NX Robot Controller

COMARC Training Manual

Revised 11/25/05

NOT FOR RESALE

November 25, 2005

MOTOMAN 805 Liberty Lane West Carrollton, OH 45449 TEL: (937) 847-6200 FAX: (937) 847-6277 24-HOUR SERVICE HOTLINE: (937) 847-3200 WWW.MOTOMAN.COM

The information contained within this document is the proprietary property of Motoman, Inc., and may not be copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman, Inc. 2004 by MOTOMAN All Rights Reserved

PREFACE
PURPOSE OF THIS MANUAL
MOTOMAN TECHNICAL EDUCATION CENTER training manuals are not intended for use as stand alone training tools. This manual is to be used in conjunction with the NX COMARC course.

WHO SHOULD USE THIS MANUAL

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

HOW TO USE THIS MANUAL

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

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

NOTE:

This manual is not for resale and will not be sold separately. All training manuals developed by MOTOMAN TECHNICAL EDUCATION CENTER are copyrighted. Do not copy any portion of these manuals.

CONTENTS
1.0 COMARC SEAM TRACKING .............................................. 1-1
1.1 Connection Verification ........................................................................ 1-1 1.2 Arc Sensor Function ............................................................................ 1-2 1.3 Setting Up for ComArc Seam Tracking ................................................ 1-4
1.3.1 Program the Path ........................................................................................... 1-4 1.3.2 Registering the ComArc instructions ............................................................... 1-5

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

1.4.1 1.4.2 Measurement and Registration of Phase Compensation ............................. 1-7 Measurement and Registration of Sensing Conditions ................................ 1-9

1.5 Testing COMARC .............................................................................. 1-12 1.6 COMARC Condition File ................................................................... 1-13
1.6.1 1.6.2 U/D & L/R Correction Selection ................................................................. 1-13 Passover Function .................................................................................... 1-14

1.7 Dead Zone ........................................................................................ 1-15 1.8 COMARCSET ................................................................................... 1-15 1.9 SCOMARC ........................................................................................ 1-15

2.0

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

2.1 POSITION VARIABLES....................................................................... 2-1
2.1.1 2.1.2 Access to Position Variable Display ............................................................ 2-1 Establishing Data Type ............................................................................... 2-2

2.2 Programming Motion with Position Variables ....................................... 2-3 2.3 Position Variable Functions ................................................................. 2-3
2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 CNVRT ....................................................................................................... 2-3 GETE ......................................................................................................... 2-4 SETE ......................................................................................................... 2-5 GETS ......................................................................................................... 2-5 Reference Points ........................................................................................ 2-5

2.4 SYSTEM VARIABLES ($) ................................................................... 2-6 2.5 Temporary Shift Instruction (SFTON/SFTOF) ....................................... 2-7 2.6 Touch jobs ........................................................................................... 2-9
2.6.1 2.6.2
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Reference Point Location ............................................................................ 2-9 Touch Jobs ................................................................................................. 2-9

TOC-1
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1.0

COMARC SEAM TRACKING

Seam Tracking is a function of ComArc that uses amperage feedback from the arc to determine the location of the weld joint. It is recommended for fillet joints only, in the 1F or 2F positions. Out of Position tracking is not recommended. Weaving is required. Most of the ComArc Seam Tracking programming functions can only be performed in the Management Security level. To access the Management Security Level, perform the following: 1. 2. 3. 4. With the MAIN MENU displayed, choose SYSTEM INFO. Choose SECURITY. Press SELECT, cursor to MANAGEMENT and press SELECT. Enter the appropriate password and press ENTER.

The security level indicator in the STATUS area should now show Management Mode.

1.1

Connection Verification
Specific hardware is required to use the COMARC function. This hardware (the NCP02 card) processes the amperage, or current feedback from the power source. This information can be displayed and indicates that the board is functioning properly. To view the signals being input to the NCP02, perform the following: 1. 2. In the PLAY mode, with a welding job selected and the cursor on the NOP, choose In/Out from the Main Menu. Choose NCP02 I/O.

The screen in Figure 1 will be displayed.

