Training on FANUC ROBOTS

Introduction to Robots
Training Topics
 Basic Introduction

What is a Robot?

An Industrial robot is a reprogrammable multifunctional assembly

of linkages called manipulator, designed to carry out operations
through variable programmed motions.
 Major Components of a Robot

MECHANICAL MANIPULATOR

ROBOT CONTROLLER

END OF ARM TOOLING (EOAT)

TEACH PENDANT
Major Components of a Robot
 Mechanical Manipulator
 A manipulator is a mechanical assemblage of rigid links
consisting of axis and arms which are driven by servo motors.

 When the mechanical linkages are connected in series the

linkage is an articulated system
EOAT (End of the Arm Tool)
 The EOAT (End of the Arm tool) attached to the Robot flange
performs the process that the robot is expected to carry out. (ex.,
Spot welding gun, Arc welding torch, Material handling gripper,
Sealant dispensing nozzle etc.,)
 Teach Pendant
The Teach Pendant is the interface between the human and the
Robot. A teach pendant is used to program the various points of the
robot, through which it moves.
 Robot Controller
 The Robot controller includes a power supply unit, motion
controlling unit, memory circuit, i/o circuit etc.

The motion controlling circuit controls the servo amplifier

which moves all the robot axes via the main CPU PCB.

The memory circuit can store programs and process related

data.

The IO circuit interfaces the controller with the peripheral units

by receiving and sending signals via the i/o link cable and
peripheral connection cable.
 Latest FANUC Controllers
 RJ3iB
 RJ3iC / R30iA
 Robot Specification
Some important specifications to look out for in a Robot:
Application.
Payload
Work envelope.
No. of axes.
 Applications

Welding

Material Handling

Dispensing

Painting

Assembly
Payload
Work Envelope
No. Of Axes
 The Major and Minor Axis of Robot

The first three axes of a robot are known as the major axes
because they help in positioning the wrist at a required point on the
work piece.

The last three axes of a robot are called as the minor axes because
they allow the wrist to reorient in any required direction without
changing its position.
Teach Pendant Keys
Led Indication
Menu Screens
 Jogging The Robot
 Jogging the robot is the operation of moving the robot as
desired by manually selecting the axes or direction of motion on
the teach pendant.

Two modes of jogging:

 Joint jogging
 XYZ jogging
Jogging The Robot
COORDINATE SYSTEM
 Coordinate System
A coordinate system is a set of three planes at right angles to
each other.
 The point where the three planes intersect each other is the
origin. This set of planes is called the Cartesian coordinate
system.
It is used to specify the position of a point in space
The various types of coordinate systems used in a Robot are:
• The Base Coordinate System
• The World Coordinate System
• Tool Coordinate System
• The Work Object Coordinate System
 Z+
Y+
X+
Tool coordinate system

Z+

User coordinate system

Origin
Z+

X+ Y+ X-

Y-

Y+

X+
Base coordinate
Z- system
 Coordinate System

Base / Jog Frame Coordinate System:

• It is the default frame which cannot be altered.
• It is set at the base of the J1 and the origin lies on the of J1 axis.
• The origin of the base coordinate system is (0,0,0,0,0,0).
 Coordinate System
Tool Coordinate System:
• The tool mounted on the robot flange requires its own
coordinate system.
• The origin of the tool coordinate system is the Tool Centre
Point (TCP).
 Coordinate System
Reasons to Define TCP:
• Programmed velocity is achieved at the tool tip.
• In case of tool damage/replacement only the TCP has to be re-
defined.
• Re-orientation of the tool during programming will be easy.
• Co-ordinate motion with external axis will be accurate.
• Tool load is defined in TCP, hence robot performance is
optimized.
 Coordinate System
User Coordinate System:
• Work object coordinate system (Wobj) is a user defined
coordinate system.

