FANUC > series R-30*A CONTROLLER DISPENSE TOOL
OPERATOR’S MANUAL
B-82594EN-4/01
FANUC > series R-30*A CONTROLLER DISPENSETOOL
OPERATOR’S MANUAL (Volume 1 of 2)
B-82594EN-4/01
FANUC > series R-30*A CONTROLLER DISPENSETOOL
OPERATOR’S MANUAL (Volume 2 of 2)
B-82594EN-4/01
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand the content. This manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller labeled R-J3iC, you should read R-30iA as R-J3iC throughout this manual.
• No part of this manual may be reproduced in any form. • All specifications and designs are subject to change without notice. The products in this manual are controlled based on Japan’s “Foreign Exchange and Foreign Trade Law”. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice. In this manual we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as ”impossible”.
TABLE OF CONTENTS
B-82594EN-4/01
TABLE OF CONTENTS Volume 1 of 2 1
INTRODUCTION ..................................................................................... 1 1.1 1.2 1.3 1.4
2
MANUAL PLAN ............................................................................................. 2 WORKERS .................................................................................................... 5 GENERAL SAFETY PRECAUTIONS ............................................................ 6 SAFETY PRECAUTIONS ............................................................................ 11
OVERVIEW ........................................................................................... 17 2.1
2.2 2.3
APPLICATION TOOL SOFTWARE ............................................................. 19 2.1.1
System Setting........................................................................................................19
2.1.2
Jog Feed of the Robot.............................................................................................19
2.1.3
Program ..................................................................................................................19
2.1.4
Test Operation (Test Execution) ............................................................................20
2.1.5
Automatic Operation (Operation Execution) .........................................................20
ROBOT........................................................................................................ 21 CONTROLLER ............................................................................................ 22 2.3.1
Teach Pendant ........................................................................................................23 2.3.1.1
3
Display Screen of the Teach Pendant ................................................................ 28
2.3.2
Operator Panel........................................................................................................32
2.3.3
Remote Controller ..................................................................................................33
2.3.4
CRT/KB..................................................................................................................33
2.3.5
Communication ......................................................................................................33
2.3.6
Input/Output ...........................................................................................................34
2.3.7
Peripheral I/O .........................................................................................................34
2.3.8
Motion of the Robot ...............................................................................................35
2.3.9
Emergency Stop Devices........................................................................................35
2.3.10
Extended Axis ........................................................................................................35
SETTING UP THE HANDLING SYSTEM ............................................. 36 3.1
3.2
I/O................................................................................................................ 37 3.1.1
Digital I/O...............................................................................................................43
3.1.2
Group I/O ...............................................................................................................50
3.1.3
Analog I/O..............................................................................................................54
ROBOT I/O .................................................................................................. 59 c-1
TABLE OF CONTENTS 3.3 3.4 3.5
3.6 3.7 3.8
3.9
3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17
4
B-82594EN-4/01
PERIPHERAL I/O ........................................................................................ 63 OPERATOR’S PANEL I/O ........................................................................... 74 I/O Link SCREEN ........................................................................................ 77 3.5.1
I/O Link List Screen ...............................................................................................77
3.5.2
Model B Unit List Screen.......................................................................................78
3.5.3
Signal Count Setting Screen...................................................................................80
I/O CONNECTION FUNCTION ................................................................... 82 SIMULATED INPUT SKIP FUNCTION........................................................ 84 SETTING AUTOMATIC OPERATION ......................................................... 86 3.8.1
Robot Service Request (RSR) ................................................................................87
3.8.2
Program Number Selection (PNS) .........................................................................90
3.8.3
Prog Select Screen..................................................................................................94
3.8.4
Cell Interface I/O..................................................................................................102
SETTING COORDINATE SYSTEMS ........................................................ 108 3.9.1
Setting a Tool Coordinate System........................................................................110
3.9.2
Setting a User Coordinate System........................................................................121
3.9.3
Setting a Jog Coordinate System..........................................................................132
SETTING A REFERENCE POSITION....................................................... 138 JOINT OPERATING AREA ....................................................................... 142 USER ALARM ........................................................................................... 144 VARIABLE AXIS AREAS ........................................................................... 146 SPECIAL AREA FUNCTION ..................................................................... 148 SYSTEM CONFIG MENU ......................................................................... 152 SETTING THE GENERAL ITEMS ............................................................. 159 OTHER SETTINGS ................................................................................... 161
PROGRAM STRUCTURE ................................................................... 162 4.1
4.2 4.3
PROGRAM DETAIL INFORMATION......................................................... 165 4.1.1
Program Name......................................................................................................165
4.1.2
Program Comment................................................................................................166
4.1.3
Subtype.................................................................................................................166
4.1.4
Group Mask..........................................................................................................167
4.1.5
Write Protection ...................................................................................................167
4.1.6
Interruption Disable..............................................................................................168
LINE NUMBER, PROGRAM END SYMBOL, AND ARGUMENT .............. 171 MOTION INSTRUCTIONS ........................................................................ 174 4.3.1
Motion Format......................................................................................................175
4.3.2
Position Data ........................................................................................................177 c-2
TABLE OF CONTENTS
B-82594EN-4/01
4.4
4.5
4.6
4.7
4.8
4.9 4.10 4.11 4.12 4.13
4.14
4.3.3
Feedrate ................................................................................................................184
4.3.4
Positioning Path....................................................................................................187
4.3.5
Additional Motion Instructions ............................................................................188
PALLETIZING INSTRUCTIONS ................................................................ 202 4.4.1
Palletizing Instruction...........................................................................................202
4.4.2
Palletizing Motion Instruction..............................................................................203
4.4.3
Palletizing End Instruction ...................................................................................203
REGISTER INSTRUCTIONS..................................................................... 204 4.5.1
Register Instructions.............................................................................................205
4.5.2
Position Register Instructions...............................................................................207
4.5.3
Position Register Axis Instructions ......................................................................208
4.5.4
Arithmetic Palletizing Register Instructions.........................................................210
I/O INSTRUCTIONS .................................................................................. 212 4.6.1
Digital I/O Instructions.........................................................................................212
4.6.2
Robot I/O Instructions ..........................................................................................213
4.6.3
Analog I/O Instructions ........................................................................................215
4.6.4
Group I/O Instruction ...........................................................................................216
BRANCH INSTRUCTIONS........................................................................ 217 4.7.1
Label Instruction...................................................................................................217
4.7.2
Program End Instruction ......................................................................................218
4.7.3
Unconditional Branch Instructions.......................................................................218
4.7.4
Conditional Branch Instructions...........................................................................219
4.7.5
Arguments ............................................................................................................223
WAIT INSTRUCTIONS.............................................................................. 233 4.8.1
Time-specified Wait Instruction...........................................................................233
4.8.2
Conditional Wait Instructions ..............................................................................233
SKIP CONDITION INSTRUCTION ............................................................ 237 OFFSET CONDITION INSTRUCTION ...................................................... 240 TOOL OFFSET CONDITION INSTRUCTIONS ......................................... 241 FRAME INSTRUCTIONS .......................................................................... 242 PROGRAM CONTROL INSTRUCTIONS .................................................. 244 4.13.1
Halt Instruction.....................................................................................................244
4.13.2
Abort Instruction ..................................................................................................244
OTHER INSTRUCTIONS .......................................................................... 245 4.14.1
RSR Instruction ....................................................................................................245
4.14.2
User Alarm Instruction .........................................................................................246
4.14.3
Timer instruction ..................................................................................................246 c-3
TABLE OF CONTENTS
4.15
4.14.4
Override Instruction .............................................................................................247
4.14.5
Comment Instruction ............................................................................................247
4.14.6
Message Instruction..............................................................................................247
4.14.7
Parameter Instruction............................................................................................248
4.14.8
Maximum Speed Instructions...............................................................................251
MULTIAXIS CONTROL INSTRUCTIONS ................................................. 252 4.15.1
4.16
5
Program Execution Instruction.............................................................................252
OPERATION GROUP INSTRUCTIONS.................................................... 253 4.16.1
Asynchronous Operation Group Instruction ........................................................253
4.16.2
Synchronous Operation Group Instruction...........................................................254
PROGRAMMING................................................................................. 255 5.1
5.2
5.3
5.4
5.5
TIPS ON EFFECTIVE PROGRAMMING................................................... 257 5.1.1
Motion Instructions ..............................................................................................257
5.1.2
Predefined Position...............................................................................................259
TURNING ON THE POWER AND JOG FEED .......................................... 261 5.2.1
Turning On the Power and Turning Off the Power..............................................261
5.2.2
Three-Mode Switch ..............................................................................................263
5.2.3
Moving the Robot by Jog Feed ............................................................................269
CREATING A PROGRAM ......................................................................... 277 5.3.1
Registering a Program ..........................................................................................278
5.3.2
Changing a Standard Motion Instruction .............................................................283
5.3.3
Teaching a Motion Instruction .............................................................................285
5.3.4
Teaching an Supplementary Motion Instruction ..................................................287
5.3.5
Teaching a Control Instruction.............................................................................290
5.3.6
TP Start Prohibition..............................................................................................296
CHANGING A PROGRAM ........................................................................ 299 5.4.1
Selecting a Program..............................................................................................299
5.4.2
Changing a Motion Instruction.............................................................................300
5.4.3
Changing a Control Instruction ............................................................................312
5.4.4
Program Edit Instructions.....................................................................................314
PROGRAM OPERATION .......................................................................... 332 5.5.1
5.6 5.7
6
B-82594EN-4/01
Changing Program Information............................................................................332
BACKGROUND EDITING ......................................................................... 337 SINGULAR POINT CHECK FUNCTION ................................................... 348
EXECUTING A PROGRAM................................................................. 349 6.1
PROGRAM HALT AND RECOVERY ........................................................ 350 c-4
TABLE OF CONTENTS
B-82594EN-4/01
6.2
6.3
6.4
6.5 6.6
6.7
7
Halt by an Emergency Stop and Recovery...........................................................351
6.1.2
Halt by a Hold and Recovery ...............................................................................352
6.1.3
Halt Caused by an Alarm .....................................................................................353
EXECUTING A PROGRAM ....................................................................... 357 6.2.1
Starting a Program................................................................................................357
6.2.2
Robot Motion .......................................................................................................358
6.2.3
Resuming a Program ............................................................................................361
TESTING ................................................................................................... 366 6.3.1
Specifying Test Execution....................................................................................367
6.3.2
Step Test ...............................................................................................................368
6.3.3
Continuous Test....................................................................................................373
6.3.4
Program Look/Monitor.........................................................................................375
MANUAL I/O CONTROL ........................................................................... 377 6.4.1
Forced Output.......................................................................................................377
6.4.2
Simulated I/O .......................................................................................................379
6.4.3
Standby Release ...................................................................................................380
OPERATING THE HAND MANUALLY ...................................................... 382 AUTOMATIC OPERATION ....................................................................... 384 6.6.1
Automatic Operation by Robot Start Request (RSR)...........................................385
6.6.2
Automatic Operation with Program Number Selection (PNS).............................387
6.6.3
External Override Selection Function ..................................................................390
ONLINE POSITION MODIFICATION ........................................................ 392
STATUS DISPLAY .............................................................................. 398 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11
8
6.1.1
LEDS ON THE TEACH PENDANT............................................................ 399 USER SCREEN......................................................................................... 400 REGISTERS .............................................................................................. 401 POSITION REGISTERS............................................................................ 403 PALLETIZING REGISTERS ...................................................................... 407 CURRENT POSITION ............................................................................... 408 SYSTEM VARIABLES ............................................................................... 411 PROGRAM TIMER .................................................................................... 413 SYSTEM TIMER........................................................................................ 415 EXECUTION HISTORY............................................................................. 416 MEMORY USE STATUS DISPLAY ........................................................... 418
FILE INPUT/OUTPUT ......................................................................... 420 8.1
FILE INPUT/OUTPUT UNITS .................................................................... 421 c-5
TABLE OF CONTENTS
8.2 8.3
8.4
8.5
8.6 8.7
8.8
9
B-82594EN-4/01
8.1.1
Memory Card .......................................................................................................424
8.1.2
USB Memory .......................................................................................................425
SETTING A COMMUNICATION PORT..................................................... 430 FILES......................................................................................................... 435 8.3.1
Program File .........................................................................................................435
8.3.2
Default Logic File ................................................................................................436
8.3.3
System File/Application File................................................................................436
8.3.4
Data File ...............................................................................................................436
8.3.5
ASCII File ............................................................................................................437
SAVING FILES .......................................................................................... 438 8.4.1
Saving with Program Selection Screen ................................................................438
8.4.2
Saving all the Program Files Using the File Screen .............................................440
8.4.3
Saving with a Function Menu ..............................................................................444
8.4.4
File Manipulation .................................................................................................446
LOADING FILES........................................................................................ 449 8.5.1
Loading Using the Program Selection Screen......................................................449
8.5.2
Loading a Specified Program File Using the File Screen ....................................451
PRINTING FILES....................................................................................... 457 AUTOMATIC BACKUP.............................................................................. 461 8.7.1
Overview of Automatic Backup ...........................................................................461
8.7.2
Usable Memory Cards..........................................................................................461
8.7.3
Setting of Automatic Backup ...............................................................................462
8.7.4
Perform Automatic Backup ..................................................................................464
8.7.5
Version Management............................................................................................465
8.7.6
Restore the Backup...............................................................................................466
IMAGE BACKUP FUNCTION .................................................................... 467
UTILITY ............................................................................................... 470 9.1
9.2
9.3 9.4 9.5
MACRO INSTRUCTION............................................................................ 471 9.1.1
Setting Macro Instructions ...................................................................................472
9.1.2
Executing Macro Instructions ..............................................................................478
SHIFT FUNCTIONS .................................................................................. 484 9.2.1
Program Shift Function ........................................................................................485
9.2.2
Mirror Shift Function ...........................................................................................491
9.2.3
Angle-input Shift Function...................................................................................495
COORDINATE SYSTEM CHANGE SHIFT FUNCTIONS.......................... 502 SOFT FLOAT FUNCTION ......................................................................... 508 CONTINUOUS ROTATION FUNCTION.................................................... 515 c-6
TABLE OF CONTENTS
B-82594EN-4/01
9.6 9.7 9.8 9.9
9.10 9.11
POSITION REGISTER LOOK-AHEAD EXECUTION FUNCTION............. 521 OPERATION GROUP DO OUTPUT FUNCTION ...................................... 524 TIME BEFORE FUNCTION ....................................................................... 526 DISTANCE BEFORE FUNCTION ............................................................. 532 9.9.1
Overview ..............................................................................................................532
9.9.2
Specification.........................................................................................................532
9.9.3
Configuration .......................................................................................................532
9.9.4
Instruction.............................................................................................................533
9.9.5
Entering Distance before ......................................................................................542
9.9.6
Caution and Limitations .......................................................................................546
9.9.7
System Variables ..................................................................................................547
9.9.8
Error Codes...........................................................................................................548
STATE MONITORING FUNCTION ........................................................... 549 AUTOMATIC ERROR RECOVERY FUNCTION ....................................... 558 9.11.1
Overview ..............................................................................................................558
9.11.2
Outline of the Automatic Error Recovery Function .............................................558
9.11.3
Defining a Resume Program ................................................................................562
9.11.4
Teaching the RETURN_PATH_DSBL Instruction .............................................563
9.11.5
Setting the Automatic Error Recovery Function ..................................................564
9.11.6
Flowchart for Resuming a Suspended Program ...................................................573
9.11.7
Manual Operation Screen of the Automatic Error Recovery Function ................574
9.11.8
Execution of the Resume Program from The Teach Pendant and Test Mode......577
9.11.9
Changing Conditions for Executing the Resume Program...................................577
9.11.10 Other Specifications and Restrictions ..................................................................577 9.11.11 Warnings ..............................................................................................................579
9.12
9.13
9.14
REMOTE TCP FUNCTION........................................................................ 580 9.12.1
Summary ..............................................................................................................580
9.12.2
Setup.....................................................................................................................582
HIGH-SENSITIVITY COLLISION DETECTION ......................................... 586 9.13.1
Overview ..............................................................................................................586
9.13.2
Specification.........................................................................................................586
9.13.3
High-Sensitivity Collision Detection ...................................................................586
9.13.4
Cautions................................................................................................................587
LOAD SETTING ........................................................................................ 588 9.14.1
Overview ..............................................................................................................588
9.14.2
Motion Performance Screens ...............................................................................588
9.14.3
Program Instructions ............................................................................................590 c-7
TABLE OF CONTENTS 9.15
9.16
9.17
9.18
B-82594EN-4/01
LOAD ESTIMATION .................................................................................. 592 9.15.1
Overview ..............................................................................................................592
9.15.2
Operating Procedure.............................................................................................592
9.15.3
Load Estimation Procedure (for 6-Axis Robots)..................................................592
9.15.4
Calibration Procedure (for 6-Axis Robots) ..........................................................597
9.15.5
Other Related Matters...........................................................................................601
COLLISION DETECTION for AUXILIARY AXIS ........................................ 602 9.16.1
General .................................................................................................................602
9.16.2
Caution .................................................................................................................602
9.16.3
Initial Setting ........................................................................................................602
9.16.4
Tuning Procedure .................................................................................................603
GRAVITY COMPENSATION ..................................................................... 605 9.17.1
System Variables ..................................................................................................605
9.17.2
MOTION Screen ..................................................................................................605