DATA
JOB
DOUT MOVE END

EDIT
FD/CF
CF

DISPLAY

UTILITY

NCP02 I/O STATUS BOARD : NCP02#1 NO. A/D (IN) 1 2 3 4 5 6 7 8 -32768 0 0 0 0 0 0 0

(OUT)

ARC WELDING

PARAMETER

VARIABLE

SETUP

B001
IN/OUT In Out

ROBOT

SYSTEM INFO

Main Menu

Short Cut

Figure 1-1 NCP02 I/O Status Screen

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

1.2

Arc Sensor Function

An understanding of weld characteristics helps the understanding of COMARC. Amperage in the arc is dependent on many variables. Some of these are: 1. Wire diameter 2. Wire type 3. Base metal type 4. Base metal thickness 5. Shielding gas type 6. Welding Equipment (power source and wire feeder) 7. Wire feed speed 8. ESO (Electrical Stick Out) Changes to any of these will cause the amperage to vary. Since the first six (6) of these variables are not frequently changed, the amperage variances are normally caused by the Wire Feed Speed and the Electrical ESO (ESO) changes. Wire feed speed is controlled by the Amperage settings in the Arc Start Files, and can be considered fixed in this situation. Now the only variation to the amperage/current is due to changes in ESO. Figure 2 shows the relationship.

Figure 1-2 Electrical Stick Out (ESO)

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

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

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

Figure 1-4 Electrical stickout when the path is offset

Because of the inequality of ESO (and related amperage) the path should be shifted in a Left or Right direction. There may also be deviation in the path caused by the height of the parts. In this situation, the path requires a shift either Up or Down as shown in Figure 5.

Figure 1-5 Offset path (vertically)

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1.3

Setting Up for ComArc Seam Tracking

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

1.3.1 Program the Path

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

Safe Point Pullout (Departure) Finish

Start

Decel (Approach)

Figure 1-6 Fillet programming

The Job will also have a normal ARCON ASF#(X) and ARCOF AEF#(X) (or any other technique for weld programming) in the proper locations. Weave instructions must be programmed in this initial job. Use a normal WVON and WVOF instruction referencing the appropriate file. Test and PLAY the job to ensure good arc characteristics and a proper weld bead with no undercut is deposited. The Job should appear as in Figure 6.

Note:

To achieve proper results, the length of the test weld should be at least 8 inches and the amplitude of the weave should be at least 2.5 mm.
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JOB
JOB
DOUT MOVE END

EDIT
FD/CF
CF

DISPLAY

UTILITY

JOB CONTENT JOB NAME : TEST CONTROL GROUP : R1

0002 0003 0004 0005 0006 0007 0008 0009 0010

STEP NO : 002 TOOL : 00

ARC WELDING

PARAMETER

VARIABLE

SETUP

B001
IN/OUT In Out

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

ROBOT

SYSTEM INFO

=> MOVJ VJ=50.00

Main Menu

Short Cut

Figure 1-7 Job with ARCON instruction

CAUTION!

Weave settings should be the same for both the test and the production part weld. Changes can be made to the Amplitude, but changes to the Weave Frequency will cause the system to not track the part.

1.3.2 Registering the ComArc instructions

The ComArc instructions (COMARCON and COMARCOF) must be in the program after the ARCON and before the ARCOF. The COMARCON instruction will take the place of the WVON instruction. The COMARCOF instruction will take the place of the WVOF instruction. The ComArc instructions are in the INFORM LIST under the SENSOR selection. The COMARCON will need to be edited for the proper data. Use the DETAIL EDIT screen for this procedure by pressing SELECT with the cursor on the COMARCON instruction in the input line. There are at least three (3) and up to four (4) pieces of information included on the COMARCON instruction line. These available choices are: 1a. Weave File- the same as used in the original set-up job or 1b. Set AMP for amplitude and FREQ for frequency of the weave 2. Set the U/D (for the amperage/stickout) 3. Set the L/R (for offset leg lengths) 4. (optional) identify the COMARC File

NOTE:

When weaving conditions are set by AMP, FREQ, and ANGL on the COMARC line, the weaving mode is single oscillation .

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The COMARCOF instruction is programmed without any tags and will instruct the controller to both stop tracking and stop weaving.
JOB
JOB
DOUT MOVE END

EDIT
FD/CF
CF

DISPLAY

UTILITY

JOB CONTENT JOB NAME : TEST CONTROL GROUP : R1

0002 0003 0004 0005 0006 0007 0008 0009 0010

STEP NO. : 002 TOOL : 00

ARC WELDING

PARAMETER

VARIABLE

SETUP

B001
IN/OUT In Out

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

ROBOT

SYSTEM INFO

=> MOVJ VJ=50.00

Main Menu

ShortCut

Figure 1-8 Job Structure with ComArc instructions NOTE: There will only be tracking between the COMARCON and COMARCOF instructions. Any welding after the ARCON and before the COMARCON (line 0004 in Figure 1-8) or after the COMARCOF and before the ARCOF (line 0009 in Figure 1-8) will not be using the seam tracking function.

