline form and the corresponding
parameter lists.
Overviews of both the inline input boxes and the parameter lists for the ARC OFF
command can be found in Section 5.8.3.
To position the welding torch, move it to the position P2 by means of the Space Mouse or
the jog keys.
You can now save the coordinates for this point by means of the Touch Up softkey or you
can automatically save them by pressing the Cmd OK softkey or the Enter key.
Pressing Cmd OK or the Enter key closes the inline form and the created program line is
inserted into the program form. The numbers of the following program lines are automatically
updated.
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6 Program example (continued)
P1
ARC ON -- PTP
Seam 1
ARC ON --
CIRC P3
P4
Seam 2
Motion -- PTP
P2
When you select Technology ! ArcTech Analog ! ARC ON ! PTP, the following
inline form will appear:
Use the procedure described in Section 6.3. After all of the commands have been entered,
the program form contains the motion command (to point P3) in line 6 and the weld command
ARC ON -- PTP (to point P4) in line 7.
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P1 P8
P7
Seam 2/2 P4
P6
P5 Seam 2/1
P2
ARC (SWI)
CIRC LIN
The first section of the seam is programmed as ARC SWITCH with the LIN motion type
and the second section as ARC SWITCH with the CIRC motion type. The ARC OFF
command with the LIN motion type ends the seam.
After entering the motion and weld parameters and moving to point P5, press the Cmd OK
softkey or the Enter key. The program form is updated accordingly.
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6 Program example (continued)
Unlike seams along a straight line, whose end point coordinates are automatically saved
when the command is ended, the auxiliary point coordinates for a CIRC motion have to be
saved by means of Teach Aux.
For this purpose, position the welding torch to the auxiliary point P6 (pay attention to the
orientation during this motion) and press the Teach Aux softkey. Answer the question
Touchup really? with the YES softkey.
Then move the torch to the end point P7 of this seam section; again paying attention to the
orientation. You can save the current robot coordinates immediately using the Teach End
softkey, or press the Cmd OK softkey or the Enter key.
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7 Altering existing programs
Move the edit cursor to line 6 (P3) by means of the arrow keys.
Press the Change softkey. The inline form for this command line is opened.
Press the LIN/CIRC softkey. Alternatively, the LIN motion type can also be selected using
the status key at bottom right if the first box on the left (PTP motion type) is active. The inline
form changes accordingly.
Enter the new parameters and then press the Cmd OK softkey or the Enter key. The inline
form is closed and the program form is updated accordingly.
This command line is to be deleted. To do so, move the edit cursor to line 10 and press the
Program menu key.
Select Line delete using the arrow key or press the key 1 on the numeric keypad (do not
press Enter). If you answer the request for confirmation in the message window with Yes,
the selected line is deleted and the program form is updated accordingly.
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(P3)
P12
ARC ON
Motion --PTP
--PTP P4
P3 Motion
--PTP
P2 P9 P10 P11
ARC ON
--PTP
For design reasons, the seam for the new part must be welded using different parameters:
it is to be welded as a normal straight seam in the first section and mechanical triangular
weaving is to be used in the second.
There are several ways of achieving this, e.g. the new seam could be welded last. However,
this would not be an efficient procedure for the entire sequence. To optimize execution and
the time taken to perform the operation, it is better to execute the welding process for this
new part immediately after seam 1 has been welded.
The following changes, therefore, have to be made to the program:
-- Alteration of the Motion command (P3)
-- Insertion of the ARC ON command (P9)
-- Insertion of the ARC SWITCH command (P10)
-- Insertion of the ARC OFF command (P11)
-- Insertion of the Motion command (P12)
The modified welded assembly is illustrated in Fig. 41.
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7 Altering existing programs (continued)
Start position
ARC ON -- PTP
P1 P8
ARC OFF
Seam 3/3
--LIN
P7
ARC OFF P12
Seam 1 Seam 3/2
--LIN
ARC (SWI) ARC ON
--CIRC Seam 3/1
P6 --PTP
P5 P4
Motion P3 Motion
--PTP ARC (SWI) --PTP
--LIN
P11
P2 P9 P10
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7.3.3 Inserting the welding start for the new seam -- ARC ON
Before opening the menu, make sure that the edit cursor (the blinking vertical line) is on
line 6. Insert the ARC ON -- PTP command for the new point P9. Use the procedure
described in Section 5.6.
7.3.4 Inserting the first section of the new seam -- ARC SWITCH
Select the ARC SWITCH -- LIN command for the first section (from P9 to P10) of the new
seam.
After entering the motion and weld parameters, press the Cmd OK softkey or the Enter key.
The program form is updated accordingly.
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7 Altering existing programs (continued)
7.3.5 Inserting the second section of the new seam -- ARC OFF
The second section (from P10 to P11) is executed using Mechanical weaving. As the seam
ends at P11, the ARC OFF command is used. Select the ARC OFF -- LIN command from
the Technology menu or by means of the softkey bar.
Enter the motion and weld parameters into both the inline form and the corresponding
parameter lists. To enter the parameters for mechanical weaving, open the Mechanical
weaving parameter list.
Select the desired weave pattern (Triangular weaving in our example) by means of the
bottom right status key. To do so, the Weave type input box must be active. Then enter the
values for the weave length, the lateral deflection (weave amplitude), and the angle of the
torch (weave angle).
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8 Online optimizing
8 Online optimizing
Online optimizing is only available in the user groups Expert and Administrator.
In order to activate online optimizing, a program has to be selected.
Online optimizing is selected using the menu function Program ! Modify ! Arc Tech
Online Optimizing. This option is activated with the Enter key, which will place a check mark
to the left of the option.