PASSWORD FUNCTION .......................................................................... 607 9.18.1
Overview of the Password Function.....................................................................607
9.18.2
Password Operations by the Install User..............................................................609
9.18.3
Disabling the Password Function .........................................................................613
9.18.4
Password Operations by Program Users and Setup Users ...................................614
9.18.5
Password Configuration File ................................................................................618 9.18.5.1 Overview ......................................................................................................... 618
9.19
9.20 9.21 9.22 9.23
9.18.6
XML Syntax for Password Configuration Files...................................................620
9.18.7
Password Log .......................................................................................................624
9.18.8
Screen Restrictions According to Password Level...............................................626
9.18.9
Password Auto Login Function ............................................................................629
SOFT PANEL ............................................................................................ 630 9.19.1
Application-Specific Soft Panel Function ............................................................630
9.19.2
Custom I/O ...........................................................................................................631
MIXED LOGIC INSTRUCTION.................................................................. 633 PMC MONITOR FUNCTION ..................................................................... 653 PMC EDIT FUNCTION .............................................................................. 656 OPERATION LOG BOOK (OPTION)......................................................... 659 9.23.1
Overview ..............................................................................................................659
9.23.2
Recorded Events...................................................................................................662
9.23.3
Setting Up Book ...................................................................................................665
9.23.4
Operations ............................................................................................................666
9.23.5
Extended Alarm Log ............................................................................................671 c-8
TABLE OF CONTENTS
B-82594EN-4/01
9.23.5.1 Setup ................................................................................................................ 671 9.23.5.2 How to display alarm log................................................................................. 672
9.24 9.25
ORIGINAL PATH RESUME....................................................................... 674 PROGRAM TOOLBOX.............................................................................. 680 9.25.1
Cross Car Mirror Shift..........................................................................................680
9.25.2
Flip Knuckle .........................................................................................................684
9.25.3
Soft Limit Setting .................................................................................................687
10 PALLETIZING FUNCTION.................................................................. 690 10.1 10.2 10.3
10.4
10.5 10.6 10.7
PALLETIZING FUNCTION ........................................................................ 691 PALLETIZING INSTRUCTIONS ................................................................ 694 TEACHING THE PALLETIZING FUNCTION............................................. 696 10.3.1
Selecting a Palletizing Instruction ........................................................................697
10.3.2
Inputting Initial Data ............................................................................................698
10.3.3
Teaching a Stacking Pattern .................................................................................705
10.3.4
Setting Path Pattern Conditions............................................................................712
10.3.5
Teaching a Path Pattern ........................................................................................716
10.3.6
Notes on Teaching the Palletizing Function.........................................................720
EXECUTING THE PALLETIZING FUNCTION .......................................... 721 10.4.1
Palletizing Register...............................................................................................722
10.4.2
Controlling the Palletizing Function by a Palletizing Register ............................724
MODIFYING THE PALLETIZING FUNCTION ........................................... 725 PALLETIZING FUNCTION WITH EXTENDED AXES ............................... 727 PALLETIZING ALL-POINT TEACHING..................................................... 728
11 FANUC iPendant ................................................................................ 730 11.1 11.2
OVERVIEW ............................................................................................... 731 APPEARANCE AND OPERATIONS ......................................................... 732 11.2.1
Appearance and Switches.....................................................................................732
11.2.2
Key Switches........................................................................................................733
11.2.3
Status Window .....................................................................................................734
11.2.4
Splitting the Screen ..............................................................................................735
11.2.5
Changing the Operation Target Screen ................................................................738
11.2.6
Internet Browser Screen .......................................................................................739
11.2.7
Screen Selection Menu and Screen Menus on the Edit Screen ............................742
11.2.8
Status Subwindow ................................................................................................743 11.2.8.1 Current position display................................................................................... 744 11.2.8.2 Operator panel status display........................................................................... 744 11.2.8.3 Safety signal status display .............................................................................. 745
c-9
TABLE OF CONTENTS 11.2.9
11.3 11.4 11.5
B-82594EN-4/01
Color Display According to the Alarm Severity ..................................................745
TOUCH PANEL ......................................................................................... 747 SETTING UP iPendant .............................................................................. 748 RESTRICTIONS ........................................................................................ 761
12 DISPENSE TOOL................................................................................ 762 12.1
OVERVIEW ............................................................................................... 763 12.1.1
Controller .............................................................................................................763 12.1.1.1 Type III analog output ..................................................................................... 763 12.1.1.2 Motion ............................................................................................................. 763
12.2
DISPENSETOOL COMMON SETUP ........................................................ 764 12.2.1
Setting Up DispenseTool Configuration ..............................................................764
12.2.2
Flow Rate Control ................................................................................................767 12.2.2.1 12.2.2.2 12.2.2.3 12.2.2.4 12.2.2.5
Overview ......................................................................................................... 767 Speed compensation ........................................................................................ 767 Flow type ......................................................................................................... 772 Flow rate calculation (traditional method)....................................................... 772 Flow rate calculation: 2PNT (two point calibrated calculation method) ......... 774
12.2.3
Setting Up Schedules............................................................................................775
12.2.4
Process Timing Protocols .....................................................................................780 12.2.4.1 12.2.4.2 12.2.4.3 12.2.4.4 12.2.4.5 12.2.4.6 12.2.4.7 12.2.4.8 12.2.4.9 12.2.4.10 12.2.4.11 12.2.4.12
Overview ......................................................................................................... 780 Generic Dispense system response time at a corner ........................................ 780 Equipment ant-time and additional ant-time.................................................... 781 Effects of using positive gun on ant-time ........................................................ 781 Effects of using negative gun on ant-time ....................................................... 782 Effects of positive bead shaping ant-time........................................................ 782 Effects of negative bead shaping ant-time ....................................................... 783 Effects of pre-pressure time............................................................................. 783 Effects of seal start offset ................................................................................ 784 Effects of seal end offset.................................................................................. 784 Corner adjustment............................................................................................ 784 Generic dispense process signal timing protocols ........................................... 785
12.2.5
Setting Up Equipment Information ......................................................................786
12.2.6
Equipment Calibration .........................................................................................789 12.2.6.1 12.2.6.2 12.2.6.3 12.2.6.4 12.2.6.5 12.2.6.6
Overview ......................................................................................................... 789 Flow rate control calibration............................................................................ 790 Bead shaping air (atomizing air) calibration.................................................... 795 Maximum analog out (meter)/maximum meter speed calibration ................... 799 Material pressure calibration ........................................................................... 804 Two point (2PNT) flow rate calibration .......................................................... 809
12.2.7
Setting Up Equipment I/O ....................................................................................815
12.2.8
Gun Purge.............................................................................................................821 c-10
TABLE OF CONTENTS
B-82594EN-4/01
12.2.9
Channel 2 Analog Control Setup..........................................................................822 12.2.9.1 Concepts .......................................................................................................... 823 12.2.9.2 Setup and calibration ....................................................................................... 828 12.2.9.3 Timing diagram ............................................................................................... 833
12.2.10 Nonlinear Flow Model .........................................................................................833 12.2.11 Error Status Summary ..........................................................................................834 12.2.11.1 Group 1 ............................................................................................................ 835
12.3
SETTING UP THE CELL ........................................................................... 838 12.3.1
DispenseTool Cell Communication Setup ...........................................................838
12.3.2
DispenseTool Cell Interface I/O Signals ..............................................................840 12.3.2.1 12.3.2.2 12.3.2.3 12.3.2.4
12.3.3
Interference Zone Setup .......................................................................................850 12.3.3.1 12.3.3.2 12.3.3.3 12.3.3.4
12.3.4
12.4
Overview ......................................................................................................... 840 DispenseTool cell interface input signals ........................................................ 842 DispenseTool cell interface output signals ...................................................... 845 Setting up DispenseTool cell interface I/O signals.......................................... 849 Interference zone setup overview .................................................................... 850 Cell controller setup......................................................................................... 851 Teach pendant program example..................................................................... 852 Macro commands............................................................................................. 853
DispenseTool Cell Controller Error Recovery .....................................................854
PLANNING AND CREATING A PROGRAM.............................................. 858 12.4.1
Planning a Program ..............................................................................................858 12.4.1.1 Application program guidelines for DispenseTool.......................................... 858 12.4.1.2 Guidelines for using sub type program............................................................ 858
12.4.2
Writing and Modifying a Program .......................................................................859 12.4.2.1 Creating and writing a new DispenseTool program ........................................ 859 12.4.2.2 Defining predefined positions in DispenseTool programs .............................. 867
12.5
PROGRAM ELEMENTS............................................................................ 871 12.5.1
Overview ..............................................................................................................871
12.5.2
Program Header Information................................................................................872 12.5.2.1 12.5.2.2 12.5.2.3 12.5.2.4 12.5.2.5 12.5.2.6 12.5.2.7 12.5.2.8 12.5.2.9 12.5.2.10 12.5.2.11
Overview ......................................................................................................... 872 Sub type ........................................................................................................... 875 Cycle Time....................................................................................................... 877 Last cycle time ................................................................................................. 878 Gun on time ..................................................................................................... 878 Last gun on time .............................................................................................. 878 Material volume............................................................................................... 878 Last material volume ....................................................................................... 878 Default user frame ........................................................................................... 878 Default tool frame............................................................................................ 879 Equipment number........................................................................................... 879
c-11
TABLE OF CONTENTS 12.5.3
B-82594EN-4/01
Dispensing Instructions ........................................................................................879 12.5.3.1 Overview ......................................................................................................... 879 12.5.3.2 Dispense (seal) start instructions ..................................................................... 880 12.5.3.3 Dispense (seal) end instructions ...................................................................... 880
12.5.4
Program Control Instructions ...............................................................................880 12.5.4.1 Error program instruction for DispenseTool ................................................... 880 12.5.4.2 Resume program instruction for DispenseTool ............................................... 881
12.6
TESTING A PROGRAM AND RUNNING PRODUCTION ......................... 882 12.6.1
OVERVIEW.........................................................................................................882
12.6.2
Program Pause and Recovery...............................................................................883 12.6.2.1 ERROR_PROG and RESUME_PROG........................................................... 883 12.6.2.2 DispenseTool fault recovery procedures ......................................................... 886
12.6.3
Test Cycle.............................................................................................................891 12.6.3.1 Test cycle setup................................................................................................ 891 12.6.3.2 Controlling WET/DRY mode manually .......................................................... 893
12.6.4
Soft Panel .............................................................................................................894 12.6.4.1 Soft panel overview ......................................................................................... 894 12.6.4.2 General and application-specific soft panel functions ..................................... 894
12.7
12.6.5
Maintenance and Repair .......................................................................................896
12.6.6
Enabling or Disabling Joint Motion Warning ......................................................897
STATUS DISPLAYS AND INDICATORS................................................... 898 12.7.1
Status Indicators ...................................................................................................898 12.7.1.1 12.7.1.2 12.7.1.3 12.7.1.4
12.8
Teach pendant status indicators ....................................................................... 898 DispenseTool status ......................................................................................... 899 Application status ............................................................................................ 901 Program status for DispenseTool..................................................................... 902
PROGRAM AND FILE MANIPULATION ................................................... 904 12.8.1
Manipulating Files................................................................................................904 12.8.1.1 Backing up files ............................................................................................... 904
12.9
ADVANCED FUNCTIONS ......................................................................... 905 12.9.1
Error Recovery (Option) ......................................................................................905 12.9.1.1 DispenseTool-specific information.................................................................. 905
12.10
NEMO PUMP............................................................................................. 908 12.10.1 Overview ..............................................................................................................908 12.10.2 Limitations............................................................................................................908 12.10.3 Setting Up Process Axes ......................................................................................909 12.10.4 Setting Up DispenseTool Configuration ..............................................................911 12.10.5 Setting Up NEMO Pump Information..................................................................913 12.10.6 Setting Up Schedules............................................................................................915 12.10.7 NEMO Pump Status .............................................................................................917 c-12
TABLE OF CONTENTS
B-82594EN-4/01
12.10.8 Resetting Pulse Coder Alarms..............................................................................918 12.10.9 Error Status Summary ..........................................................................................919
12.11
ISD GEAR METER .................................................................................... 921 12.11.1 OVERVIEW.........................................................................................................921 12.11.2 SETTING UP PROCESS AXES..........................................................................921 12.11.3 Setting up Dispense Configuration.......................................................................926 12.11.4 SETTING UP ISD I/O .........................................................................................927 12.11.5 SETTING UP EQUIPMENT INFORMATION ..................................................930 12.11.6 SETTING UP ISD INFORMATION ...................................................................933 12.11.7 ISD TRANSDUCER FINE TUNING..................................................................934 12.11.8 ERROR STATUS SUMMARY ...........................................................................939
Volume 2 of 2 APPENDIX A
SPOT I/O SEQUENCE ........................................................................ 947 A.1 A.2 A.3 A.4 A.5 A.6 A.7
B
SPOT I/O SEQUENCE .............................................................................. 948 SPOT MACRO........................................................................................... 952 WELD MODE............................................................................................. 954 MULTI APPLICATION ............................................................................... 956 APPLICATION STATUS ............................................................................ 958 ALARM RECOVERY ................................................................................. 959 DISABLE FAULT CHECKING ................................................................... 963
APPENDIX .......................................................................................... 967 B.1
B.2
START MODE ........................................................................................... 968 B.1.1
Start Up Methods..................................................................................................968
B.1.2
Initial Start............................................................................................................969
B.1.3
Controlled Start ....................................................................................................970
B.1.4
Cold Start..............................................................................................................972
B.1.5
Hot Start ...............................................................................................................974
MASTERING ............................................................................................. 975 B.2.1
Jig Mastering ........................................................................................................977
B.2.2
Mastering at the Zero-degree Positions................................................................979
B.2.3
Quick Mastering ...................................................................................................981
B.2.4
Single Axis Mastering ..........................................................................................984
B.2.5
Setting Mastering Data .........................................................................................987 c-13
TABLE OF CONTENTS B.3 B.4 B.5
B.6 B.7 B.8
SOFTWARE VERSION ............................................................................. 989 ROBOT AXIS STATUS.............................................................................. 992 DIAGNOSIS SCREEN............................................................................... 998 B.5.1
Outline ..................................................................................................................998
B.5.2
About Reducer Diagnosis.....................................................................................998
B.5.3
Procedure..............................................................................................................999
B.5.4
Each Item............................................................................................................1000
WORLD FRAME ORIGIN ........................................................................ 1004 I/O MODULE SETTING ........................................................................... 1005 SETTINGTHE FSSB LINE....................................................................... 1011 B.8.1
Definition of FSSB line......................................................................................1011
B.8.2
Setting 1 (FSSB line)..........................................................................................1012
B.8.3
Setting 2 (Number of total axes on FSSB line 1) ...............................................1012
B.8.4
Setting 3 (Hardware start axis) ...........................................................................1012
B.8.5
Setup Examples ..................................................................................................1013 B.8.5.1 B.8.5.2 B.8.5.3
B.9 B.10 B.11
C
Example 1 ...................................................................................................... 1013 Example 2 ...................................................................................................... 1014 Example 3 ...................................................................................................... 1015
POSITIONER SETUP.............................................................................. 1016 EXTENDED AXIS SETUP ....................................................................... 1022 INDEPENDENT ADDITIONAL AXIS BOARD (NOBOT) STARTUP PROCEDURE.......................................................................................... 1028
ALARM CODES ................................................................................ 1033 C.1 C.2
D
B-82594EN-4/01
DESCRIPTION OF AN ALARM CODE TABLE ....................................... 1034 ALARM CODES....................................................................................... 1045
SYSTEM VARIABLES ...................................................................... 1234 D.1 D.2
FORMAT OF A SYSTEM VARIABLE TABLE.......................................... 1235 SYSTEM VARIABLES ............................................................................. 1237
c-14
1.INTRODUCTION
B-82594EN-4/01
1
INTRODUCTION This chapter explains the manual plan and the safety precautions that must be observed in working with the FANUC Robot. Contents of this chapter 1.1 1.2 1.3 1.4
MANUAL PLAN .........................................................................2 WORKERS...................................................................................5 GENERAL SAFETY PRECAUTIONS .......................................6 SAFETY PRECAUTIONS.........................................................11
-1-
1.INTRODUCTION
1.1
B-82594EN-4/01
MANUAL PLAN
About this manual FANUC Robot series (R-30iA CONTROLLER) Operator’s Manual. This manual describes how to operate the FANUC Robot, an all-purpose compact robot. It is controlled by the FANUC R-30iA controller (called the robot controller hereinafter) containing the FANUC Robot software. This manual describes the following items for manipulating workpieces with the robot: • Setting the system for manipulating workpieces • Operating the robot • Creating and changing a program • Executing a program • Status indications • Alarm codes and system variables
Using this manual Each chapter of the manual describes a single operation of the robot. The user can select and read chapters describing required operations. The user can understand all the information presented in this the manual in five or six hours if he or she reads it from cover to cover once. Chapter 1 Introduction Chapter 2 Overview Chapter 3 Setting the System for Robot Chapter 4 Program Structure Chapter 5 Creating a Program Chapter 6 Executing a Program Chapter 7 Status Indications Chapter 8 File Input/Output Chapter 9 Utility Chapter 10 Palletizing Function Chapter 11 FANUC iPendant Chapter 12 Dispense Tool Appendix Alarm Codes and System Variables
Describes how to use this manual and the safety precautions that must be observed in working with the robot. All users must read the safety precautions. Gives a basic knowledge of the robot. It describes the basic configuration of the robot and the system for Robot. Describes the procedure for setting the system for Robot including input/output, coordinate system, and reference position. Describes the program structure and the syntax of program instructions. Describes how to design, create, change, delete, and copy a program. It also describes the procedures for turning the power on and moving the robot by jog feed. Describes how to execute and stop a program. It also describes the test operation, automatic operation, and recovery from the alarm state. Describes how to check the operating status of the robot, using the status indicator LEDs. Describes how to store, read, and print a program file or system file. Describes additional utility functions, macro functions, program shift and mirror shift. Describes the setting and executing of palletizing function. Describes the FANUC iPendant. Describes the Dispense Tool function. Describes lists of the menus, screens, program instructions and detail of program. Lists the alarm codes and system variables.