1.4

Measurement and Registration of Information

Two tests must be performed when setting up a COMARC weld. The first is a Phase Compensation test. The second is a Sensing Test. The information fed back to the controller as A/D data is delayed from real time based on the length of the cables and harnesses.
Welding current peak value Welding current wave form

Both ends of weaving motion

Weaving motion

Figure 1-9 Phase Difference

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

NOTE:

Once a weld is set-up for tracking, changes in the Weave frequency will cause the system not to track properly. Measurement and Registration of Phase Compensation
After a job has been created to properly weld the example weld joint, a single weld is made to accumulate the Phase Compensation data.

1.4.1

NOTE:

This test may not establish good data if only run a single time. If tracking fails, run the test multiple times (up to 10 may be required) and use either the Mean data or the Median number.
This weld will be made in the same location as the original but without the top plate.

weave direction

weave direction

Original Joint

PC Test Joint

Figure 1-10 PC Test Joint

This wide variation of ESO allows the controller to recognize the time delay, or the Phase Compensation required. This measurement will be in milliseconds. To measure and register phase compensation value, set the parameter SxE197 to a value of 1. This setting instructs the controller to calculate the Phase Compensation value. To place the controller in the Measurement Mode, perform the following keystrokes: 1. 2. 3. 4. 5. Select the Job for measurement. Select PLAY. In the MENU area, choose UTILITY. Choose SETUP SPECIAL RUN. Cursor down to COMARC MEASURE MODE and press SELECT.
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SPECIAL PLAY LOW SPEED START SPEED LIMIT DRY-RUN SPEED MACHINE ROCK CHECK-RUN WEAV PROHIBIT IN CHK-RUN COMARC MEASURE MODE INVALID INVALID INVALID INVALID INVALID INVALID VALID

Figure 1-11 Setup Special Run Screen

This should make the Measure Mode VALID and display a message on the Message Line COMARC MEASURE MODE. Run the job. 1. 2. 3. From the MAIN MENU, choose JOB. In the sub menu, choose JOB. Execute the job (weld).

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

The screen for the Phase Compensation will be displayed as shown in Figure 1-12. Note the parameter number and the Phase Comp value.
COMARC PHASE COMP JOB NAME TEST PARAMETER NO. PHASE COMP SENSOR SL 1 63 286 msec

Figure 1-12 COMARC Phase Compensation Screen

To record the results of the PC test, perform the following: 1. 2. 3. 4. From the Main Menu, choose PARAMETER. Choose SxE. With the cursor on the Parameter numbers (left side) press SELECT, enter the parameter number from the above test and press ENTER. Cursor to the Value side (right side), press Select, enter the value of the Phase Comp and press ENTER.
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NX ComArc 1.4.2 Measurement and Registration of Sensing Conditions

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

LEFT

UP

DOWN

RIGHT

Horizontal direction

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

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

weave direction

weave direction

Original Joint

Sensing Test Joint

Figure 1-14 Sensing Test Joint

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

NOTE:

Parameter SxE197 sequences the COMARC COND MODIFY screen. This will allow the display the Phase Comp display (value of 1) or the ComArc Cond Modify display (value of 0).
2. 3. 4. 5. Select the Job for measurement. Select PLAY. In the Menu Area, choose UTILITY. Choose SETUP SPECIAL RUN.

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

NOTE:

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

SPECIAL PLAY LOW SPEED START SPEED LIMIT DRY-RUN SPEED MACHINE ROCK CHECK-RUN WEAV PROHIBIT IN CHK-RUN COMARC MEASURE MODE INVALID INVALID INVALID INVALID INVALID INVALID VALID

Figure 1-15 Setup Special Run Screen

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

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

DATA
MODIFY COMARC COND DOUT MOVE
END

EDIT
FD/CF
CF

DISPLAY

UTILITY

COMARC COND. MODIFY JOB NAME : TEST!!! SENSOR SL1 STEP CURRENT OFFSET-CURRENT 03 04 05 239 236 238 0.0 0.0 0.0

ARC WELDING

PARAMETER

VARIABLE

SETUP

B001
IN/OUT In Out

ROBOT

SYSTEM INFO

Main Menu

Short Cut

Figure 1-16 COMARC COND MODIFY screen

This is the information that the COMARC function has seen as compared to the information initially programmed into the COMARCON instruction.
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To register this information into the COMARCON instruction in the job, perform the following keystrokes: 1. 2. 3. In the Menu Area, choose DATA. MODIFY COMARC COND will be the only pull down. Choose or SELECT to register the U/D and L/R information in the COMARCON instruction in the job.

U/D data is the actual amperage that the controller recorded as the Sensing Test was performed. This should be close to the ARCON data if the Power Source Condition File is set for Amperage. If the Power Source Condition File is set for Wire Feed Speed, there will be no correlation between the ARCON and the U/D data. L/R data is the difference between the Upper Leg amperage and the Lower Leg amperage. Values other than 0 technically indicate that the weld is not equal leg length.