User Coordinate System:

 Coordinate System
User Coordinate System:
•A fixture may include several work objects that are to be
processed or handled by the robot.
• Coordinate system for
each object is defined to
make it easier to adjust the
program if the object is
moved or if a new object is
to be programmed at a
different location.
 Programming Methods
 Teach and Replay

 Teaching by coordinates

 OLP
 Robot Motions
JOINT MOTION

LINEAR MOTION

CIRCULAR MOTION
 Motion Instruction
ADVANCE
INSTRUCTIONS

1. J P[1] 100% FINE

2. J P[2] 100% CNT 20
3. L P[3] 1500mm/sec FINE
4. L P[4] 2000mm/sec FINE
5. C P[5]
P[6] 100mm/sec FINE
Motion Termination
Creating Programs
Sample Program
 Practical 1
P[1]

P[3]
P[2]
P[8]

P[9]
P[4]

P[6]

P[7]
P[5]
Day1 Overview
Day1 Overview
 DAY 2

 EDIT COMMANDS
 Introduction to some common INSTRUCTION
 Explanation of frames
 TOOL frame setup
 USER frame Setup
 Tool and User frame Offset
 Status Menu
 Setup of Macros
 BACKUP and LOADING of programs & Auto backup
EDIT COMMANDS

INSERT
DELETE
COPY
FIND
REPLACE
RENUMBER
INIII
COMMENT
UNDO
 1: L P[1] 2000mm/sec FINE
1: L P[1] 2000mm/sec FINE
2: L P[2] 2000mm/sec FINE
2: L P[2] 2000mm/sec FINE
3: L P[3] 2000mm/sec FINE
3: L P[3] 2000mm/sec FINE
4: L P[4] 2000mm/sec FINE
4: L P[4] 2000mm/sec FINE

PRESS “F5” <<EDCMD>> DELETE

PRESS “F5” <<EDCMD>> INSERT
DELETE LINE(S)?
HOW MANY LINES TO INSERT?
YES.
1.

1: L P[1] 2000mm/sec FINE

2: L P[3] 2000mm/sec FINE
3: L P[4] 2000mm/sec FINE

PRESS “F5” <<EDCMD>> RENUMBER

RENUMBER OK?
YES.
ROBOT GROUPS:
1. Group 1-
6 Robot axis and 3 extended axis(J1,J2,J3,J4,J5,J6,E1,E2,E3)
2. Group 2-
Nobot axis and positioner axis(J1,J2,J3)
 P[9] P[1]

P[8] P[2]

P[3]
P[7]

P[6] P[4]

P[5]
 INSTRUCTIONS
REGISTERS
I/O
IF SELECT
WAIT
JUMP LABEL
CALL
MISCELLENOUS
RSR
UALM
TIMER
OVER RIDE
INSTRUCTIONS
DATA
 SAMPLE PROGRAMS

1: R[1]=0 1: R[1]=0
2 R[1]=R[1]+1 2: LBL[1]
3: L P[1] 2000mm/sec FINE 3: R[1]=R[1]+1
4: L P[1] 2000mm/sec FINE 4: L P[1] 2000mm/sec FINE
END 5: L P[1] 2000mm/sec FINE
6: IF R[1]<6 JMP LBL[1]
END

1: R[1]=0
2: LBL[1] 1: L P[1] 2000mm/sec FINE
3: R[1]=R[1]+1 2: L P[1] 2000mm/sec FINE
4: L P[1] 2000mm/sec FINE 3: CALL xxx
5: L P[1] 2000mm/sec FINE END
6: WAIT 2.0 sec
7: IF R[1]<6 JMP LBL[1]
END
1: TIMER[1]=RESET 1: OVERRIDE=50%
2: TIMER[1] START 2: TIMER[1]=RESET
3: LBL[1] 3: TIMER[1] START
4: R[1]=R[1]+1 4: LBL[1]
5: L P[1] 2000mm/sec FINE 5: R[1]=R[1]+1
6: L P[1] 2000mm/sec FINE 6: L P[1] 2000mm/sec FINE
7: WAIT 2.0 sec 7: L P[1] 2000mm/sec FINE
8: IF R[1]<6 JMP LBL[1] 8: WAIT 2.0 sec
9: TIMER[1] STOP 9: IF R[1]<6 JMP LBL[1]
END 10:TIMER[1] STOP
END

1: TIMER[1]=RESET
2: TIMER[1] START
3: LBL[1]
4: R[1]=R[1]+1
5: L P[1] 2000mm/sec FINE
6: L P[1] 2000mm/sec FINE
7: WAIT 2.0 sec
8: IF R[1]<6 JMP LBL[1]
9:UALM[1]
10: TIMER[1] STOP
END
 OFFSET INSTRUCTION
PR[ i ]
PR[ i , j ]=

i=position register no.