-2-
1.INTRODUCTION
B-82594EN-4/01
Identification For editions and order files of software, read the following sections: Item to be checked
Section
Edition of your software Order No. of your software
B.3 Software Version A.1 List of Menus
Specifications of products For memory statuses or software option list, see the following sections: Item to be checked
Section
Memory status Software option list Menu displayed when an option is selected Program instruction that can be used when an option is selected
7.11 Memory Use Status Display A.1 List of Menus A.1 List of Menus A.3 List of Program Instructions
Related manuals The following manuals are available: Robot controller
OPERATOR’S MANUAL (This manual)
MAINTENANCE MANUAL
Mechanical unit
Operator’s/ Maintenance manual
-3-
Intended readers: Operators responsible for designing, introducing, operating, and adjusting the robot system at the work site. Topics: Functions, operations and the procedure for operating the robot. Programming procedure, interface and alarm. Use: Guide to teaching, introducing, and adjusting the robot at the work site, and application designing. Topics: Installing and activating the system, connecting the mechanical unit to the peripheral device and maintenance the robot. Topics: Installing and activating the robot, connecting the mechanical unit to the controller, maintaining the robot. Use: Guide to installation, activation, connection, and maintenance.
1.INTRODUCTION
B-82594EN-4/01
Notation This manual contains safety precautions against injury and property damage. Those precautions are labeled ”Warning” or ”Caution,” according to the degree of importance. Supplementary explanation is given under ”Note.” Before starting to use a robot, carefully read the ”Warning,” ”Caution,” and ”Note.”
WARNING Failure to follow the instruction given under ”Warning” can cause fatal or serious injury to the user. This information is indicated in bold type in a box so that it can be easily distinguished from the main body of this manual. CAUTION Failure to follow the instruction given under ”Caution” can cause injury to the user or property damage. This information is indicated in a box so that it can be easily distinguished from the main body of this manual. NOTE The information given under ”Note” is a supplementary explanation, which is neither a warning nor a caution. Carefully read and save this manual.
-4-
1.INTRODUCTION
B-82594EN-4/01
1.2
WORKERS A robot cannot do anything alone. The robot can operate only after it is equipped with a hand or other device and connected with peripheral equipment to form a system. Give considerations for the safety of not only the robot but also the entire system. When using the robot, provide a safety fence and other safety measures. FANUC defines the system personnel as indicated below. Check which worker should be trained in a specialist robot course.
Operator The jobs of an operator are: • Turning on and off the system • Starting and stopping programs of a robot • Recovering the system from an alarm state The operator must not enter the area enclosed by the safety fence to do his or her work.
Programmer or teaching operator The jobs of the programmer or teaching operator include the jobs of the operator and the following: • Teaching of a robot, adjustment of the peripheral equipment, and other work that must be done in the area enclosed by the safety fence The programmer or teaching operator should be trained in a specialist robot course.
Maintenance engineer The jobs of the maintenance engineer include the jobs of the programmer and the following: • Repair and maintenance of the robot The maintenance engineer should be trained in a specialist robot course.
-5-
1.INTRODUCTION
1.3
B-82594EN-4/01
GENERAL SAFETY PRECAUTIONS This section lists general safety precautions. Before starting to use the robot, read the precautions. The subsequent sections of the manual indicate other precautions. Take each of the precautions.
General rules WARNING 1 When the robot is used, the following precautions should be taken. Otherwise, the robot and peripheral equipment can be adversely affected, or workers can be severely injured. - Avoid using the robot in a flammable environment. - Avoid using the robot in an explosive environment. - Avoid using the robot in an environment full of radiation. - Avoid using the robot under water or at high humidities. - Avoid using the robot to carry a person or animal. - Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.) 2 Robot personnel must wear the following safety articles: - Clothing suitable for each job - Safety shoes - Helmet NOTE Programmers and maintenance staff should be trained in a suitable course at FANUC.
Notes on installation WARNING The robot should be transported and installed by accurately following the procedures recommended by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe injury to workers. CAUTION In the first operation of the robot after installation, the operation should be restricted to low speeds. Then, the speed should be gradually increased to check the operation of the robot. -6-
1.INTRODUCTION
B-82594EN-4/01
Notes on operation WARNING Before the robot is started, it should be checked that no one is in the area of the safety fence. At the same time, a check must be made to ensure that there is no risk of hazardous situations. If detected, such a situation should be eliminated before the operation. CAUTION Operators should be ungloved while manipulating the operator’s panel or teach pendant. Operation with gloved fingers could cause an operation error. NOTE Programs, system variables, and other information can be saved on memory card or floppy disks. Be sure to save the data periodically in case the data is lost in an accident. (See the file input/output section for saving the data.)
Notes on programming WARNING Programming should be done outside the area of the safety fence as far as possible. If programming needs to be done in the area of the safety fence, the programmer should take the following precautions: - Before entering the area of the safety fence, ensure that there is no risk of dangerous situations in the area. - Be prepared to press the emergency stop button whenever necessary. - Robot motions should be made at low speeds. - Before starting programming, check the entire system status to ensure that no remote instruction to the peripheral equipment or motion would be dangerous to the user. CAUTION After programming is completed, a text execution should be given according to a specified procedure. (See the section of program execution on this manual). During the text execution, workers must stay out of the safety fence.
-7-
1.INTRODUCTION
B-82594EN-4/01
NOTE Programmers should be trained in a suitable course at FANUC.
Notes on maintenance WARNING 1 During maintenance, the robot and system should be in the power-off state. If the robot or system is in the power-on state, a maintenance operation could cause a shock hazard. If necessary, a lock should be provided to prevent any other person from turning on the robot or system. If maintenance needs to be executed in the power-on state, the emergency stop button should be pressed. 2 When replacing a part, the maintenance worker should read the manuals for the controller and the mechanical unit and learn the replacement procedure beforehand. If a wrong procedure is followed, an accident may occur, causing damage to the robot and injury to the worker. 3 When entering the area enclosed by the safety fence, the maintenance worker should check the entire system to make sure that no dangerous situations are present. If the worker needs to enter the area of the fence while a dangerous situation exists, the worker should always take extreme care and check the current system status. 4 A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used. Such a fuse may cause a fire. 5 When a motor or brake is removed, the robot arm should be supported with a crane or other equipment beforehand so that the arm would not fall during the removal. 6 If a robot motion is necessary during maintenance, the following precautions should be taken: - Reserve an escape route. During the maintenance, always check the motions of the whole system so that the escape route will not be blocked by the robot or peripheral equipment. - Always pay attention to risk of dangerous situations and get prepared to press the emergency stop button whenever necessary.
-8-
1.INTRODUCTION
B-82594EN-4/01
WARNING 7 When a motor, decelerator, or other heavy load is handled, a crane or other equipment should be used to protect maintenance workers from excessive load. Otherwise, the maintenance workers would be severely injured.
1 2
3
4
5
6
7 8
CAUTION Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent dangerous falls. The robot should not be stepped on or climbed up during maintenance. If it is attempted, the robot would be adversely affected. In addition, a misstep can cause injury to the worker. The following parts are heated. If a maintenance worker needs to touch such a part in the heated state, the worker should wear heat-resistant gloves or use other protective tools. - Servo motor - Inside the control unit When a part is replaced, all bolts and other related components should put back into their original places. A careful check must be given to ensure that no components are missing or left unmounted. Before the maintenance of the pneumatic system is started, the supply pressure should be shut off and the pressure in the piping should be reduced to zero. After a part is replaced, a text execution should be given for the robot according to a predetermined method. (See the program execution of this manual.) During the text execution, the maintenance staff should work outside the safety fence. After the maintenance is completed, spilled oil or water and metal chips should be removed from the floor around the robot and within the safety fence. When a part is replaced, care must be taken to prevent dust from entering the robot.
-9-
1.INTRODUCTION
B-82594EN-4/01
NOTE 1 Each maintenance worker or inspection worker should be trained in a suitable course at FANUC. 2 Maintenance should be done under suitable light. Care must be taken that the light would not cause any danger. 3 The robot should be periodically inspected. (Refer to the manual for the controller or the mechanical unit.) A failure to do the periodical inspection can adversely affect the performance or service life of the robot and also may cause an accident.
- 10 -
1.INTRODUCTION
B-82594EN-4/01
1.4
SAFETY PRECAUTIONS
Safety precautions Unlike ordinary automatic machines, robots have arms and wrists which can be moved in all operation space. A robot is quite flexible, but on the other hand, it is quite dangerous. The robot is usually connected with peripheral equipment to comprise an automated system. Users must take safety precautions for the entire system. The safety precautions are described below.
Safety precautions related to installation and layout •
Use warning lamps and other provisions to indicate that the robot is operating.
Fig. 1.4 (a) Alarm Indications
•
Put a protective fence with safety door around the system so that only the operator can enter the operating area by the door. Design the system so that it will stop when the door is opened.
NOTE 1 Connect the *FENCE input signal to the safety door. Refer to the maintenance manual for explanations about how to connect. 2 When the *SFSPD (safety speed) input signal is turned off, the control unit halts the robot. •
Put a protective fence so that the motion range of the robot is surrounded completely. Moreover, put the controller outside of the protective fence.
- 11 -
1.INTRODUCTION
B-82594EN-4/01
Fig. 1.4 (b) Safety fence
•
Install an emergency stop button where it will be readily accessible to the operator.
NOTE Upon receiving an emergency stop signal, the controller immediately stops the robot.
Fig. 1.4 (c) Safety Plug
Safety precautions related to system design •
Install a safety joint between robot wrists. If an abnormal external force is applied to the robot, the safety joint breaks and the robot stops.
NOTE When the hand break (*HBK) input signal goes off, the controller immediately stops the robot. • •
Hand breakage detection can be disabled when the *HBK input signal is off. This can be set on the system setting screen. See the section of the system config menu. Ground all peripheral units properly.
- 12 -
1.INTRODUCTION
B-82594EN-4/01
• • •
When a desired operating area is smaller than the maximum operating area of the robot, the desired area can be specified by parameters. The robot receives interlock signals sent from remote equipment. Upon receiving a signal indicating the operating status of the remote equipment, the robot can stop or halt. When required, install a lock so that only authorized personnel can switch the power on.
NOTE The circuit breaker on the control unit door is designed such that power-on can be disabled by setting a padlock.
Fig. 1.4 (d) Locking the Circuit Breaker
Safety precautions related to inspection and maintenance • • • •
Before starting the inspection or maintenance, turn off the controller. Lock the circuit breaker or place a guard to prevent someone else from switching the power on. Before disconnecting the pneumatic system, release the supply pressure. Before starting an inspection in which the electrical system of the robot need not be operated, press the emergency stop button. When carrying out an inspection in which the robot needs to be operated, carefully observe the motion of the robot. Immediately press the emergency stop button whenever required.
Fig. 1.4 (e) Emergency Stop Button
- 13 -
1.INTRODUCTION
B-82594EN-4/01
Safety precautions related to transportation • •
When carrying the robot or another unit on a carrier such as a crane or fork lift, securely fasten the robot to the carrier. Carefully inspect the crane, fork lift, other carrying equipment, and carrying handle on the product.
Fig. 1.4 (f) Carrying the Robot
Safety precautions related to operation • • •
•
All robot system operators are requested to attend FANUC training courses to learn the safety precautions and functions of the robot. Before beginning to program the robot, make sure that there are no abnormal or dangerous conditions around the robot and peripheral equipment. Before working within the operating area of the robot, even when the robot is not running, switch the power off or press the emergency stop button. Place a guard to prevent someone else from entering the operating area of the robot or activating the robot from the operator’s panel. While programming the robot in its operating area, place a guard so that the robot can be immediately stopped in an emergency.
Fig. 1.4 (g) Danger Monitoring by Two Persons
- 14 -
1.INTRODUCTION
B-82594EN-4/01
Table 1.4 Safety precautions item Workshop
Operator
Transportation and installation
Keep the workshop neat, tidy, and clean. Install a protective fence and warning indications. Provide ventilation. Never bring flammable material to the workshop.
Keep the transportation lane free from obstacles. When carrying the robot or another unit on a carrier such as a fork lift or crane, securely fasten it to the carrier. Keep a sufficient operating area. Make connection s properly.