NOTE:

Manually changing the U/D data will either increase or decrease the stickout. Changing the L/R data will create an offset fillet weld. One leg will be shorter than the other. If the weld is currently offset, modification of the L/R data can be used to force the equalization of the fillet legs.
To turn off all Measurement Modes: 1. 2. 3. 4. 5. Display the current job and put the system back in the PLAY mode. In the Menu Area, choose UTILITY. Choose SETUP SPECIAL RUN. Cursor to COMARC MEASURE MODE. Press SELECT to make this INVALID.
SPECIAL PLAY LOW SPEED START SPEED LIMIT DRY-RUN SPEED MACHINE ROCK CHECK-RUN WEAV PROHIBIT IN CHK-RUN COMARC MEASURE MODE INVALID INVALID INVALID INVALID INVALID INVALID INVALID

Figure 1-17 Measurement Mode INVALID

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1.5

Testing COMARC
All information for COMARC Seam Tracking has now been collected and recorded. Checking the COMARC function and current set-up is performed by welding using the COMARCON/COMARCOF instructions with the part in the nominal position. A second weld is made with the part shifted horizontally at the ARCOF end of the weld.

NOTE:

By default, the COMARC correction values are between 100 and 150 microns (.100mm to .150 mm) per weave cycle. If the controller cannot correct enough to follow the joint, the tracking may appear not to work. Changing the parameter for correction amount may allow the controller to properly track the joint.
A third weld is made with the part shifted vertically at the ARCOF end of the weld. A fourth weld is made with the part shifted both horizontally and vertically at the ARCOF end of the weld. More testing may be performed. If it is not feasible to shift the parts, the same scenario may be created by modifying the taught points away from the part.

NOTE:

Incorrect tracking of the offset part may indicate the need to perform the set-up tests again or correction of COMARC parameters.
The amount of correction applied by the COMARC function can be viewed by performing the following: 1. 2. From the Main Menu choose Arc Welding. Choose COMARC CORRECT.

The following screen will be displayed.

DATA
JOB
DOUT MOVE END

EDIT
FD/CF
CF

DISPLAY

UTILITY

CORRECTING LIST NO. OF STEPS : 3 STEP SENSOR : SL1 STEP VAR-U VAR-D V AR-L VAR-R 003 004 005 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

ARC WELDING

PARAMETER

VARIABLE

SETUP

B001
IN/OUT In Out

ROBOT

SYSTEM INFO

Main Menu

Short Cut

Figure 1-18 COMARC Correcting List

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1.6

COMARC Condition File

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

COMARC COND NO. : 1 / 16 CORRECTION SELECT <PASS OVER MONITOR> CONDITION VERTICAL MONITOR HORIZONTAL MONITOR NO. U/D & L/R ALARM 0.0 mm 0.0 mm 1 time(s)

Figure 1-19 COMARC File 1.6.1 U/D & L/R Correction Selection
There are 16 COMARC files that are able to be specified in any COMARCON instruction. These are viewable through the use of the PAGE key, or through the Direct Open key from the job. The first item in the file is the Correction Select. This can be selected as:

Table 1-1 COMARC Condition Correction Select

Setting

Function

U/D & L/R

Corrects the path in the Up, Down and Left, Right directions

L/R

Corrects the path in the Left and Right directions only (Up and Down directions are not corrected). Corrects the path in the Up and Down directions only (Left and Right directions are not corrected).

U/D

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NX ComArc 1.6.2 Passover Function

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

ALARM

An alarm occurs, and the manipulator stops.

Pass-over occurred, and the manipulator stops.

Actual welding line

Pass-over monitor value

Taught line

TEACHING POSITION

Sensing stops, and the manipulator returns to the taught position and continues welding.

Pass-over occurred

Restarts sensing from the taught position

Sensing stops, and the manipulator returns to the taught position.

CORRECTION The taught position just after the occurrence of pass-over. The manipulator restarts welding from a position adjusted for the amount of shift from the taught position just RETAIN before the occurrence of the pass-over.
Sensing restarts at a new, adjusted position. The distance between this new position and the taught position is equal to the amount of shift from the taught position just before the passover.

Pass-over occurred

Amount of shift from the taught position

Taught position just before the occurrence of pass-over

Taught position just after the occurrence of pass-over

NOT MONITOR

The pass-over is not monitored.

The Vertical Monitor sets the pass-over monitor value for the up/down directions. When set to 0.0, the up/down direction is not monitored. The range is 0.0 to 25.5. The Horizontal Monitor sets the pass-over monitor value for the left/right directions. When set to 0.0, the left/right direction is not monitored. The range is 0.0 to 25.5. No. is the number of times the manipulator passes outside the vertical and/or horizontal limits. The range is 1-10.