Once online optimizing has been activated, a yellow cursor appears in the program window
and the first command line is highlighted in yellow. Override is deactivated at the same time.
Online optimizing is possible in modes T1, T2, and AUT, but not in EXT.
When, during program execution, ARC SWI or ARC OFF commands arise, a specially
defined parameter list is opened in which the modifications can then be carried out.
Every time a program is aborted or reset, the online optimizing function is deactivated and
the last override value for correction motion is restored.
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Wire Feed
Example based on the weld velocity in the parameter list displayed above.
If the online optimizing function had not been activated, the 0.5 m/min displayed above
would be realized with an override of 100%.
With online optimizing selected, however, the general override is set in the background to
50% and, in order to enable optimization, the weld velocity is increased in the background
to 1 m/min.
At most, the weld velocity can be doubled or reduced to 1% of the original value. The actual
override varies in accordance with the modification to the weld velocity. The velocity
parameters are always read and processed in the advance run.
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8 Online optimizing (continued)
In online optimizing mode, changing the velocity also influences the acceleration
characteristics. For this reason, online optimizing mode is only suitable for the start--up
process or for adapting the weld parameters.
After the online optimizing mode has been deselected, the override should be adapted.
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Default
The value of the variable A_SYNERG_OPT (power sources with correction channel) can
be set to TRUE, thus influencing the specified channel.
Further information on the relationships between the parameters may be found in the
chapter [Mechanical weaving], in the section 5.9.1 Weave frequency, weave length, path
velocity.
If, in the event of online optimizing, this variable has the value 0, the following message
is generated in the message window: No cyclical analog outputs activated -- and no
changes can be made to the analog channels.
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9 Override for correction motions
9.1 Restrictions
-- Due to the reduction of the override, the weld velocity can only be increased as
far as the path velocity limit data. A corresponding message is displayed.
-- The reduction of the override changes the acceleration characteristics of the
robot. The lower the override, the slower the acceleration.
In online optimizing mode, changing the velocity also influences the acceleration
characteristics. For this reason, online optimizing mode is only suitable for the start--up
process or for adapting the weld parameters.
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10 Customization
Further software settings can be made in order to ensure optimal adaptation to the specific
requirements of the customer:
G Application--specific headings can be given to the parameter lists and units of the start,
weld and end crater parameters for each of the analog channels used.
For more details, refer to the documentation [KUKA.ArcTech Analog -- Configuration]
G The customer--specific settings are saved in the KUKA_CON.MDB file.
G Adaptations relating to burnback times can be removed from the display.
G Reinitialization mechanisms for programming increments and units in the parameter list
display.
In addition, there is the option of creating dynamically generated error messages, which can
be adapted to the application that is running. This means that it is possible to break down
a standard group error message and generate separate specific messages.
The configuration is saved in the ARC_MSG.SRC file. This greatly simplifies any
troubleshooting that may be necessary during operation.
1
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Index
Symbols D
#ACT_PAR, 19 Delay of weld start, 28
$TECH_ANA_FLT_OFF, 49 Deleting command lines, 65
Double 8, 43
DRY, 17
A
A_ACT_AN_MAX, 10, 53 E
A_AP_DIS_TCH=5.0, 31, 33 End Set, 54
A_BB_MODE, 10, 19
A_RAMP_OPTION, 10, 51 F
A_RAMP_OPTION = TRUE, 34, 39 Figure--eight weaving, 43
A_TH_WEAVE_OPT, 10, 48 Function overview, 72
A50_OPTION (KUKA.ArcSense), 10
Adding commands, 66 G
Altering command lines, 65
Gas postflow time, 54
Amplitude, weaving, 44 Gas preflow time, 23, 25, 27, 28
ARC OFF, 8, 35, 59
ARC OFF CIRC, 37
H
ARC OFF LIN, 36
HOT/COLD, 17
ARC OFF weld and end parameters, 38, 39
ARC ON, 8, 22, 58
ARC ON CIRC, 27
I
ARC ON LIN, 25 INI, 8
ARC ON PTP, 23 Inline form, 16
Installation, 13
ARC SWITCH, 8, 29, 62
Interrupt response, 74
ARC SWITCH LIN, 30, 32
ARC SWITCH weld parameters, 34
K
KUKA.ArcSense, 40
B
Basic settings, 19 L
Block selection response, 73 LIN, 22
Burnback mode, 19
Burnback time, 39, 41, 54 M
Maximum weave frequency, 46
Mechanical weaving, 42, 69
C
Menu keys, 15
CIRC, 22 Modification of the parameters, 72
Combined mechanical and thermal weaving, Modifying the weave parameters, 74
50 Modifying the weld voltage, 73
Controlling welding, 17 Modifying the wire feed, 74
Crater time, 39, 54 Motion characteristics of the robot, 46
Crater voltage, 39 Motion type, 22
Index -- i
Index
N T
Nomogram, 45
Thermal weaving, 48
O TRACK, 40
S
W
Seam sections, 29
Sensor, 40 Weave amplitude, 42
Softkeys, 16
Weave angle, 42
Spiral weaving, 43
Start parameters, 23, 25, 27 Weave frequency, 45
Start time, 23, 25, 27, 28 Weave length, 44, 45
Start voltage, 23, 25, 27, 28
Weave type, 42
Start welding -- ARC_ON, 22
Status key +, 17 Weld velocity, 41, 45
Status key --, 17 Weld voltage, 41
Status key DRY, 18
Wire feed, 17, 23
Status key HOT/COLD, 17
Status keys, 15 Wire feed rate, 25, 27, 39, 41
System response, 75 Wire feed rate at start, 28
Index -- ii