Operation
Maintenance and inspection
Hand
Attend training classes. Master the operating procedures. Exclude unauthorized personnel.
Use only FANUC products for repair. Before starting maintenance or inspection, turn the power off. Close the controller door.
Inspect and take care of cables. Check the pneumatic pressure. Inspect the hand mechanism.
Avoid dangerous behavior. Wear working clothes, safety shoes, and a safety helmet.
Fig. 1.4 (h) Safety Clothes and Safety Helmet
•
Before approaching the robot to program it, hold the teach pendant in your hand, press the deadman switch, and set the teach pendant enable switch on.
NOTE If the deadman switch is released while the teach pendant enable switch is on, the robot immediately stops.
Fig. 1.4 (i) Deadman switch and Teach pendant enable switch
- 15 -
1.INTRODUCTION
B-82594EN-4/01
• •
Before moving the robot by jog feed, carefully observe the operation of the jog keys and the robot. Before moving the robot by jog feed, sufficiently lower the feedrate override of the robot.
- 16 -
2.OVERVIEW
B-82594EN-4/01
2
OVERVIEW This chapter shows the basic configuration of the FANUC Robot System and briefly describes the functions of each component. Contents of this chapter 2.1 APPLICATION TOOL SOFTWARE ........................................19 2.2 ROBOT.......................................................................................21 2.3 CONTROLLER..........................................................................22
- 17 -
2.OVERVIEW
B-82594EN-4/01
A FANUC robot system consists of the tool software for manipulating workpieces, the mechanical unit of the robot itself (FANUC Robot series), and the Robot control unit. The FANUC robot offers outstanding performance when handling or welding.
Tool software for application The tool software for application is a software package for all kinds of Robot’s manipulations installed on the Robot control unit. Any work can be performed by specifying menus and instructions from the teach pendant. The tool software for manipulating workpieces contains instructions for controlling the robot, hands, remote control units, and other peripheral devices. The I/O between an additional axis or control unit and another peripheral device can be controlled. Other peripheral devices include cell controllers or sensors.
Robot Robot has a hand or another end effector interface for control to do work. The FANUC robot is ideal for manipulating workpieces.
Controller The Robot control unit supplies power to drive the mechanical unit. The tool software for manipulating workpieces is installed on the Robot control unit to control the teach pendant, operator’s panel, and external peripheral devices. Peripheral devices, including remote control units, are required to configure a system for manipulating workpieces. • The remote control units are used to control the Robot control unit. • The hands, sensors, and other devices are operated using I/O and serial communication units. Fig. 2 shows a typical robot system for manipulating workpieces. The system consists of a robot, the Robot control unit, and peripheral devices.
Fig. 2 Assembly system for car doors
- 18 -
2.OVERVIEW
B-82594EN-4/01
2.1
APPLICATION TOOL SOFTWARE The Application tool software has been specially designed to perform manipulating workpieces operations. The Application tool software is contained in the Robot and enables the following: • Setting up the system for Robot applications • Creating a program • Performing the test operation of a program • Performing the automatic operation • Status display or monitoring When optional functions are incorporated, the system can be expanded and the management functions can be enhanced.
2.1.1
System Setting The Application tool software has an interface for specifying parameters of operation of the manipulation system. (For how to set the Robot system, see Chapter 3.) With the Application tool software, the Handling remote controller, and other external units can be controlled. Before the manipulation is started, the following must be specified: input from and output to the hand and other peripheral units, the coordinate system, communication, and automatic operation.
2.1.2
Jog Feed of the Robot Jog feed of the robot is the operation of moving the robot as desired by manually entering commands on the teach pendant. When a motion instruction of a program is executed, the robot is moved to the target position by jog feed, then the position is recorded. (For the jog feed of the robot, see Subsection 5.2.3.)
2.1.3
Program A program contains motion instructions, input/output instructions, register instructions, and branch instructions. (For the program structure, see Chapter 4.) Each instruction is assigned a statement number. The target work is accomplished by sequentially executing the instructions. The Spot teach pendant is used to create or correct a program. (For creation of a program, see Chapter 5.) The program contains the following instructions. Fig. 2.1.3 shows a basic program for manipulating workpieces. • Motion instruction: Moves the tool to the target position within the operating range. • Additional motion instruction: Performs an additional (special) operation during a motion. • Register instruction: Places (loads) numerical data into a register. - 19 -
2.OVERVIEW
B-82594EN-4/01
• • • • • • • • • •
Position register instruction: Places (loads) position data into a register. Input/output instruction: Sends or receives a signal to or from a peripheral unit. Branch instruction: Changes the flow of a program. Wait instruction: Holds execution of the program until the specified conditions are satisfied. Routine call instruction: Calls and executes a subprogram. Macro instruction: Calls a specified program and executes it. Palletizing instruction: Palletizes workpieces. Program end instruction: Terminates execution of a program. Comment instruction: Adds a comment to a program. Other instructions
Fig. 2.1.3 Robot Program
2.1.4
Test Operation (Test Execution) After the system is set and a program is created, perform the test operation in the test execution mode to check the program for normal operation. (For the test operation, see Section 6.3.) The test execution of the program is one of the important steps in creating a good program. Before starting automatic operation, execute the test program.
2.1.5
Automatic Operation (Operation Execution) Automatic operation (operation execution) is the final step in executing programs. In automatic operation, the following processing is executed: • Specified programs are started one after another. (For automatic operation, see Sections 3.8 and 6.6.) • During automatic operation, position data can be corrected (online position correction Section 6.7). • The processing is halted, then aborted or resumed. (For halting a program, see Section 6.1.) - 20 -
2.OVERVIEW
B-82594EN-4/01
2.2
ROBOT A robot is a mechanical unit consisting of axes and arms driven by servo motors. A place at which arms are connected is a joint, or an axis. J1, J2, and J3 are main axes. The basic configuration of the robot depends on whether each main axis functions as a linear axis or rotation axis. The wrist axes are used to move an end effecter (tool) mounted on the wrist flange. The wrist itself can be rotated about one wrist axis and the end effector rotated about the other wrist axis.
Fig. 2.2 (a) Main axes and wrist axes
Fig. 2.2 (b) Hand with Fingers
Fig. 2.2 (c) Hand with Suction Cups and No Fingers
- 21 -
2.OVERVIEW
2.3
B-82594EN-4/01
CONTROLLER Robot controller includes a power unit, user interface circuit, motion controlling circuit, memory circuit, and input/output circuit. The user should use a teach pendant and operator's box to operate the control unit. The operation control circuit controls the servo amplifier which moves all the robot axes, including any additional axes, via the main CPU printed circuit board. The memory circuit can store programs and data set by the user in the C-MOS RAM on the main CPU printed circuit board. The input/output (I/O) circuit interfaces the controller with the peripheral units by receiving and sending signals via the I/O link cable and peripheral connecting cable. The remote input/output signal is used for communication with the remote controller. Robot controller Operator panel Three mode switch
Teach pendant
Fig. 2.3 Robot controller
The circuitry of the controller depends on the robot and the system it controls. For details, refer to the maintenance manual.
- 22 -
2.OVERVIEW
B-82594EN-4/01
2.3.1
Teach Pendant The teach pendant provides an interface between the Application tool software and the operator. The teach pendant is connected to the PC board in the controller by a cable. The following operations can be performed using the teach pendant: • Jog feed of the robot • Program generation • Test execution • Actual work • Status check The teach pendant includes the following: • Liquid crystal display of 40 characters by 16 lines • 11 LEDs • 61 keys (Four keys of them are for exclusive use of each application)
CAUTION The operator of the teach pendant should use gloves that would not cause any operation error. The following switches are also provided: Teach pendant enable switch Deadman switch
Emergency stop button
This switch enables or disables the teach pendant. When the teach pendant is disabled, a jog feed, program generation, or test execution cannot be carried out. DEADMAN SWITCH is used as an enabling device. When the teach pendant is enabled, this switch allows robot motion only while the deadman switch is gripped. If you release this switch, the robot stops immediately. When pressed, the emergency stop button immediately stops the robot.
Fig. 2.3.1 (a) Switches on the Teach Pendant
- 23 -
2.OVERVIEW
B-82594EN-4/01
Fig. 2.3.1 (b) shows the teach pendant.
Fig. 2.3.1 (b) Teach Pendant
- 24 -
2.OVERVIEW
B-82594EN-4/01
Keys on the teach pendant The teach pendant has the following keys: • Keys related to menus • Keys related to jog feed • Keys related to execution • Keys related to editing Table 2.3.1 (a) Keys related to menus Key
Function The function (F) key to select a function menu at the last line of the screen. The next page key to switch the function key menu on the next page.
The MENUS key to display the screen menu. The FCTN key to display the function menu. The SELECT key to display the program selection screen. The EDIT key to display the program edit screen. The DATA key to display the program data screen. The HOT EDIT key displays the manual operation screen.
The STATUS key displays the current position screen.
The I/O key displays the I/O screen.
The POSN key displays the current position screen.
Application-dedicated keys differ depending on the application. Table 2.3.1 (b) Keys related to handling Key
Function This key makes manual pressurization. This key makes manual stroke switching. This key switches the unit number and gun number for the above manual pressurization and manual stroke.
- 25 -
2.OVERVIEW
B-82594EN-4/01
Table 2.3.1 (c) Keys related to jog feed Key
Function The SHIFT key is used to execute a jog feed of the robot, teach the position data, and start a program. The right and left Shift keys have the same function. The jog keys are effective while a Shift key is held down. They are used for jog feed.
The COORD key selects a manual-feed coordinate system (jog type). Each time the COORD key is pressed, it selects the next jog type in the order: JOINT, JGFRM, World frame, TOOL, USER. When this key is pressed while a Shift key is held down, a jog menu for changing the coordinate system appears. The override key adjusts the feedrate override. Each time the override key is pressed, it selects the next override in the order: VFINE, FINE, 1%, 5%, 50%, 100%.(changing amount 5% for 5% or less and changing amount 5% for 5% or more.) Table 2.3.1 (d) Keys related to execution Key
Function The FWD key or BWD key (+ SHIFT key) starts a program. When the shift key is released during regeneration, the program halts. The HOLD key causes a program to halt.
The STEP key selects step or continuous test operation.
Table 2.3.1 (e) Keys related to editing Key
Function The PREV key restores the most recent state. In some cases, the screen may not return to the immediately preceding status. The ENTER key enters a numeral or selects a menu.
The BACK SPACE key deletes the character or numeral immediately before the cursor. The cursor key moves the cursor. The cursor is the highlighted part which can move on the teach pendant screen. This part becomes the object of operation ( input or change of the value or contents) from the teach pendant key. The ITEM key moves the cursor to a line whose number is specified.
- 26 -
2.OVERVIEW
B-82594EN-4/01
LEDs on the teach pendant
SEAL ENBL PRODMODE TEST CYC JOINT XYZ TOOL
Fig. 2.3.1 (c) LEDs on the teach pendant
LED FAULT HOLD STEP BUSY
RUNNING JOINT XYZ
TOOL SEAL ENBL PRODMODE TEST CYC
Table 2.3.1 (f) LEDs on the teach pendant Function The FAULT LED indicates that an alarm has occurred. The HOLD LED indicates that the HOLD button is being pressed or HOLD signal is being input The STEP LED indicates that it is under step operation mode. The BUSY LED is lit while the robot is working. It is also lit when a program is executed or when the printer or floppy disk drive unit is operating. The RUNNING LED indicates that the program is being executed. The JOINT LED is lit when joint jog is selected as the manual-feed coordinate system (jog type). The XYZ LED is lit when Cartesian jog (JGFRM World frame or USER) is selected as the manual-feed coordinate system (jog type). The TOOL LED is lit when tool jog (TOOL) is selected as the manual-feed coordinate system (jog type). This LED indicates that WET RUN is enabled. The PRODMODE LED indicates that it is under automatic operation mode. The TEST CYC indicates that it is under test execution mode.
Each of the LEDs I/O ENBL, PROD MODE, and TEST CYC is an application-dedicated LED on the teach pendant for handling tools. Application-dedicated LEDs differ depending on the application tool.
- 27 -
2.OVERVIEW
2.3.1.1
B-82594EN-4/01
Display Screen of the Teach Pendant The liquid crystal display screen (liquid crystal display) displays the Application tool software screen shown in Fig. 2.3.1.1 (a). To operate the robot, select a screen corresponding to a desired function. The screen is selected by the screen menus shown in Fig. 2.3.1.1 (b).
Fig. 2.3.1.1 (a) Program Edit Screen
Screen menu and function menu Menus are used to operate the teach pendant. The screen menu is selected by the MENUS key and the function menu is selected by the FCTN key. Fig. 2.3.1.1 (b), Fig. 2.3.1.1 (c), and Fig. 2.3.1.1 (d) show the screen menu, auxiliary menu, and quick menu respectively.
- 28 -
2.OVERVIEW
B-82594EN-4/01
- Screen menu The screen menu is used to select a screen. The screen menu lists the following options. (For the list of menus, see Appendix A.1. For the screen type, see Appendix A.2.) To display the screen menu, press the MENUS key on the teach pendant.
SOFT PANEL
USER2 BROWSER
Fig. 2.3.1.1 (b) Screen menu Table 2.3.1.1 (a) Screen menu Function
LED UTILITIES TEST CYCLE MANUAL FCTNS ALARM I/O SETUP FILE SOFT PANEL USER SELECT EDIT DATA STATUS POSITION SYSTEM USER2 BROWSER
- 29 -
The utility screen is used to display the hints’. The test cycle screen is used to specify the data for test operation. The manual operation screen is used to execute macro instructions. The alarm history screen shows the history and details of alarms. The I/O screen is used to display and set manual output, simulated input/output, and assign of signals. The setting screen is used to set the system. The file screen is used to read or store files. This screen is used to execute frequently used functions. The user screen shows user messages. The program selection screen is used to list or create the programs. The program edit screen is used to correct and execute a program. The program data screen shows the values in registers, position registers, and pallet register. The status screen shows the system status. The current position screen shows the current position of the robot. The system screen is used to set system variables and mastering. This screen displays messages output from KAREL programs. This screen is used to brows Web pages on the network. (Displayed only when the iPendant teach pendant is used.)
2.OVERVIEW
B-82594EN-4/01
- Function menu The function menu is used to execute a miscellaneous function. (For the list of menus, see Appendix A.1.) To display the function menu, press the FCTN key on the teach pendant.
UNSIM ALL I/O CYCLE POWER ENABLE HMI MENUS
Fig. 2.3.1.1 (c) Function menu
LED
Table 2.3.1.1 (b) Function menu Function
ABORT (ALL) Disable FWD/BWD CHANGE GROUP TOGGLE SUB GROUP TOGGLE WRIST JOG
RELEASE WAIT
QUICK/FULL MENUS SAVE PRINT SCREEN PRINT UNSIM ALL I/O CYCLE POWER ENABLE HMI MENUS
- 30 -
ABORT forces a program which is being executed or temporarily halted to terminate. Disable FWD/BWD enables or disables starting a program with a teach pendant Changes the operation group for jog feed. Displayed only when multiple groups are set. TOGGLE SUB GROUP toggles jog between robot standard axes and extended axes. TOGGLE WRIST JOG toggles jog between the attitude control feed and the wrist joint feed which does not maintain the wrist attitude in linear feed. Skips the wait instruction currently being executed. When the wait state is released, execution of the program stops temporarily at the line subsequent to the wait instruction. QUICK/FULL MENUS toggles the menu between a usual screen menu and a quick menu. SAVE saves the data related to the current screen on a floppy disk or memory card. PRINT SCREEN prints the data displayed on the current screen. PRINT prints the data on the current screen exactly. Cancels the simulated settings of all IO signals. Makes a restart (power OFF/ON). Used to select whether to display the HMI menu when the MENUS key is pressed.
2.OVERVIEW
B-82594EN-4/01
Restart It is now possible to make a restart (power off/on) from the FCTN key.