NOTE:

The COMARC Condition File is optionally used for the seam tracking function.

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1.7

Dead Zone

Figure 1-20 Tee Joint with Tack

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

1.8

COMARCSET
COMARCSET is an instruction that will change the COMARC function. This allows the changing of the weave data, the weave file, the U/D data, the L/R data, and/or the COMARC file #. This instruction is programmed between the COMARCON and the COMARCOF instructions. The controller will start using the new data at the point of the instruction.

1.9

SCOMARC
SCOMARC is the tracking function/Instruction that is used with systems using Coordinated Motion. As the controller is coordinating motion between a robot and a positioner (normally), it must also coordinate the COMARC tracking. The set-up is performed the same as in the previous section. The Instruction is available in the Inform List, when applicable.

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SxE Parameters

Parameter No. 0 1~19 20

Contents Application designation Not used Analog signal input channel

Unit -

Initial Value SL1: 1 SL2: 2 SL3: 1 100

Setting Range 1 to 8

21 22

Compensation value for conversion of an AD value to a current value Number of times that correction was prohibited at COMARCON Number of times that correction was prohibited at MIN: correction prohibited current Correction prohibited minimum current Correction prohibited maximum current Not used Dead zone U/D Dead zone L/R Not used Correction amount Y+ (Weaving frequency less than 2.0 [Hz]) Correction amount Y(Weaving frequency less than 2.0 [Hz]) Correction amount Z+ (Weaving frequency less than 2.0 [Hz]) Correction amount Z(Weaving frequency less than 2.0 [Hz]) Correction amount Y+ (Weaving frequency 2.0 [Hz] or more, less than 3.0 [Hz])

[%] -

0 to 100 0 to 10000 -

4 0

23

24 25 26 27 28 29 30

[0.1A] [0.1A] [0.1A] [0.1A] [m]

500 10000 50 50 150

0 to 10000 0 to 10000 0 to 10000 0 to 10000 0 to 10000

[m]

150

0 to 10000

31

[m]

150

0 to 10000

32

[m]

150

0 to 10000

33

[m]

150

0 to 10000

34

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SxE Parameters

Parameter No. 35

Contents Correction amount Y(Weaving frequency 2.0 [Hz] or more, less than 3.0 [Hz]) Correction amount Z+ (Weaving frequency 2.0 [Hz] or more, less than 3.0 [Hz]) Correction amount Z(Weaving frequency 2.0 [Hz] or more, less than 3.0 [Hz]) Correction amount Y+ (Weaving frequency 3.0 [Hz] or more, less than 4.0 [Hz]) Correction amount Y(Weaving frequency 3.0 [Hz] or more, less than 4.0 [Hz]) Correction amount Z+ (Weaving frequency 3.0 [Hz] or more, less than 4.0 [Hz]) Correction amount Z(Weaving frequency 3.0 [Hz] or more, less than 4.0 [Hz]) Correction amount Y+ (Weaving frequency 4.0 [Hz] or more) Correction amount Y(Weaving frequency 4.0 [Hz] or more) Correction amount Z+ (Weaving frequency 4.0 [Hz] or more) Correction amount Z(Weaving frequency 4.0 [Hz] or more) Not used Sampling interval Not used Phase compensation value Not used Measurement mode (1: Phase compensation value measurement) Not used

Unit [m]

Initial Value 150

Setting Range 0 to 10000

[m]

150

0 to 10000

36

[m]

150

0 to 10000

37

[m]

100

0 to 10000

38

[m]

100

0 to 10000

39

[m]

100

0 to 10000

40

[m]

100

0 to 10000

41

42 43 44 45 46~49 50 51~59 60~179 180~196 197 198,199

[m] [m] [m] [m] [msec] [msec] -

100 100 100 100 2 0 -

0 to 10000 0 to 10000 0 to 10000 0 to 10000 1 to 10 0,1 MOTOMAN

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ComArc III Touch Sensing

2.0 SEAMFINDING/ TOUCHSENSING

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

2.1

POSITION VARIABLES
The NX controller has 128 Position Variable addresses, #P000-P127, that can be used for storing position and shift data.

2.1.1

Access to Position Variable Display

To access the Position Variable display, complete the following steps: 1. 2. 3. or Use the PAGE key to go to the next address; use SHIFT + PAGE keys to go to previous address. or Choose EDIT, choose SEARCH, enter desired address number, then press ENTER. From MAIN MENU; choose VARIABLE. Choose POSITION (ROBOT). Touch PAGE on the Position Variable display screen, enter the desired address number, then press ENTER.