j=position and orientation

PR[10]
PR[10,1] refers to X coordinate
PR[10,2] refers to Y coordinate
PR[10,3] refers to Z coordinate
PR[10,4] refers to W coordinate
PR[10,5] refers to P coordinate
PR[10,6] refers to R coordinate
1: L P[1] 2000mm/sec FINE
2: L PR[11] 2000mm/sec FINE
3: PR[11,2]=R[5]
4: PR[11,2]=R[5]+50
5: L PR[11] 2000mm/sec FINE
6: L P[1] 2000mm/sec FINE
END
 CONCEPT OF FRAMES

WORLD FRAME

JOG FRAME

TOOL FRAME

USER FRAME.
FRAME DEFINATION

STATUS MENU

MACRO SETUP
BACKUP
 DAY 2

 EDIT COMMANDS
 Introduction to some common INSTRUCTION
 Explanation of frames
 TOOL frame setup
 USER frame Setup
 BACKUP and LOADING of programs
 MASTERING

ZERO MASTERING
QUICK MASTERING
QUICK MASTER REFERENCE
SINGLE AXIS REFERENCE
CALIBRATION
 ZERO MASTERING

 MATCH THE ARROWS OF BOTH MOVABLE

AND FIXED SIDE SCALES OF EACH AXIS OF THE ROBOT
 PRESS ZERO POSITION MASTER
 PRESS “YES’
 MOVE THE CURSOR TO “CALIBRATION”
 PRESS ENTER
 PRESS “YES”
 PRESS “DONE”
 QUICK MASTERING

MATCH THE ARROWS OF BOTH MOVABLE

AND FIXED SIDE SCALES OF EACH AXIS OF THE ROBOT
SO THAT BOTH THE ARROWS ARE WITHIN 8 DEGREE
 PRESS “QUICK MASTER”
 PRESS “YES’
 MOVE THE CURSOR TO “CALIBRATION”
 PRESS ENTER
 PRESS “YES”
 PRESS “DONE”
 SINGLE AXIS MASTERING
 PRESS “SINGLE AXIS MASTER”
 MOVE THE CURSOR TO THE AXIS NUMBER YOU WANT TO MASTER
 MATCH THE ARROWS FOR THAT AXIS
 MOVE THE CURSOR TO “SEL” COLUMN. MAKE IT 1 & PRESS ENTER
 MOVE THE CURSOR BACK TO MASTER POSITION COLUMN.
 THE “SEL” COLUMN WILL BECOME 0 AND STATUS COLUMN WILL BECOME
2 IF THE MASTERING IS SUCCESSFUL
 PRESS PREVIOUS
 MOVE THE CURSOR TO “CALIBRATE”
 PRESS ENTER
 “YES”
 “DONE”
NOTE:
FOR EACH AXIS PULSE CODE VALUE IS GIVEN IN DATA
SHEET.IF THERE IS A MECHANICAL FAULT OR BATTERY ZERO
THEN THE PULSE CODER VALUES ARE DIRECTLY ENTERED IN
THE PARAMETER.

MENU
SYSTEM
VARIABLE
$DMR_GRP
ENTER
ENTER
$MASTER_COUN
ENTER THE MASTERING DATA
PREV
SET “$MASTER_DONE” TO “TRUE”
CYCLE POWER THE CONTROLLER
 USER FRAME

User Frame :- The user frame by default has world frame as its reference. When the user frame is setup, all the
positions are automatically recorded in the user frame in the program. The user frame makes it easy to do re-
teaching when the object is shifted without actually teaching all points once again. Up to 10 numbers of user
frame can be set up in each robot.