- Condition • •
The teach pendant is enabled. The controller is in a cold start status.
1 2 3
Press the [FCTN] key. Select [CYCLE POWER]. The screen below appears.
- Step
This will cycle power. Are you sure ? [NO]
YES
4 5
Press the [NEXT] key and select [YES]. Press the [ENTER] key.
- Quick menu When a quick menu is selected in QUICK/FULL MENUS of FUNCTIONS, the screen that can be displayed by using the screen menu is limited to the following: • ALARM / alarm occurrence and alarm history screen • UTILITIES / hint screen • TEST CYCLE screen • DATA / register screen • Tool 1 / Tool 2 screen • STATUS/axis screen • I/O/digital/group/Robot I/O screen • POSITION screen • SETUP / Coordinate system setup screen • USER / USER 2 screen • SETUP PASSWORD screen • BROWSER screen (only when iPendant is used)
TEST CYCLE
MANUAL FCTNS I/O STATUS
USER Tool1 Tool2 USER2 SETUP PASSWORD BROWSER
SETUP
Page 1
Page 2
Fig. 2.3.1.1 (d) Quick menu
- 31 -
2.OVERVIEW
B-82594EN-4/01
NOTE 1 The program selection screen can be displayed by the SELECT key. But the only available function is selecting a program. 2 The program edit screen can be displayed by the EDIT key. But the only available functions are changing position and speed values.
2.3.2
Operator Panel The operator panel has buttons, switches, and connectors. Fig. 2.3.2 shows the operator panel on the cabinet. The buttons on the operator panel can be used to start a program, release the alarm state, and perform other operations.
CAUTION Do not wear gloves which would likely cause operator errors when using the operator panel. The operator panel also has an RS-232C communication port and a USB communication port. Table 2.3.2 (a) lists the switches on the operator’s panel. Table 2.3.2 (b) lists the LEDs on the operator panel.
Switch
Table 2.3.2 (a) Switches on the Operator Panel Function
Emergency stop button Alarm release button Start button Three mode switch
LED Alarm Battery Alarm
Press this button to stop the robot immediately. Turn the emergency stop button clockwise to release it. Release the alarm state. Starts the currently selected program. Lit while the program is being started. Enables the user to select operation mode suitable to the robot operation conditions or the status of its use. Table 2.3.2 (b) LEDs on the Operator Panel Function Indicates the alarm state. Press the alarm release button to release the alarm state. Indicates that the voltage of the memory backup battery is low. Replace the battery as soon as possible.
- 32 -
2.OVERVIEW
B-82594EN-4/01
Start button Alarm release button Alarm
Emergency stop button
Battery alarm Three-mode switch
Fig. 2.3.2 Operator Panel (standard)
2.3.3
Remote Controller Remote control units are external devices connected to the Robot control unit to configure a system. These are control units for controlling the operation of the system created by the user using peripheral devices and I/O provided by the robot control unit.
2.3.4
CRT/KB The CRT/KB is an optional operation unit. An external CRT/KB is connected to the control unit via an RS-232-C cable. The CRT/KB can be used to execute almost all teach pendant functions excluding those related to robot operation. Functions related to robot operation can only be executed using the teach pendant.
2.3.5
Communication For communications, the following interfaces are provided (communication ports Section 8.2). • One standard RS-232-C port (external 1) • One optional RS-232-C ports (internal 1) • One optional RS-422 ports (internal 1)
- 33 -
2.OVERVIEW
2.3.6
B-82594EN-4/01
Input/Output General-purpose and specialized input/output (I/O) signals are used to send the data of an external unit to the Spot tool software. The general-purpose signal (user-defined signal) is controlled by a program and is used to send or receive data to or from the external units or hand. The specialized signal (system-defined signal) is applied to a specific use. The input/output signals include the following: • Peripheral I/O (See Section 3.3.) • Operator’s panel I/O (See Section 3.4.) • Robot I/O (See Section 3.2.) • Digital I/O (See Subsection 3.1.1.) • Group I/O (See Subsection 3.1.2.) • Analog I/O (See Subsection 3.1.3.) The number of the I/O signals and their types depend on the hardware of the control unit and the number of selected I/O modules and their types. I/O unit model A, I/O unit model B, and Process I/O PC board can be connected to the controller.
2.3.7
Peripheral I/O Peripheral I/O is a signal specialized for sending and receiving data to or from the remote controller or peripheral equipment. (See Section 3.3, ”PERIPHERAL I/O”). Peripheral I/O signals perform the following: • Select a program • Start and stop a program • Recover the system from the alarm state • Others
- 34 -
2.OVERVIEW
B-82594EN-4/01
2.3.8
Motion of the Robot A single motion instruction specifies a motion of the robot, or a movement of the tool center point (TCP) from the current position to the target position. The Robot uses a motion control system that comprehensively controls the tool path, acceleration/deceleration, positioning, feedrate, and other factors. The Robot control unit can control up to 40 axes, divided into up to five operation groups (multiple motion function). The control unit can control up to nine axes for a group. The operation groups are independent of one another, but can be synchronized to operate the robot simultaneously. The robot moves according to a jog feed specified on the teach pendant or a motion instruction specified in a program. To execute a jog feed of the robot, use the corresponding key on the teach pendant. In jog feed, the motion of the robot depends on the selected manual-feed coordinate system (jog type) and feedrate override. When a motion instruction is used, the motion of the robot depends on the position data, motion format, positioning path, traveling speed, and feedrate override specified in the instruction. One of three motion formats -- Linear, Circular, and Joint -- can be selected to operate the robot. When Joint is selected, the tool is moved arbitrarily between two specified points. When Linear is selected, the tool is moved along a straight line between the two specified points. When Circular is selected, the tool is moved along an arc connecting three specified points. A positioning path can be selected from two options, Fine and Cnt.
2.3.9
2.3.10
Emergency Stop Devices
Extended Axis
This robot has following emergency stop devices. • Two emergency stop buttons ( installed on the operator’s panel and the teach pendant ) • External emergency stop ( input signal ) When an emergency stop button is pushed, the robot stops immediately in any cases. The external emergency stop outputs or inputs the emergency stop signal for peripheral devices (e.g. safety fence, gate). The signal terminal is on the controller and operator’s box inside.
A maximum of three axes of one group can be added to the standard axes (usually six axes) of the robot. The Robot can control up to 40 axes (with an optional servo card). The extended axis has the following two types: • Extended axes This can be controlled regardless of the robot motion and can move only at the joint motion. • Integrated axes Controlled together with the robot during linear or circular robot operation. Use these axes to perform linear or circular robot operation. - 35 -
3.SETTING UP THE HANDLING SYSTEM
3
B-82594EN-4/01
SETTING UP THE HANDLING SYSTEM The Robot system can be used after required data is specified. This chapter describes the data that can be specified. Contents of this chapter 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17
I/O...............................................................................................37 ROBOT I/O ................................................................................59 PERIPHERAL I/O......................................................................63 OPERATOR’S PANEL I/O .......................................................74 I/O Link SCREEN ......................................................................77 I/O CONNECTION FUNCTION...............................................82 SIMULATED INPUT SKIP FUNCTION..................................84 SETTING AUTOMATIC OPERATION ...................................86 SETTING COORDINATE SYSTEMS....................................108 SETTING A REFERENCE POSITION...................................138 JOINT OPERATING AREA....................................................142 USER ALARM.........................................................................144 VARIABLE AXIS AREAS......................................................146 SPECIAL AREA FUNCTION .................................................148 SYSTEM CONFIG MENU......................................................152 SETTING THE GENERAL ITEMS ........................................159 OTHER SETTINGS .................................................................161
- 36 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
3.1
I/O Input/output signals (I/O) are electric signals that allow the controller to communicate with the robot, end effector, external equipment, and other peripheral equipment of the system. The signals are divided into two group s: general-purpose I/O and specialized I/O.
General-purpose I/O The user can define the general-purpose I/O as required. This group includes the following signals: • Digital I/O: DI[i]/DO[i] • Group I/O: GI[i]/GO[i] • Analog I/O: AI[i]/AO[i] [i] represents the logic number of each I/O signal and group signal.
Specialized I/O The use of the specialized I/O has already been defined. This group includes the following signals: • Peripheral (UOP) I/O: UI[i]/UO[i] • Operator’s panel (SOP) I/O: SI[i]/SO[i] • Robot I/O: RI[i]/RO[i] [i] represents the logic number of each I/O signal and group signal. • For Digital, Group, Analog, and Peripheral I/O, the logic ports can be mapped to the physical ports. They can be redefined. • The physical numbers of the robot I/O are always the same as the logic numbers. They cannot be redefined.
Configuring I/O An I/O module consists of the following hardware components. For details, refer to the ”Maintenance Manual”.
Rack The rack indicates the kind of hardware which composes I/O module. 0 = Process I/O PC board 1 to 16 = I/O Unit-MODEL A / B
SLOT The slot indicates numbers of I/O module parts which compose the rack. • When the process I/O PC board is used, the first connected board is SLOT 1, the second is SLOT 2 and others are numbered sequentially as this. • When the I/O Unit-MODEL A or B is used, SLOT is the number identifying the connected module.
- 37 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Process I/O PC board As for Input/Output signal lines on the process I/O PC board, when the peripheral I/O is allocated to the process I/O PC board, 18 input and 20 output signals are allocated in the peripheral I/O. (See Section 3.3, ”PERIPHERAL I/O”) I/O signal lines except the peripheral I/O are allocated in digital I/O and group I/O (See Subsections 3.1.1, ”Digital I/O” and 3.1.2, ”Group I/O”).
NOTE The first four signal lines on the process I/O printed circuit board are fixed to 24 V common.
Fig. 3.1 (a) Process I/O PC board
Fig. 3.1 (b) Process I/O PC board Configuration
For details of process I/O PC board, refer to MAINTENANCE MANUAL.
- 38 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Peripheral equipment A1
Peripheral equipment A2
Peripheral equipment A3
Peripheral equipment A4
Peripheral equipment B1
Peripheral equipment B2
Welding interface
Analog input interface
In** and out** are physical numbers. ain *-C is the common signal line for ain *.
Fig. 3.1 (c) Process I/O PC board interface
- 39 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
I/O Unit-MODEL A I/O Unit-MODEL A (Modular I/O) is the I/O module which includes the plural modules. Plural modules can be connected within the limits of 1024 signal lines in all modules. The I/O unit-MODEL A can be used only in master mode. Before using it, contact FANUC.
Fig. 3.1 (d) I/O Unit-MODEL A
Fig. 3.1 (e) I/O Unit-MODEL A Configuration
When using only the I/O unit, assign 18 inputs and 20 outputs of the peripheral device I/O to appropriate signal lines (→ Section 3.3, ”Peripheral Devices”). When the I/O unit and process I/O printed circuit board are used simultaneously, the inputs and outputs of the peripheral device I/O are automatically assigned to signal lines on the process I/O printed circuit board. For details of FANUC I/O Unit-MODEL A, refer to FANUC I/O Unit-MODEL A manual (B-61813EN) - 40 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Fig. 3.1 (f) I/O Unit MODEL A interface
- 41 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
I/O unit-MODEL B The I/O unit-MODEL B consists of an interface unit and more than one DI/DO unit. The DI/DO units are used to input/output signals. The interface unit is used to assemble I/O information in the DI/DO units and transfers it to or from the robot controller. Combining an appropriate number of DI/DO units of different types makes it possible to provide a necessary number of input/output points. Twisted pair cables are used to connect the DI/DO units with the interface unit, thus allowing the DI/DO units to be installed at a distance from the interface unit.
Fig. 3.1 (g) I/O Unit-MODEL B
Refer to the FANUC I/O Unit Model B Connection Manual (B-62163EN) for details of the I/O unit-MODEL B. When the I/O unit-MODEL B is used, the setting is needed on I/O link screen.
- 42 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
3.1.1
Digital I/O Digital I/O (DI/DO) is a group of general-purpose signals that send or receive the data of the peripheral equipment via the process I/O printed circuit board (or I/O unit). Moreover, this can send or receive the data of master (CNC) of I/O link. The digital signal is set on or off.
Configuration of Input/Output In digital I/O, the configuration of the signal lines can be redefined. Eight signal lines band. Eight signal lines which is included in the same class are allocated at the same time. The following items are set. Refer to 3.1 for the configuration of the rack and slot.
CAUTION 1 When a process I/O printed circuit board is connected, the standard assignment is made at the factory. When no process I/O printed circuit board is connected and I/O unit model A/B is connected, all digital input/output signals are assigned to the digital I/O at the factory. No digital input/output signals are assigned to the peripheral device I/O. Divide the digital input/output signals between the digital I/O and peripheral device I/O and reassign the signals to them. 2 Before the physical numbers are re-defined, the use of the signals should be carefully checked. Otherwise, injury or property damage would occur.
RACK The rack indicates the kind of hardware which composes I/O module. • 0 = Process I/O PC board • 1 to 16 = I/O Unit-MODEL A and MODEL B Racks 1, 2, and so on are assigned to the base units of I/O unit model A and the interface units of I/O unit model B in the order in which they are connected.
SLOT The slot indicates the number of I/O module parts which composes RACK. • When the process I/O PC board is used, the first connected board is SLOT 1, the second is SLOT 2 and others are numbered sequentially as this. • When the I/O unit of model A is used, the number of the backplane slot in which the module is placed is the slot value of the module. • When the I/O unit-MODEL B is used, the slot number of the basic unit is specified by the DIP switch in the basic unit.
- 43 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
START PT START PT allocates the logical number to the physical number to map the signal lines. The first physical number in the class of eight signals should be specified.
NOTE 1 A physical number specifies the pin of Input/Output lines on the I/O module. Logical number is allocated to this physical number. And eight signal lines which are represented in logical number and are included in the same class are allocated at the same time. 2 Physical numbers starting with in 19 and out 21 can be assigned to the digital I/O because 18 input physical numbers (in 1 to 18) and 20 output physical numbers (out 1 to 20) on the process I/O printed circuit board are assigned to the peripheral device I/O. 3 Any physical number can be specified as the start point. Not allocated signal is automatically allocated to other logical number.
Polarity The polarity selects whether the current is switched on or off when the signal is set on. NORMAL = The current is turned on when the signal is set on. INVERSE = The current is turned on when the signal is set off.
Complementary Complementary is the function to set on or off two successive digital output signals: When a signal having an odd number goes on (off), complementary sets the next signal having an even number off (on). I/O configuration can be done with I/O configuration screen and I/O detail screen. When the allocation or settings of I/O is changed, turn the power off and on to use new information. When the kind of I/O PC board are changed to the different one, I/O configuration may be done again.
Output The value of a digital output signal can be specified by executing a program or performing manual operation. (See Section 4.6, “I/O INSTRUCTION,” and Section 6.4, “MANUAL I/O CONTROL”.)
Simulated input/output When simulated input/output is selected, a program can be tested without sending or receiving signals to or from the external equipment. (See Subsection 6.3.1,“Specifying Test Execution”)
- 44 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Skipping simulated signals If a wait using a wait command is performed on an input signal set as a simulated one, the wait can be automatically canceled by detecting a timeout.
Fig. 3.1.1 Digital I/O and Group I/O Interfaces
- 45 -
3.SETTING UP THE HANDLING SYSTEM Procedure 3-1
B-82594EN-4/01
Configuring Digital I/O CAUTION When a process I/O printed circuit board is connected, the standard assignment is made at the factory. When no process I/O printed circuit board is connected and I/O unit model A/B is connected, all digital input/output signals are assigned to the digital I/O at the factory and no digital input/output signals are assigned to the peripheral device I/O. Divide the digital input/output signals between the digital I/O and peripheral device I/O and reassign the signals to them.
Step 1 2 3 4
Press the MENUS key. The screen menu is displayed. Select 5 [I/O]. Press F1 [TYPE]. The screen change menu is displayed. Select “Digital.”
5
To switch the input screen to the output screen, or vice versa, press the F3 key, IN/OUT.