DATA

EDIT

DISPLAY

UTILITY

POSITION VARIABLE #P000 :S L U R B T ******* * * * * * * NAME: TOOL: **

Main Menu

ShortCut

!Turn on servo power

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

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ComArc III Touch Sensing 2.1.2 Establishing Data Type

To delete data and/or change the data type of the displayed variable address, complete the following steps: Cursor to highlight the existing data type; press SELECT. Cursor to YES for the CLEAR DATA? question; press SELECT. or Choose DATA; Choose CLEAR DATA; press SELECT.

NOTE:

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

DATA

EDIT

DISPLAY

UTILITY

POSITION VARIABLE #P000 :S L U R B T PULSE 0 0 0 0 -80000 27000 NAME: TOOL: 00

Main Menu

ShortCut

!Turn on servo power

DATA

EDIT

DISPLAY

UTILITY

POSITION VARIABLE #P000 ROBOT R1:X 330.000 Y 0.000 Z -10.000 0.00 Rx Ry 0.00 Rz 0.00 NAME: TOOL: 00 <TYPE> FRONT UP FLIP

S<180 R<180 T<180

DIRECT PAGE
Main Menu ShortCut
!Turn on servo power

Figure 2-2 Position Variable formats

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

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2.2

Programming Motion with Position Variables

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

NOTE:

If no speed is desired, cursor to the MOV_ and press SELECT. Choose the V or VJ area of DETAIL EDIT and select UNUSED.
Job Example: LINE 0001 0002 0003 0004 INSTRUCTION MOVJ P000 VJ=25.00 MOVJ VJ=100.00 MOVL P018 V=76 MOVL P126 V=220 PL=0

NOTE:

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

2.3
2.3.1

Position Variable Functions

CNVRT
The CNVRT instruction converts a Position variable from Pulse or any XYZ Frame to only an XYZ type ( BF, RF, UF, or TF). The converted data may be stored in the same address or another designated Position variable address. Examples: CNVRT PX003 PX003 RF CNVRT LPX004 LPX005 UF#(24)
LP004) (Converts data of P003 into RF type)

(Converts data of LP005 into UF type in

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CNVRT PX[B006] PX000 BF

address

(Converts data of P000 into BF type in P determined by B006)

CNVRT LPX[I007] LPX[B009] TF

(Converts data of LP address determined by B009 into TF type and stores in LP address determined by I007)

stores status results in B000)

2.3.2

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

DISPLAY

POSITION VARIABLE
UTILITY

POSITION VARIABLE #P001 :S L U R B T PULSE 12956 20 0 0 459 1427

#P000 ROBOT R1:X 330.000 0.000 1st Y NAME: -10.000 2nd Z TOOL: 00 0.00 3rd Rx 0.00 4th Ry 0.00 5th Rz

NAME: TOOL: 00 <TYPE> FRONT UP FLIP

S<180 R<180 T<180

6th

DIRECT PAGE
Main Menu Main Menu ShortCut ShortCut
!Turn on servo power

!Turn on servo power

Figure 12-1 Position Variable Elements NOTE: The X, Y, & Z elements are stored as thousandths of a millimeter (microns), and the Rx, Ry, & Rz elements are stored as hundredths of a degree.
Examples: GETE D099 P007 (3)
(Gets third element of P007 and stores value in D099) (Gets element, determined by B099, of P address, determined by I005, and store value in LD000)

GETE LD000 P[I005] (B099)

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ComArc III Touch Sensing 2.3.3 SETE

SET ELEMENT sets the designated element in a Position variable equal to a constant or a value stored in a D-variable address. Examples: SETE P007 (1) 500000 SETE P007 (5) -4500 SETE LP005 (B002) LD[B002]
(Sets constant into first element of P007) (Sets constant into fifth element of P007) (Sets data from LD address determined by B002 into LP005s element also determined by B002)

2.3.4

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

2.3.5

Reference Points
Reference Points are taught positions. The controller does NOT move the robot to these positions, rather uses the locations for reference information. This may be the orientation of a part for a Weave instruction, or the nominal location of a part for Touch Sensing. To program a Reference Point, perform the following: 1. 2. 3. 4. Jog the robot to the location desired. With the cursor on the Address Side, press the number 0 key to bring REFPT into the buffer line. Cursor to the Reference Point number and press SELECT. Enter the desired Reference Point number, press ENTER to enter it into the buffer line, and INSERT and ENTER to enter it into the job.