User Frame is referred as UFRAME in FANUC

 21: ;
1: !***** MAIN PROGRAM ***** ; 22: LBL[11] ;
2: ; 23: TIMER[1]=RESET ;
3: CALL WELD_CHK ; 24: TIMER[1]=START ;
4: ; 25: ;
5: UTOOL_NUM=1 ; 26: !*** YV4 *** ;
6: UFRAME_NUM=0 ; 27: CALL O0011 ;
7: PAYLOAD[1] ; 28: ;
8: $SGGUN1.$SETUP.$WRDWN_COMP=1 ; 29: TIMER[1]=STOP ;
9: ; 30: JMP LBL[99] ;
10: !*** HOME POSITION *** ; 31: ;
11:J PR[1:HOME POSITION] 10% FINE ; 32: LBL[128] ;
12: ; 33: ;
13: !*** I/O RESET *** ; 34: !*** TIP DRESS PROGRAM *** ;
14: CALL IO_RESET ; 35: CALL O0128 ;
15: ; 36: ;
16: CALL FIX_WDN ; 37: JMP LBL[99] ;
17: ; 38: ;
18: !*** MODEL CHECK 1 *** ; 39: LBL[99] ;
19: R[1:PRG SELECTION]=GI[1:OSTYLE No.] ; 40: UTOOL_NUM=1 ;
20: JMP LBL[R[1]] ;
41: ;
42: !*** RESET IO *** ;
43: CALL IO_RESET ;
44: ;
45: !*** HOME POSITION *** ;
46:J PR[1:HOME POSITION] 10% FINE ;
47: ;
48: R[1:PRG SELECTION]=0 ;
49: R[2:PRG CONFIRMATION]=0 ;
 1: !*** YV4 607X *** ; 23: !*** ABNORMAL MODEL CHECK *** ;
2: ; 24: UALM[1] ;
3: UTOOL_NUM=1 ; 25: JMP LBL[1] ;
4: UFRAME_NUM=0 ; 26: ;
5: PAYLOAD[1] ; 27: LBL[2] ;
6: ; 28: ;
7: !*** I/O RESET *** ; 29: !*** WAIT 2ND POSITION *** ;
8: CALL IO_RESET ; 30: WAIT DI[1:START 2]=ON ;
9: ; 31: ;
10: !*** AROUND HOME POSITION *** ; 32: !*** JIG 6060 IN *** ;
11:J PR[2:AROUND HOME POS] 10% FINE ; 33: DO[56:6070 NON INT]=OFF ;
12:J P[1] 50% CNT0 ; 34: ;
13: ; 35: TIMER[1]=RESET ;
14: ; 36: TIMER[1]=START ;
15: LBL[1] ; 37: ;
16: !*** WAIT 2ND POSITION *** ; 38:J P[2] 100% CNT50 ;
17: WAIT DI[1:START 2]=ON ; 39:L P[3] 2000mm/sec CNT50 ;
18: ; 40: ;
19: !*** MODEL CHECK 2 *** ; 41: !61312 ;
20: R[2:PRG CONFIRMATION]=GI[1:OSTYLE No.] ; 42:L P[4:61312] 2000mm/sec FINE
21: IF R[1:PRG SELECTION]=R[2:PRG : SPOT[SD=2,P=1,S=1,ED=2] ;
CONFIRMATION],JMP LBL[2] ;
41: ;
42: !*** RESET IO *** ;
43: CALL IO_RESET ;
44: ;
45: !*** HOME POSITION *** ;
46:J PR[1:HOME POSITION] 10% FINE ;
47: ;
48: R[1:PRG SELECTION]=0 ;
49: R[2:PRG CONFIRMATION]=0 ;
 1: !*** YV4 607X *** ; 23: !*** ABNORMAL MODEL CHECK *** ;
2: ; 24: UALM[1] ;
3: UTOOL_NUM=1 ; 25: JMP LBL[1] ;
4: UFRAME_NUM=0 ; 26: ;
5: PAYLOAD[1] ; 27: LBL[2] ;
6: ; 28: ;
7: !*** I/O RESET *** ; 29: !*** WAIT 2ND POSITION *** ;
8: CALL IO_RESET ; 30: WAIT DI[1:START 2]=ON ;
9: ; 31: ;
10: !*** AROUND HOME POSITION *** ; 32: !*** JIG 6060 IN *** ;
11:J PR[2:AROUND HOME POS] 10% FINE ; 33: DO[56:6070 NON INT]=OFF ;
12:J P[1] 50% CNT0 ; 34: ;
13: ; 35: TIMER[1]=RESET ;
14: ; 36: TIMER[1]=START ;
15: LBL[1] ; 37: ;
16: !*** WAIT 2ND POSITION *** ; 38:J P[2] 100% CNT50 ;
17: WAIT DI[1:START 2]=ON ; 39:L P[3] 2000mm/sec CNT50 ;
18: ; 40: ;
19: !*** MODEL CHECK 2 *** ; 41: !61312 ;
20: R[2:PRG CONFIRMATION]=GI[1:OSTYLE No.] ; 42:L P[4:61312] 2000mm/sec FINE
21: IF R[1:PRG SELECTION]=R[2:PRG : SPOT[SD=2,P=1,S=1,ED=2] ;
CONFIRMATION],JMP LBL[2] ;
109: !61291 ;
110:L P[29:61291] 2000mm/sec FINE
: SPOT[SD=1,P=1,S=22,ED=2] BREAK ;
111: ;
112: ;
113: !*** ENTER ZONE1 607W *** ;
114: DO[25:607W NON INT]=OFF ;
115: WAIT DI[25:607W RB NON INT]=ON ;
116: ;
117: ;
118: !61292 ;
119:L P[30:61292] 2000mm/sec FINE
: SPOT[SD=1,P=1,S=23,ED=2] BREAK ;
120: ;
121: ;
122: !** ENTER ZONE1 2ND CHECK 607W ** ;
123: WAIT DI[25:607W RB NON INT]=ON ;
145:L P[42] 2000mm/sec FINE ;
146: ;
147: !*** SPOT COMPLETE *** ;
148: !*** CYCLE COMPLETE *** ;
149: DO[1:CYCLE COMP.]=PULSE,1.0sec ;
151: !*** JIG 6070 OUT *** ;
152: DO[56:6070 NON INT]=ON 155:
153: !*** EXIT ZONE1 607W *** ;
156: DO[25:607W NON INT]=ON ;
157: ;
158: ;
159: TIMER[1]=STOP ;
160: ;
161:J P[43] 100% CNT50 ;
162: ;
163: !*** AROUND HOME POSITION *** ;
164:J PR[2:AROUND HOME POS] 100% FINE ;
165: ;
166: !*** HOME POSITION *** ;
167:J PR[1:HOME POSITION] 10% FINE ;
168: ;
169: !*** I/O RESET *** ;
170: CALL IO_RESET ;
EVALUTION TEST
 I/O,S