- 46 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
6
To allocate I/O, press F2,CONFIG.To return to the selection screen, press F2,MONITOR.
7
Manipulating the I/O assignment screen a) Place the cursor on “Range,” and specify the range of signals to be assigned. b) Line division is performed automatically according to the specified range. c) Enter appropriate values for “Rack,” “Slot,” and “Start point.” d) When the entered values are valid, abbreviation “PEND” is displayed in “Status.” If any entered value is invalid, abbreviation “INVAL” is displayed in “Status.” Unnecessary lines can be deleted by pressing F4 (Delete). The abbreviations that will appear in “Status” mean the following: ACTIV : This assignment is now in use. PEND : Assignment is normal. Turning the power off and on again causes the ACTIV status to be entered. INVAL : A specified value is invalid. UNASG : No assignment has been made.
NOTE If process I/O printed circuit boards are connected, 18 input signals and 24 output signals on the first board are connected to the peripheral I/O by standard setting. 8
To return to the list screen, press F2,MONITOR.
- 47 -
3.SETTING UP THE HANDLING SYSTEM 9
10
11 12
B-82594EN-4/01
To set the attribute of I/O, press NEXT key and press F4, DETAIL of the next page.
To return to the selection screen, press PREV key. To add a comment: a Move the cursor to the comment line and press the ENTER key.
b Select the method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press the ENTER key. To set the item, move the cursor to the setting column, and select the function key menu. To set the next digital I/O group, presses F3, NEXT.
- 48 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
13
When you are finished, press the PREV key to return to the selection screen.
14
Turn off the controller. Turn on the controller so it can use the new information.
WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage would occur. CAUTION 1 In the first power-up after I/O re-allocation, power recovery would not be executed even if it is enabled. 2 After all I/O signals are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed. 15
To perform forced output or simulated input/output of a signal, place the cursor on ON or OFF and press the corresponding function key.
For the forced output and simulated input of a signal, see Chapter 6, Section 6.4.
- 49 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
WARNING The controller uses signals to control the peripheral equipment. The forced output or simulated input/output may adversely affect the security of the system. Check the use of signals in the system before attempting the forced output or simulated input/output.
3.1.2
Group I/O Group I/O (GI/GO) is a group of general-purpose signals that send or receive the data by using two or more signal lines as the same group. The value of the group I/O is represented in decimal or hexadecimal. When the data is sent, the value is transformed to the binary number.
Assignment of I/O signal In the group I/O, the signal number can be defined to one group. Signal lines from 2 to 16 can be defined as one group. The defined group can overlap with the digital I/O.
NOTE However, the defined group can not overlap with the digital output which is included in the complementary pair. - RACK The rack indicates the kind of hardware which composes I/O modules. 0 = process I/O PC board 1 to 16 = I/O Unit-MODEL A / B The base unit of the I/O unit-MODEL A and the interface unit of the I/O unit-MODEL B are defined as racks 1, 2, ... 2, according to the sequence of connection.
- SLOT The slot indicates the number of I/O module parts which composes the rack. • When the process I/O PC board is used, the first connected board is SLOT 1,the second is SLOT 2 and others are numbered sequentially as this. • When the I/O unit of model A is used, the number of the backplane slot in which the module is placed is the slot value of the module. • When the I/O unit-MODEL B is used, the slot number of the basic unit is specified by the DIP switch in the basic unit.
- START PT START PT allocates the logical number to the physical number to map the signal lines. The first physical number in the class of eight signals should be specified. The first physical number of the signal line is specified with this rack. - 50 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
NOTE 1 A physical number specifies the Input/Output pin on the I/O module. Logical number is allocated to this physical number. 2 Because the physical numbers for eighteen inputs (”in 1” to ”in 18”) and twenty outputs (”out 1” to ”out 20”) on the first process I/O printed circuit board on the I/O link are allocated to the peripheral I/O signals, the physical numbers for the group I/O signals are ”in 19” and above and ”out 21” and above. Refer to Fig. 3.1.1. 3 When two or more I/O boards are connected, the signal lines on the different boards can not be allocated to one group. - NUM PTS NUM PTS specifies the number of the digital signals which is assigned to one group.
NOTE The number of the signal allocated to 1 group is from 2 to 16 points. I/O configuration can be done with I/O configuration screen and I/O detail screen. When I/O configuration is changed, turn off the controller, and turn on the controller to use the new information.
CAUTION At the first power-on after the I/O assignment is modified, the output signals are all off regardless of whether processing for power failures is enabled.
Execution of output The value of the group output can be set by executing the program or manual I/O control.(See Section 4.6, ”I/O INSTRUCTION”, and Section 6.4,”MANUAL I/O CONTROL”)
Execution of simulated I/O Simulating I/O allows you to test a program that uses I/O. Simulating I/O does not actually send output signals or receive input signals.(See Subsection 6.3.1 ”Specifying Test Execution”)
Procedure 3-2
Configuring group I/O
Step 1 2 3
Press the MENUS key. The screen menu is displayed. Select 5 [I/O]. Press F1 [TYPE]. The screen change menu is displayed. - 51 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
4
Select Group. Group I/O list screen is displayed.
5
To switch the input screen to the output screen, or vice versa, press the F3 key, IN/OUT.
6
To allocate I/O, press F2,CONFIG.
To return to the list screen, press F2,MONITOR.
- 52 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
7
To configure the I/O, move the cursor to each item and type the value.
NOTE The physical number to which the logical number of group I/O is assigned can be the same to which the digital I/O is assigned. 8
To set the attribute of I/O, press NEXT key of the selection screen and press F4,DETAIL of the next page.
To return to the selection screen, press PREV key.
9
10 11 12
To add a comment: a Move the cursor to the comment line and press the ENTER key.
b Select the method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press the ENTER key. To set the item, move the cursor to the setting column, and select the function key menu. When you are finished, press the PREV key to return to the selection screen. Turn off the controller. Turn on the controller so it can use the new information. - 53 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage would occur. CAUTION 1 In the first power-up after I/O re-allocation, power recovery would not be executed even if it is enabled. 2 After all I/O signals are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed.
3.1.3
Analog I/O Analog I/O (AI/AO) signals are sent to and from the arc welding machine and peripheral equipment via the input/output signal lines on the process I/O printed circuit board (or I/O unit). The analog input/output voltages are converted to digital form when they are read or written. Therefore, they do not directly correspond to the input/output voltages.
Configuration of input/output The physical numbers for the analog signal lines can be redefined.
NOTE The standard configuration is factory-set up. To use a different configuration from the standard setting, make a reconfiguration. CAUTION Before the physical numbers are re-defined, the use of the signals should be carefully checked. Otherwise, injury or property damage would occur. - RACK Indicates the type of hardware composing the I/O modules. 0 = process I/O printed circuit board 1 to 16 = I/O unit-MODEL A / B The base unit of the I/O unit-MODEL A and the interface unit of the I/O unit-MODEL B are defined as racks 1, 2, ..., according to the sequence of connection.
- SLOT Indicates the number for the I/O module parts which compose RACK. The slot number for the backplane in the I/O unit-MODEL A serves as the slot number for the module. - 54 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
- CHANNEL Allocates the physical number to the logical number for mapping the signal lines.
NOTE A physical number specifies the pin of an input/output line on the I/O module. The logical number is allocated to this physical number. This allocation can be altered. I/O configuration can be done on the I/O configuration screen and I/O detail screen. When I/O configuration is changed, turn the controller off and on again to use the new information.
CAUTION At the first power-on after the I/O assignment is modified, the output signals are all off regardless of whether processing for power failures is enabled.
Execution of output The value of the analog output can be set by executing the program or manual I/O control (Sections 4.6 and 6.4).
Execution of simulated I/O Simulating I/O allows you to test a program that uses I/O. Simulating I/O does not actually send output signals or receive input signals (Subsection 6.3.1).
Fig. 3.1.3 Analog I/O Interface
- 55 -
3.SETTING UP THE HANDLING SYSTEM Procedure 3-3
B-82594EN-4/01
Setting analog I/O NOTE The standard configuration is factory-set up. To use a different configuration from the standard setting, reconfigure the I/O.
Step 1 2 3 4
Press the MENUS key. The screen menu is displayed. Select 5, [I/O]. Press F1, [TYPE]. The screen change menu is displayed. Select Analog. The analog I/O list screen is displayed.
5
To switch the input screen to the output screen, press F3, [IN/OUT].
6
To allocate I/O, press F2, [CONFIG].
- 56 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
To return to the list screen, press F2, [MONITOR].
7 8
9
To configure the signals, move the cursor to each item and enter the value. To return to the list screen, press F2, [MONITOR].
Press NEXT key of the selection screen and press F4, [DETAIL] of the next page. The analog I/O detail screen is displayed.
- 57 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
To return to the configuration screen, press the PREV key.
10
11 12 13
To add a comment: a Move the cursor to the comment line and press the ENTER key.
b Select the method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press the ENTER key. To specify the signal attribute, move the cursor to the corresponding field, and select the function key. When you are finished, press the PREV key to return to the selection screen. Turn the controller off and on again so that it can use the new information.
WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage would occur. CAUTION 1 In the first power-up after I/O re-allocation, power recovery would not be executed even if it is enabled. 2 After all I/O signals are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed.
- 58 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
3.2
ROBOT I/O
Robot I/O are signals digital signals Robot to operate the following executions. • Other signals are used as the end effector I/O via the robot. The end effector I/O is connected to the connector at the end of the robotic arm to enable its use. The end effector I/O consists of eight input and eight output general-purpose signals. No signal numbers can be redefined for these signals.
NOTE 1 The number of general-purpose input/output signals of the end effector I/O depends on the model of the robot. Refer to the manual. 2 To change the common setting of RI [ 1 ], connect the *RDICOM signal to 0 V or +24 V on the terminal block. (Refer to the manual.) - Hand breakage input signal, *HBK The *HBK signal is connected to the robot hand and detects a breakage in the tool. In the normal state, the *HBK signal is set on. When the *HBK signal goes off, an alarm occurs and the robot is immediately stopped.
NOTE Hand breakage detection can be disabled on the system setting screen. See the item of enabling and disabling hand breakage detection in Section 3.14, ”SYSTEM CONFIG MENU.” - Abnormal air pressure input signal, *PPABN input The *PPABN signal detects a drop in the air pressure. In the normal state, the *PPABN signal is set on. When a drop in air pressure occurs, the *PPABN signal goes off, an alarm is issued, and the robot is immediately stopped.
- *ROT input The overtravel (robot overtravel) signal indicates an overtravel along each axis of the mechanical unit of the robot. In the normal status, the *ROT signal is on. When this signal is turned off, an alarm is generated and the robot is stopped immediately. The *ROT input does not appear on the cable terminal of the end effector because it is processed within the mechanical unit of the robot. While the *HBK or *ROT signal is off, the alarm state can temporarily be released by holding down the shift key and pressing the alarm release key. While holding down the shift key, move the tool to the appropriate position by jog feed. - 59 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
RI [1 to 8] INPUT RO [1 to 8] OUTPUT The end effector signals, (RI [1 to 8] and RO [1 to 8], are general-purpose input and output signals.
Procedure 3-4
Setting Robot I/O
Step 1 2 3 4
Press the MENUS key. The screen menu is displayed. Select 5 (I/O). Press the F1 key, [TYPE]. The screen change menu is displayed. Select “Robot.”
5
To switch the input screen to the output screen, press the F3 key, IN/OUT.
- 60 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
6
7
8 9
10
To set the attribute of I/O, press NEXT key and press F4, DETAIL of the next page.
To return to the selection screen, press the PREV key. To add a comment: a Move the cursor to the comment line and press the ENTER key. b Select the method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press ENTER key. To set the polarity and the complementary pair, move the cursor to the setting column, and select the function key menu. When you are finished, press PREV to return to the list screen.
Turn off the controller. Turn on the controller so it can use the new information.
WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage would occur.
- 61 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
CAUTION After all I/O signals are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed. 11
To perform forced output of a signal, place the cursor on ON or OFF and press the corresponding function key.
For the forced output of a signal, see Chapter 6, Section 6.4.
WARNING The controller uses signals to control the peripheral equipment. The forced output may adversely affect the security of the system. Check the use of signals in the system before attempting the forced output.
- 62 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
3.3
PERIPHERAL I/O Peripheral I/O signals (UI/UO) are a group of specialized signals whose usage is decided by the system. These signals are connected with a remote controller and the peripheral devices via the following interfaces and I/O links and they are used to control the robot from the outside.
Configuration of I/O The peripheral device I/O is automatically assigned to the first 18 input and 20 output I/O signal lines on the first process I/O printed circuit board. For the assignment of the peripheral device I/O, see Fig. 3.3.
CAUTION When a process I/O printed circuit board is connected, the standard assignment is made at the factory. When no process I/O printed circuit board is connected and I/O unit model A/B is connected, all digital input/output signals are assigned to the digital I/O at the factory. No digital input/output signals are assigned to the peripheral device I/O. Divide the digital input/output signals between the digital I/O and peripheral device I/O and reassign the signals to them.
Remote condition When the robot is in the remote state, the program can be started by using the peripheral I/O. Signals(*HOLD,ENBL) which has relation to safety is always effective whether the remote condition is satisfied or not. When the following remote conditions are satisfied, the robot is in the remote state. ■ The teach pendant enable switch is set off. ■ The remote signal (SI[2]) is on. (For how to turn the remote signal on and off, see the description of Remote/Local setup in Section 3.15, ”SYSTEM CONFIG MENU.”) ■ The *SFSPD input of the peripheral device I/O is on. ■ The ENBL input of the peripheral device I/O is on. ■ A value of 0 (peripheral device) is set for system variable $RMT_MASTER.
NOTE $RMT_MASTER Specifies the kind of remote device. 0 : Peripheral device 1 : CRT/KB 2 : Host computer 3 : No remote device
- 63 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
A program including a motion (group) can be started only when the remote conditions and the following operation conditions are satisfied: ■ The ENBL signal of the peripheral I/O is set on. ■ The servo power is on (not in the alarm state). The CMDENBL signal indicates whether the above conditions are satisfied. The signal is output when the following conditions are satisfied: ■ The remote conditions are satisfied. ■ Not alarm status. ■ The continuous operation mode is selected (the single step mode is disabled).
NOTE Peripheral I/O signals are disabled in the initial state. To enable these signals, set TRUE at ”Enable UI signals” on the system configuration screen.
- 64 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Main CPU printed circuit board
Process I/O printed circuit board
JD4A
JD1A
CRM2A
Peripheral device A1
CRM2B
Peripheral device A2
JD4B
Peripheral device A1
Physical number 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
CRM2A
in 1 in 2 in 3 in 4 in 5 in 6 in 7 in 8 in 9 in 10 in 11 in 12 in 13 in 14 in 15 in 16 0V 0V
19 20 21 22 23 24 25 26 27 28 29 30 31 32
out 13 out 14 out 15 out 16 COM-A4 out 17 out 18 out 19 out 20 COM-A5 in 17 in 18 in 19 in 20
out 1 33 out 2 34 out 3 35 out 4 36 37 COM-A1 out 5 38 out 6 39 out 7 40 out 8 41 42 COM-A2 43 out 9 44 out 10 45 out 11 46 out 12 47 COM-A3 48 49 +24E 50 +24E
Standard peripheral device I/O settings Physical Logical Peripheral Physical number number device input number in 1 in 2 in 3 in 4 in 5 in 6 in 7 in 8 in 9 in 10 in 11 in 12 in 13 in 14 in 15 in 16 in 17 in 18 in 19 in 20
UI 1 UI 2 UI 3 UI 4 UI 5 UI 6 UI 7 UI 8 UI 9 UI 10 UI 11 UI 12 UI 13 UI 14 UI 15 UI 16 UI 17 UI 18 UI 19 UI 20
*IMSTP *HOLD *SFSPD CSTOPI FAULT RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSTROBE PROD_START
out 1 out 2 out 3 out 4 out 5 out 6 out 7 out 8 out 9 out 10 out 11 out 12 out 13 out 14 out 15 out 16 out 17 out 18 out 19 out 20
Logical Peripheral number device input UO 1 UO 2 UO 3 UO 4 UO 5 UO 6 UO 7 UO 8 UO 9 UO 10 UO 11 UO 12 UO 13 UO 14 UO 15 UO 16 UO 17 UO 18 UO 19 UO 20
CMDENBL SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK1/SNO2 ACK1/SNO3 ACK1/SNO4 ACK1/SNO5 ACK1/SNO6 ACK1/SNO7 ACK1/SNO8 SNACK RESERVED
Fig. 3.3 Peripheral I/O Interface
WARNING When connecting the peripheral equipments related to the emergency stop function (for example Protective Fence) to each signal of a robot (for example external emergency stop, fence, servo, etc.), confirm whether emergency stop can work to prevent from connecting incorrectly. - 65 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
*IMSTP input UI [1] (Always enabled.) The immediate stop signal specifies an emergency stop by the software. The *IMSTP input is on in the normal status. When this signal is turned off, the following processing is performed: ● An alarm is generated and the servo power is turned off. ● The robot operation is stopped immediately. Execution of the program is also stopped.