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2.4

SYSTEM VARIABLES ($)

System variables are storage locations of information that the controller sees. As indicated below, this could be things such as the robots current position (both in Pulse and XYZ), the status of a touch or search, or the position of Reference Points. There are 6 types of System Variables used with the XRC. All are designated by the $ symbol. The four ARITHMETIC types $B, $I, $D, & $R, and the CONTROL GROUP AXES POSITION type $PX, are fetched using the GETS Arithmetic Function and stored in the corresponding User type. The $C-type is used only in Concurrent I/O programming. Each System Variable address is dedicated for a specific use. Some samples for dedicated use are included in table 4-1:

Table 2-1 System Variables

SYSTEM VARIABLES $B-typ e

USER TYPE B-typ e

DEDICATED USE $B002= Re turn co d e fo r SRCH instructio n $B006 = Re turn co d e fo r HSEN instructio n $B008= Re turn co d e fo r SYSTART instructio n $PX000 = Curre nt inte rp o late d p ath p o sitio n d ata in PULSE fo r R1 syste m o r slave o f R1 + R2 syste m $PX001 = Curre nt inte rp o late d p ath p o sitio n in XYZ (BF) fo r R1 o r inte rp o late d p ath p o sitio n d ata in PULSE fo r maste r o f R1+R2 $PX002 = Actual FEEDBACK PULSE p o sitio n d ata fo r R1 syste m o r slave o f R1+R2 syste m $PX003 = Actual FEEDBACK XYZ (BF) p o sitio n fo r R1 o r actual FEEDBACK PULSE fo r maste r o f R1+R2.

$PX-typ e

PX-typ e (Gro up s o f P-typ e )

$PX011 = REFP1 Pulse $PX012 = REFP2 Pulse $PX013 = REFP3 Pulse $PX014 = REFP4 Pulse $PX015 = REFP5 Pulse $PX016 = REFP6 Pulse $PX017 = REFP7 Pulse $PX018 = REFP8 Pulse $PX021 = SREFP1 Pulse $PX022 = SREFP2 Pulse $PX023 = SREFP3 Pulse $PX024 = SREFP4 Pulse $PX025 = SREFP5 Pulse $PX026 = SREFP6 Pulse $PX027 = SREFP7 Pulse $PX028 = SREFP8 Pulse $C000-$C015 TIMER (Op e rand # 6010-# 6027) $C016-$C031 COUNTER (Op e rand # 6030-# 6047)

$C-typ e

C.I/O o nly

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2.5

Temporary Shift Instruction (SFTON/SFTOF)

The Shift Function provides the ability to transfer (shift) a single or group of programmed positions by a specified distance and orientation. It uses position variables for offsets in the X, Y, Z, RX, RY, and RZ directions. The shift value is the difference of X, Y, or Z in the specified coordinate system between the programmed position, the shifted position, and the tool displacement of degrees RX, RY, and RZ. Shifts may also be performed using PULSE data type position variables. By using the Shift Function, a minimal number of robot positions are programmed in order to provide execution at multiple locations. This simplifies and reduces the time required to teach a job. This function is extremely useful for palletizing, stacking, loading/unloading, and other applications that perform repeated functions at multiple locations. The Shift Function is activated by programming a SFTON (shift on) instruction and specifying a position variable and relative coordinate frame tag. If no coordinate frame is specified, then it is defaulted to the Base Frame upon execution of that program line.

NOTE:

The shift data in the position variable may be set up in advance by manual editing, by using the CNVRT instruction, or it may be calculated using the MSHIFT instruction.
When the SFTON is executed, programmed positions are shifted by the data indicated in the specified position variable. The Shift Function will affect servo recorded Command Positions and motion programmed with position variables. If a CALL JOB or JUMP JOB instruction is executed during SFTON section of a job, the positions is these child jobs will also be shifted. The SFTON instruction remains active until the SFTOF instruction is executed. In the job example the motions in Lines 0013, 0014, and 0015 will be shifted during continuous operation in Play mode or with INTERLOCK + TEST START in Teach. LINE 0011 0012 0013 0014 0015 0016 0017 INSTRUCTION MOVJ VJ=25.00 SFTON P127 UF#(5) MOVJ P000 VJ=100.00 MOVL V=1250 MOVL V=1250 SFTOF MOVJ VJ=100.00

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To program the SFTON instruction, complete the following steps: 1. 2. 3. 4. 5. Display the job in Teach mode with the cursor on the Address side. Press the INFORM LIST key and choose SHIFT. Choose SFTON. Press SELECT with the cursor on SFTON at the Edit Buffer line to access the DETAIL EDIT screen. Cursor to the existing P-VAR ROBOT address, press SELECT, enter the desired address number; press ENTER.