Example of input signals

1. Proximity switch
2. Limit switch
3. Reed switch
4. Light curtains

Example of output signals

1. Solenoid operations
2. Sealant ON/OFF
 I/O,S
The I/O system provides the interface between the controller, teach
pendant, robot, and any other external device in your workcell. Controller
I/O can consist of the following kinds of I/O:

•User Operator Panel (UOP) Inputs (UI)

•User Operator Panel (UOP) Outputs (UO)
•Robot Inputs (RI)
•Robot Outputs (RO)
•Digital Inputs (DI)
•Digital Outputs (DO)
•Group Inputs (GI)
•Group Outputs (GO)
•Analog Inputs (AI)
•Analog Outputs (AO)
I/O’s
EXTERNAL AXIS

EXTENDED AXIS

NOBOT AXIS

POSITIONER AXIS
SPOT WELDING

Weld
Controller
Spot Welding Guns

X GUN
C GUN
 Advantages of servo guns over pneumatic guns:
Improved weld quality as force is stable
No guessing force as closed loop feedback on pressure
Force is maintained with a few percent for whole of life
Low maintenance and longer life ( typical 4 times longer than cylinders)
Minimizes panel damage as softer approach ( software dependant)
Automatic re calibration of TCP after tip dressing ( software dependant)
Faster processing time , Weld can fire as soon as pressure attained
Gun opening totally controlled to optimum distances
Gun opening distances can be optimized for each component condition
Less noise for operators so improved working conditions
More reliable as no external position sensors ( high lift) or air valves
The production of air is very expensive and inefficient ( that’s apart from air leaks
in factories) typically servo units are about 80% efficient while pneumatic systems are
only 15 to 20% efficient
Guns last longer due to less impact forces
 Distance OR
BackUp( ED/SD)

Pressure
 SPOT INSTRUCTION

1. L P[3] 1500mm/sec FINE

SPOT[SD=1,P=1,S=1,ED=1]

Start Schedule
distance

Pressure End
distance
Concept of tip compensation
 PROGRAM NOMENCLATURE

PROGRAM O0071 -----GET HAND FOR MODEL 1

PROGRAM O0271 -----GET HAND FOR MODEL 2
PROGRAM O0072 -----PUT HAND FOR MODEL 1
PROGRAM O0271 -----PUT HAND FOR MODEL 2

PROGRAM O0031 -----HANDLING FOR MODEL 1

PROGRAM O0231 -----HANDLING FOR MODEL 2
PROGRAM O0011 -----SPOT WELDING FOR MODEL 1
PROGRAM O0211 -----SPOT WELDINGFOR MODEL 2
PROGRAM O0128 -----TIP DRESSING
 DAY 3

 Explanation of I/O’s
 Explanation of MASTERING
 Introduction to External axis
 Introduction to Spot welding.