WARNING The *IMSTP signal is controlled by software. The use of this signal for safety-critical processing is not recommended. To link this signal with the emergency stop, use this signal together with the EMGIN1 or EMGIN2 signal on the operator’s panel printed circuit board. For details of these signals, refer to the “Maintenance Manual.”
*HOLD input UI [2] (Always enabled.) The temporary stop signal specifies a temporary stop from an external device. The *HOLD input is on in the normal status. When this signal is turned off, the following processing is performed: ● The robot is decelerated until its stops, then the program execution is halted. ● If ENABLED is specified at ”Break on hold” on the general item setting screen, the robot is stopped, an alarm is generated, and the servo power is turned off.
*SFSPD input UI [3] (Always enabled.) The safety speed signal temporarily stops the robot when the safety fence door is opened. This signal is normally connected to the safety plug of the safety fence door. The *SFSPD input is on in the normal status. When this signal is turned off, the following processing is performed: ● The operation being executed is decelerated and stopped, and execution of the program is also stopped. At this time, the feedrate override is reduced to the value specified for $SCR.$FENCEOVRD. ● When the *SFSPD input is off and a program is started from the teach pendant, the feedrate override is reduced to the value specified for $SCR.$SFRUNOVLIM. When jog feed is executed, the feedrate override is reduced to the value specified for $SCR.$SFJOGOVLIM. When *SFSPD is off, the feedrate override cannot exceed these values.
- 66 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
WARNING The *SFSPD signal controls deceleration and stop by software. To stop the robot immediately for safety purposes, use this signal together with the FENCE1 or FENCE2 signal on the operator’s panel printed circuit board. For details of these signals, refer to the “Maintenance Manual.” NOTE When the *IMSTP, *HOLD, and *SFSPD signals are not used, jumper these signal lines.
CSTOPI input UI [4] (Always enabled.) The cycle stop signal terminates the program currently being executed. It also releases programs from the wait state by RSR. ● When FALSE is selected for CSTOPI for ABORT on the Config system setting screen, this signal terminates the program currently being executed as soon as execution of the program completes. It also releases (Clear) programs from the wait state by RSR. (Default) ● When TRUE is selected for CSTOPI for ABORT on the Config system setting screen, this signal immediately terminates the program currently being executed. It also releases (Clear) programs from the wait state by RSR.
WARNING When FALSE is selected for CSTOPI for ABORT on the Config system setting screen, CSTOPI does not stop the program being executed until the execution is complete.
Fault reset input signal, RESET, UI [5] The RESET signal cancels an alarm. If the servo power is off, the RESET signal turns on the servo power. The alarm output is not canceled until the servo power is turned on. The alarm is canceled at the instant this signal falls in default setting.
Enable input signal, ENBL, UI [8] The ENBL signal allows the robot to be moved and places the robot in the ready state. When the ENBL signal is off, the system inhibits a jog feed of the robot and activation of a program including a motion (group). A program which is being executed is halted when the ENBL signal is set off.
NOTE When the ENBL signal is not monitored, strap the signal with the ground.
- 67 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
RSR1 to RSR8 inputs UI [9-16] (Enabled in the remote state.) These are robot service request signals. When one of these signals is received, the RSR program corresponding to the signal is selected and started to perform automatic operation. When another program is being executed or is stopped temporarily, the selected program is added to the queue and is started once the program being executed terminates. (→ Subsection 3.8.1, ”Robot service request”)
PNS1 to PNS8 UI [9-16] PNSTROBE UI [17] (Enabled in the remote state.) [Option = external program selection] These are program number select signals and a PN strobe signal. When the PNSTROBE input is received, the PNS1 to PNS8 inputs are read to select a program to be executed. When another program is being executed or temporarily stopped, these signals are ignored. (→ Subsection 3.8.2, ”Program number select”) When the remote conditions are satisfied, program selection using the teach pendant is disabled while PNSTROBE is on.
PROD_START input UI [18] (Enabled in the remote state.) The automatic operation start (production start) signal starts the currently selected program from line 1. This signal functions at its falling edge when turned off after being turned on. When this signal is used together with a PNS signal, it executes the program selected by the PNS signal starting from line 1. When this signal is used together with no PNS signal, it executes the program selected using the teach pendant starting from line 1. When another program is being executed or temporarily stopped, this signal is ignored. (Program number select Subsection 3.8.2)
START input UI [6] (Enabled in the remote state.) This is an external start signal. This signal functions at its falling edge when turned off after being turned on. When this signal is received, the following processing is performed: ● When FALSE is selected for START for CONTINUE only on the Config system setting screen, the program selected using the teach pendant is executed from the line to which the cursor is positioned. A temporarily stopped program is also continued. (Default) ● When TRUE is selected for START for CONTINUE only on the Config system setting screen, a temporarily stopped program is continued. When the program is not temporarily stopped, it cannot be started.
NOTE To start a program from a peripheral device, the RSR or PROD_START input is used. To start a temporarily stopped program, the START input is used.
- 68 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
CMDENBL input UO [1] The input accept enable (command enable) signal is output when the following conditions are satisfied. This signal indicates that a program including an operation (group) can be started from the remote control units. ■ The remote conditions are satisfied. ■ The operation enable conditions are satisfied. ■ The mode is continuous operation (single step disable).
SYSRDY output UO [2] SYSRDY is output while the servo power is on. This signal places the robot in the operation enable state. In the operation enable state, jog feed can be executed and a program involving an operation (group) can be started. The robot enters the operation enable state when the following operation enable conditions are satisfied: ■ The ENBL input of the peripheral device I/O is on. ■ The servo power is on (not in the alarm state).
PROGRUN output UO [3] PROGRUN is output while a program is being executed. It is not output while a program is temporarily stopped.
PAUSED output UO [4] PAUSED is output when a program is temporarily stopped and waits for restart.
HELD output UO [5] HELD is output when the hold button is pressed or the HOLD signal is input. It is not output when the hold button is released.
FAULT output UO [6] FAULT is output when an alarm occurs in the system. The alarm state is released by the FAULT_RESET input. FAULT is not output when a warning (WARN alarm) occurs.
ATPERCH output UO [7] ATPERCH is output when the robot is in a previously defined reference position. Up to three reference positions can be defined. This signal is output only when the robot is in the first reference position. For any other reference positions, general-purpose signals are assigned.
TPENBL output UO [8] TPENBL is output when the enable switch of the teach pendant is set to on.
BATALM output UO [9] BATALM indicates a low-voltage alarm for the backup battery of the control unit or robot pulse coder. Turn the power to the control unit on and replace the battery. - 69 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
BUSY output UO [10] BUSY is output while a program is being executed or while processing using the teach pendant is being performed. It is not output while a program is temporarily stopped.
ACK1 to ACK8 outputs UO [11-18] When the RSR function is enabled, ACK1 to ACK4 are used together with the function. When an RSR input is accepted, a pulse of the corresponding signal is output as an acknowledgment. The pulse width can be specified. (→ Subsection 3.8.1, ”Robot service request”)
SNO1 to SNO8 outputs UO [11-18] [Option = external program selection] When the PNS function is enabled, SNO1 to SNO8 are used together with the function. The currently selected program number (signal corresponding to the PNS1 to PNS8 inputs) is always output, in binary code, as confirmation. The selection of another program changes SNO1 to SNO8. (→ Subsection 3.8.2, ”Program number select”)
SNACK output UO [19] [Option = external program selection] When the PNS function is enabled, SNACK is used together with the function. When the PNS inputs are accepted, a pulse of this signal is output as an acknowledgment. The pulse width can be specified. (→ Subsection 3.8.2, ”Program number selection”)
Procedure 3-5
Assigning Peripheral I/O 1 WARNING When a process I/O printed circuit board is connected, the standard assignment is made at the factory. When no process I/O printed circuit board is connected and I/O unit model A/B is connected, all digital input/output signals are assigned to the digital I/O at the factory and no digital input/output signals are assigned to the peripheral device I/O. Divide the digital input/output signals between the digital I/O and peripheral device I/O and reassign the signals to them.
Step 1 2 3
Press the MENUS key. The screen menu is displayed. Select 5, [I/O]. Press the F1 key, [TYPE]. The screen change menu is displayed.
- 70 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
4
Select UOP.
5
To switch the input screen to the output screen, or vice versa, press the F3 key, IN/OUT.
6
To allocate I/O, press F2,CONFIG.
7
To return to the list screen, press F2,MONITOR Manipulating the I/O assignment screen a) Place the cursor on “Range,” and specify the range of signals to be assigned. b) Line division is performed automatically according to the specified range. c) Enter appropriate values for “Rack,” “Slot,” and “Start point.” d) When the entered values are valid, abbreviation “PEND” is displayed in “Status.” If any entered value is invalid, abbreviation “INVAL” is displayed in “Status.”
- 71 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Unnecessary lines can be deleted by pressing F4 (Delete). The abbreviations that will appear in “Status” mean the following: ACTIV : This assignment is now in use. PEND : Assignment is normal. Turning the power off and on again causes the ACTIV status to be entered. INVAL : A specified value is invalid. UNASG : No assignment has been made.
NOTE In default setting, input pins 1 to 18 and output pins 1 to 20 is assigned to the peripheral I/O. 8
9
To set the attribute of I/O, press NEXT key of the selection screen and press F4, DETAIL of the next page.
To return to the configuration screen, press the PREV key. To add a comment: a Move the cursor to the comment line and press the ENTER key.
b c d
Select the method of naming the comment. Press the appropriate function keys to add the comment. When you are finished, press the ENTER key.
NOTE The comment of peripheral equipment I/O is written by the tool software and can be changed. Even if the comment is rewritten, the function is not changed.
- 72 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
10 11 12
To set the item, move the cursor to the setting column, and select the function key menu. When you are finished, press the PREV key to return to the selection screen. Turn off the controller. Turn on the controller so it can use the new information.
WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage would occur. CAUTION 1 In the first power-up after I/O re-allocation, power failure recovery would not be executed even if it is enabled. 2 After all I/O signals are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed.
- 73 -
3.SETTING UP THE HANDLING SYSTEM
3.4
B-82594EN-4/01
OPERATOR’S PANEL I/O The operator’s panel I/O means dedicated digital signals for passing data indicating the status of the buttons and LEDs on the operator’s panel/box. The status of each input signal depends on whether the corresponding button on the operator’s panel is on or off. Each output signal is used to turn the corresponding LED lamp on the operator’s panel on or off. For the operator’s panel I/O, the signal numbers cannot be mapped (redefined). Sixteen input and sixteen output signals are defined as standard. For the definition of the signals of the operator’s panel I/O, see Fig. 3.4. When the operator’s panel is enabled, the operator’s panel I/O can be used to start a program. However, any signals which have a significant effect on safety are always enabled. The operator’s panel is enabled when the following operator’s panel enable conditions are satisfied: ■ The enable switch on the teach pendant is set to off. ■ The remote signal (SI[2]) is off. (For how to turn the remote signal on and off, see the description of #139-3-1 in Section 3.15, ”SYSTEM CONFIG MENU.”) ■ The *SFSPD input of the peripheral device I/O is on. To start a program involving operation (group), the following conditions must be satisfied: ■ The ENBL input of the peripheral device I/O is on. ■ The servo power is on (not in the alarm state). For the operator’s panel on the B cabinet control unit, additional functions can be assigned to user keys (SI[4] and SI[5]) on the operator’s panel by setting macro instructions [option functions] (→ Section 9.1, ”Macro Instructions”).
Fig. 3.4 Operator’s Panel I/O
- 74 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Input signal *HOLD SI [3] Always enabled. Not provided for the operator box. FAULT_RESET SI [2] Always enabled. REMOTE SI [2] Always enabled. Not provided for the operator box.
START SI [6] Enabled in the operator’s panel enable state.
Output signal REMOTE SO [0] Not provided for the operator box. BUSY SO [1] Not provided for the operator box. HELD SO [2] Not provided for the operator box. FAULT SO [3] BATAL output SO [4] Not provided for the operator box. TPENBL output SO [7] Not provided for the operator box.
Table 3.4 (a) Operator’s Panel Input Signals Description The temporary stop (hold) signal specifies temporary stop of the program. The *HOLD signal is on in the normal status. When this signal is turned off: ● The robot operation being executed is decelerated, then stopped. ● The program being executed is temporarily stopped. The alarm release (fault reset) signal releases the alarm state. When the servo power is off, this signal turns on the servo power. In this case, the alarm state is not released until the servo power is turned on. The remote signal (remote) switches between remote mode and local mode of the system. In remote mode (SI[2] = on), when the remote conditions are satisfied, a program can be started using the peripheral device I/O. In local mode (SI[2] = off), when the operator’s panel enable conditions are satisfied, a program can be started from the operator’s panel. To turn the remote signal (SI[2]) on and off, set Remote/Local setup on the system config menu. For details, see Section 3.15, ”SYSTEM CONFIG MENU.” The start signal starts the currently selected program using the teach pendant from the line to which the cursor is positioned or restarts a temporarily stopped program. This signal functions at its falling edge when turned off after being turned on.
Table 3.4 (b) Operator’s Panel Output Signals Description The remote signal is output when the remote conditions are satisfied (remote conditions Section 3.3, ”Peripheral I/O”). The busy signal is output while processing such as program execution or file transfer is being performed. It is not output when a program is temporarily stopped. The hold signal is output when the hold button is pressed or the HOLD signal is input.
The alarm (fault) signal is output when an alarm occurs in the system. The alarm state is released by the FAULT_RESET input. This signal is not output when a warning (WARN alarm) occurs. The abnormal battery (battery alarm) signal indicates a low-voltage alarm for the battery in the control unit. While keeping the power to the control unit on, replace the battery. The teach pendant enable (TP enable) signal is output when the enable switch on the teach pendant is on.
- 75 -
3.SETTING UP THE HANDLING SYSTEM Procedure 3-6
B-82594EN-4/01
Displaying the operator’s panel I/O NOTE For the operator’s panel I/O, the signal numbers cannot be redefined.
Step 1 2 3 4
Press MENUS to display the screen menu. Select ”5 I/O.” Press F1 [TYPE] to display the screen switching menu. Select ”SOP.”
5
Press F3 (IN/OUT) to switch the display between the input and output screens.
NOTE The input signal status can only be checked. Values cannot be changed forcibly.
- 76 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
3.5
I/O Link SCREEN The I/O link screen can be used to make settings related to FANUC I/O unit model B and display the configuration of the I/O link units. The I/O link screen consists of the following screens: ● I/O link list screen ● Model B unit list screen ● Signal count setting screen
3.5.1
I/O Link List Screen The I/O link list screen displays a list of I/O units in slave mode that are connected to the I/O link. It also displays the rack and slot numbers of each unit. For I/O unit model A/B, only the interface units are displayed. In this case, a value of 0 is displayed for the rack number. The following figure is an example of the I/O link list screen when process I/O board CA, one unit of I/O unit model B, and two units of I/O unit model A are connected to the robot control unit. The names of the I/O units are displayed in the order in which the units are connected to the robot control unit.