When entered as SFTON PXXX, the shift will be in the Base Frame regardless of the coordinate set in the Position variable. If a different coordinate/Frame is desired: 1. 2. 3. or Select UF#( ), enter the desired number; press ENTER. 4. 5. Press ENTER to exit the DETAIL EDIT screen. Press ENTER. With the cursor on the SFTON in the Edit Buffer Line, press SELECT to access the Detail Edit Screen. Cursor to the COORDINATE UNUSED and press SELECT. Cursor to BF, RF, TF, or UNUSED; press SELECT.

To program the SFTOF instruction, complete the following steps: 1. 2. 3. 4. Display the job in Teach mode with the cursor on the Address side. Press the INFORM LIST key, choose SHIFT. Choose SFTOF. Press ENTER.

NOTE:

The current shift value in the position variable may be monitored when active by displaying the SHIFT VALUE screen under the ROBOT icon menu.
The results of multiple SFTON instructions is not cumulative. Using a second SFTON with a different Position variable reference simply changes to the specified variable. SFTOF is not required to change from one set of shift data to another.

CAUTION!

If the cursor is placed on a motion step between the SFTON and SFTOF instructions and the TEST/START or the FWD key is used, the NX100 will move the robot to the command position guiding the TCP for the TOOL No. of the originally recorded step!
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2.6

Touch jobs
Touch jobs are frequently provided by Motoman. These provided jobs are designed for specific situations. TOUCH1 (or R1-TCH-1) is designed to find both the vertical and horizontal plates of a fillet weld. There are jobs designed for lap joints, single direction touches, end search, and corner search. When the logic is understood in the provided jobs, development of joint specific jobs can easily be done.

2.6.1

Reference Point Location

Reference Points are programmed in the weld job. Typical job structure would be: Placement of Reference Points is critical. These taught locations provide a normal plate location for the offset calculations.
Ref Pt 5 Ref Pt 3

Ref Pt 4

Figure 5-1 Location of Reference Points for Touch 1 Job 2.6.2 Touch Jobs
The Touch job is used as a subroutine. NOP MOVJ VJ=100.00 MOVJ VJ=100.00 MOVJ VJ=100.00 REFP 3 REFP 4 REFP 5 CALL JOB:R1-TCH-1 SFTON P001 MOVJ VJ=25.00 ARCON ASF#(1)

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The contents of a typical Touch job appear as:

NOP '******************************** 'THIS JOB USES GLOBAL P001 ONLY * 'YOUR OFFSET AMOUNT WILL BE * 'STORED IN P001 * '******************************** GETS LPX001 $PX013 GETS LPX002 $PX014 GETS LPX003 $PX015 'REF POINTS 3 4 5 '******************************** CNVRT LPX004 LPX001 BF CNVRT LPX005 LPX002 BF CNVRT LPX006 LPX003 BF 'CONVERT REF 3 4 5 TO BASE FRAME '******************************** MOVL LP001 V=12.5 'MOVE TO REF P 3 MOVL LP002 V=12.5 SRCH RIN#(1)=ON T=0.10 DIS=25.0 'SEARCH TOWARD REF P 4 '******************************** GETS LB000 $B002 'SEARCH DETECTION '******************************** JUMP *NG IF LB000=0 'TOUCH FAILED IF LB000=0 '******************************** GETS LPX007 $PX002 'GETTING 1ST DETECTION POINT '******************************** CNVRT LPX008 LPX007 BF SUB LP008 LP005 'CALCULATING 1ST SHIFT AMOUNT '******************************** MOVL LP001 V=12.5 'MOVE TO REF P 3 MOVL LP003 V=12.5 SRCH RIN#(1)=ON T=0.10 DIS=25.0 'SEARCH TOWARD REF P 5

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'******************************** GETS LB000 $B002 'SEARCH DETECTION JUMP *NG IF LB000=0 'TOUCH FAILED IF LB000=0 '******************************** GETS LPX009 $PX002 'GETTING 2ND DETECTION POINT '******************************** CNVRT LPX010 LPX009 BF SUB LP010 LP006 'CALCULATING 2ND SHIFT AMOUNT '******************************** ADD LP008 LP010 SET P001 LP008 'SETTING GLOBAL SHIFT VARIABLE '******************************** SETE P001 (4) 0 SETE P001 (5) 0 SETE P001 (6) 0 'CLEARING ROLLABOUT DATA '******************************** MOVL LP001 V=12.5 RET *NG SUB P001 P001 'RESETTING GLOBAL SHIFT VARIABLE PAUSE 'TOUCH FAILED '******************************** MOVL LP001 V=12.5 END Final offset amounts are stored in P001 and are used in the parent job as the Position Variable for the SFTON instruction. If P001 is being used for other purposes, or if there are multiple touch routines being performed, use the SET instruction in the Parent Job to transfer the offset information to another Position Variable.

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NOTES

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