To display this screen, first press MENU to display the screen menu, then select ”5 I/O.” Then, press F1, [TYPE] to display the screen switching menu, then select Link Device. The following table lists the device names displayed on the screen and the corresponding actual device names. Word on TP PrcI/O AA PrcI/O AB PrcI/O BA PrcI/O BB PrcI/O CA PrcI/O CB PrcI/O DA PrcI/O EA PrcI/O EB PrcI/O FA PrcI/O GA PrcI/O HA
Device Process I/O Board AA Process I/O Board AB Process I/O Board BA Process I/O Board BB Process I/O Board CA Process I/O Board CB Process I/O Board DA Process I/O Board EA Process I/O Board EB Process I/O Board FA Process I/O Board GA Process I/O Board HA
- 77 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Word on TP PrcI/O HB PrcI/O HC PrcI/O JA PrcI/O JB R-J2 Mate Weld I/F Others
Device Process I/O Board HB Process I/O Board HC Process I/O Board JA Process I/O Board JB R-J2 Mate. Slave Mode Weld Interface Board Other I/O devices except above devices
When F3 (DETAIL) is pressed, Model B screen or Number of Ports Setting Screen is displayed according to the type of the unit. When F3 (DETAIL) is pressed for the following units, the detail screen is displayed. When F3 (DETAIL) is pressed for other units, no screen change occurs. Each detail screen is described later. Word on TP Model B 90-30 PLC I/O adptr R-J2 Mate Unknown
Detail Screen Model B Number of Ports Number of Ports Number of Ports Number of Ports
On this screen, a comment can be specified for each I/O unit. Move the cursor to Comment and press the enter key. The screen enters comment input mode. F5 (CLR_ASG) is described later.
3.5.2
Model B Unit List Screen The model B unit list screen displays a list of units of FANUC I/O unit model B. FANUC I/O unit model B does not automatically recognize the connected DI/DO units. On this screen, set the types of the DI/DO units. The address set using the DIP switch of each DI/DO unit is used as the line number on this screen. One additional unit can be connected to each DI/DO unit. This screen can also be used to specify whether to connect an additional unit and the type of additional unit. When the cursor is positioned to a ”Model B” item on the I/O link list screen, press F3 (DETAIL) to display Model B screen as shown below:
At first, nothing is set, as shown above. To use model B, set the types of the units on this screen. - 78 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
When DI/DO unit BOD16A1 is connected to the interface unit and the address is set to 1, set the unit as shown below. Position the cursor to the position shown above (Base column on line 1), then press F4, [CHOICE]. The options are displayed as shown below:
Select BOD16A1 on this screen. The unit is set as shown below:
When the cursor is positioned to column Base and F4 [CHOICE] is pressed, a menu appears. This menu contains the following items. When no unit is set, ”*******” is displayed. ”*******” indicates that no unit is connected. ● BMD88A1 ● BID16A1 ● BOD16A1 ● BOA12A1 When the cursor is positioned to column Exp. and F4 [CHOICE] is pressed, a menu appears. This menu contains the following items. When no unit is set, ”*******” is displayed. ”*******” indicates that no unit is connected. ● BMD88P1 ● BID16P1 ● BOD16P1 ● BIA16A1 ● BMD88Q1 After a unit is set on this screen, the unit I/O can be used by turning the power off, then on again. When the setting of a unit is changed, processing for I/O power failures is not performed at the next power-on, even when processing for power failures is enabled. - 79 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
To enter a comment, press the enter key with the cursor positioned to column Comment. The comment is displayed following PRIO-100 Model B comm fault, displayed when the DI/DO unit is disconnected from the interface unit. When SAVE is selected on this screen while the auxiliary key is held down, a file named DIOCFGSV.IO is saved. This file contains the contents set on the I/O link screen. It also contains the I/O assignment, comments, and other information. Such information can be saved in this file from other I/O and file screens. F5 (CLR_ASG) is described later.
3.5.3
Signal Count Setting Screen For I/O units such as the I/O link connection unit and 90-30PLC that cannot be used without setting the number of signals, set the number of signals on this screen. When the cursor is positioned to ”90-30PLC” on the I/O link list screen, press the F3 (DETAIL) key. Then, Number of ports setting screen appears as shown below.
Move the cursor to the number indicating the number of signals and enter a numeric value to set the number of signals. The target I/O unit can be used by turning the power off, then on again after the number of signals is set on this screen. When the number of signals is changed, processing for I/O power failures is not performed at the next power-on, even when processing for power failures is enabled. When SAVE is selected on this screen while the auxiliary key is held down, a file named DIOCFGSV.IO is saved. This file contains the contents set on the I/O link screen. It also contains the I/O assignment, comment, and other information. Such information can be saved in this file from other I/O and file screens in the same way as normal. Explanation of F5 (CLR_ASG) When the number of signals is set for a model-B unit or I/O unit on the I/O link screen, the I/O assignment may differ from the standard assignment according to the setting procedure. The following operation can set all I/O assignment to the standard settings. When setting the number of signals for a model-B unit or I/O unit for the first time, perform the following operation. * When the unit is used with non-standard settings, this operation deletes the assignment information.
- 80 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Press F5 (CLR_ASG). The following message appears.
Press F4 (YES) to delete all assignment information. When the power to the control unit is turned off, then on again, the assignment is set to the standard settings.
- 81 -
3.SETTING UP THE HANDLING SYSTEM
3.6
B-82594EN-4/01
I/O CONNECTION FUNCTION The I/O connection function enables the RI/DI status to be output to DO/RO to report the signal input status to external devices. The standard input/output ranges are shown below: ● RI[mmm] → DO[nnn]. ( 1<=mmm<=8, 0<=nnn<=256 ) ● DI[iii] → RO[jjj]. ( 0<=iii<=256, 1<=jjj<=8 ) ● DI[kkk] → DO[lll]. ( 0<=kkk<=256, 0<=lll<=256 )
Explanation of the function/settings Assign signals and enable or disable each assignment on Interconnect. The following three types of screens are available: ● DI DO connection setting screen (RI → DO) ● DI DO connection setting screen (DI → RO) ● DI DO connection setting screen (DI → DO)
DI DO connection setting screen (RI → DO) Assign DO signal numbers to RI1 to RI8. Whether to enable or disable each assignment can also be set.
DI DO connection setting screen (DI → RO) Assign DI signal numbers to RO1 to RO8. Whether to enable or disable each assignment can also be set.
DI DO connection setting screen (DI → DO) Assign an DO signal number to each DI number. Whether to enable or disable each assignment can also be set. Example) When ”ENABLE DI[2] → RO[3]” is set, the status of DI[2] is output to RO[3].
NOTE 1 When DI[i] → DO[j] is set and this assignment is enabled, the status of DI[i] is output to DO[j] at regular intervals. Therefore, if the contents of DO[j] are changed using the TP or a program, the change is not reflected. 2 Whether to enable or disable each assignment can be changed only on the setting screen, described above. 3 When different multiple input signals are assigned to the same output signal, the status of each input signal is output. For example, assume that the following settings are made: ENABLE DI[1] → RI[1] → DO[ 1] ENABLE DI[2] → RI[2] → DO[ 1] In this case, when the status of RI[1] is ON and the status of RI[2] is OFF, the DO[1] output will be unpredictable. (DO[1] alternately indicates ON and OFF in practice.)
- 82 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Procedure 3-7
Setting the I/O connection function
Step 1 2 3 4
Press MENUS to display the screen menu. Select ”5 I/O.” Press F1, [TYPE] to display the screen switching menu. Select Interconnect. The DI DO connection setting screen appears.
5 6
Press SELECT. Position the cursor to the screen to be displayed and press the ENTER key or specify the item number of the screen to be displayed using a numeric key.
- 83 -
3.SETTING UP THE HANDLING SYSTEM
3.7
B-82594EN-4/01
SIMULATED INPUT SKIP FUNCTION
Overview The robot controller provides a function whereby if a wait is performed with a wait instruction on an input signal set to a simulated status, the wait is automatically canceled when a timeout is detected. The simulated input skip function can be used with digital input signals and robot input signals. It is possible to specify whether to enable the simulated input skip function for each signal. On the input signal list screen, a signal for which the simulated input skip function is enabled is displayed with a U/S enclosed in parentheses (), which indicates whether the signal is in a simulated status and whether the simulated input skip function is enabled for that signal. On the screen shown in the example below, DI[1] is set up as a simulated signal and the simulated input skip function is enabled for it whereas DI[7] is not set to a simulated status but the simulated input skip function is enabled. I/O Digital In # SIM STATUS DI[1] (S) OFF [ DI[2] U ON [ DI[3] U ON [ DI[4] U OFF [ DI[5] U OFF [ DI[6] U OFF [ DI[7] (U) OFF [ DI[8] U OFF [ DI[9] U OFF [
] ] ] ] ] ] ] ] ]
If the simulated input skip function is enabled, the prompt below appears before the program starts. Pressing the ENTER key causes program operation to start. This prompt appears if there is at least one input signal for which the simulated input skip function is enabled. The Simulated Input Skip feature is enabled ! WAIT instructions may time out automatically. ［OK］
If a timeout occurs after a wait instruction, and the wait is automatically canceled, the warning message below appears on the alarm line. PRIO-189
- 84 -
（Program, Line）WAIT will time out
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
The time after which a timeout is detected after a wait instruction can be set with the "Sim. Input Wait Delay" item on the system setup menu. If this setting is changed, the change will be applied immediately. It is possible to monitor to see if there are any input signals for which the simulated input skip function is enabled and output them as output signals. For the "Set if Sim. Skip Enabled" item on the system setup menu, set the number of the output signal that will turn on if the simulated input skip function is enabled. To make the setting effective, turn off the power and then back on.
WARNING Setting an input signal to a simulated status and using the simulated input skip function should only be temporary during test operation. Never do so during production line operation. By selecting the "UNSIM ALL I/O" item on the auxiliary menu, it is possible to release all signals from a simulated status. By setting up "Set if INPUT SIMULATED" on the system setup menu, it is possible to monitor to see if there are any input signals that are set to a simulated status and output them as output signals. For this item, set the number of the output signal that will turn on if one of digital, group, robot, and analog signals is set to a simulated status. To make the setting effective, turn off the power and then back on.
Procedure for setting up the simulated input skip function For an input signal to be skipped if in a simulated status, enable the simulated input skip function.
- Step 1. 2. 3. 4. 5. 6. 7. 8. 9.
Press the "MENUS" key. Select the "I/O" item. Press the F1 [TYPE] key. Select the "Digital" or "Robot item. If output signals are displayed, press F3 "IN/OUT" to switch to the input signal list screen. Position the cursor on the signal for which the simulated input skip function is to be enabled. Press the "NEXT" key and then the F3 "DETAIL" key. On the input signal detail screen, position the cursor on "Skip when simulated". Press the F4 "TRUE" key.
- 85 -
3.SETTING UP THE HANDLING SYSTEM
3.8
B-82594EN-4/01
SETTING AUTOMATIC OPERATION Automatic operation is the function with which the remote controller starts a program, using the peripheral I/O. The automatic operation includes the following functions: ● The robot service request (RSR) function selects and starts a program according to the robot service request signals (RSR1 to RSR8 inputs). When another program is being executed or is temporarily stopped, the selected program enters the wait state and is started once the program currently being executed terminates. ● The program number selection (PNS) function selects or examines a program, using the program number selection signals (PNS1 to PNS8 PNSTROBF) and the START signal. While a program is temporarily stopped or being executed, these signals are ignored. ● The automatic operation start signal (PROD_START input) starts the currently selected program from line 1. When another program is temporarily stopped or is being executed, this signal is ignored. ● The cycle stop signal (CSTOPI input) is used to terminate the program currently being executed. When FALSE is selected for CSTOPI for ABORT on the system setting menu, this signal terminates the program currently being executed once the execution is complete. It also releases programs from the wait state by RSR. (Default) When TRUE is selected for CSTOPI for ABORT on the system setting menu, this signal forcibly terminates the program currently being executed immediately. It also releases (Clear) programs from the wait state by RSR. ● The external start signal (START input) is used to start a program that is temporarily stopped. When FALSE is selected for START for CONTINUE only on the system setting menu, this signal starts the currently selected program from the current line. This signal also starts a temporarily stopped program. (Default) When TRUE is selected for START for CONTINUE only on the system setting menu, this signal starts only a temporarily stopped program. When no program is temporarily stopped, this signal is ignored. A program can be started by entering the peripheral I/O only when the robot is in the remote state. The remote state is established when the following remote conditions are satisfied: ■ The teach pendant enable switch is off. ■ The remote signal (SI[2]) is on. (For how to turn the remote signal (SI[2]) on and off, see the description of Remote/Local setup in Section 3.15, ”SYSTEM CONFIG MENU.”) ■ The *SFSPD signal of the peripheral I/O is set on. ■ The ENBL signal of the peripheral I/O is set on. ■ System variable $RMT_MASTER is set to 0 (peripheral equipment).
- 86 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
NOTE The value of $RMT_MASTER can be set to 0 (peripheral equipment, 1 (CRT/KB), 2 (host computer), or 3 (no remote equipment). A program including a motion (group) can be started when the following ready conditions are satisfied: ■ The ENBL input signal of the peripheral I/O is set on. ■ The servo power is turned on (not in the alarm state). The CMDENBL signal indicates whether the above conditions are satisfied. The CMDENBL signal is output when the following conditions are satisfied: ■ The remote conditions are satisfied. ■ The ready conditions are satisfied. ■ The continuous operation mode is selected (the single step mode is disabled).
NOTE If TRUE is specified at ”START for CONTINUE only” on the system configuration screen, the START signal is effective for only a program on hold.
3.8.1
Robot Service Request (RSR) The robot service request (RSR) starts a program from an external device. The eight robot service request signals (RSR1 to RSR8) are used for this function. 1 The control unit uses the RSR1 to RSR8 inputs to determine whether the input RSR signal is enabled. When the signal is disabled, it is ignored. Whether to enable or disable RSR1 to RSR8 is set in system variables $RSR1 to $RSR8 and can be changed on the RSR setting screen or by using the program RSR instruction.
NOTE In the initial status, the peripheral device input signal (UI) is disabled. To enable the signal, select TRUE for Enable UI signals on the system setting screen. 2
Eight RSR registration numbers can be registered for RSR. The value obtained by adding a base number to an RSR registration number is used as the program number (four digits). For example, when RSR2 is input, the following value is used as the program number: (Program number) = (RSR2 registration number) + (base number) The selected program is named as follows: RSR + (program number)
- 87 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
NOTE Specify the name of a program for automatic operation in ”RSR” + (program number) format. Enter a 4-digit number such as RSR0121m, not RSR121. If not, the robot will not operate. The base number is set in $SHELL_CFG.$JOB_BASE and can be changed using Base number on the RSR setting screen or a program parameter instruction. 3 A pulse of the RSR acknowledgment output (ACK1 to ACK8) corresponding to the RSR1 to RSR8 input is output. When the ACK1 to ACK8 signal is output, the control unit accepts another RSR input. 4 When a program is in the terminated state, the selected program is started. When another program is being executed or is temporarily stopped, the request (job) is entered into the queue and the selected program is started when the program being executed terminates. Jobs (RSR programs) are executed in the order in which they are entered into the queue. 5 Waiting programs are canceled (cleared) by the cycle stop signal (CSTOPI input) or upon forced program termination.
Fig. 3.8.1 (a) Robot Service Request
Starting a program by RSR is enabled in the remote state. Starting a program involving operation (group) by RSR is enabled when the operation enable conditions as well as the remote conditions are satisfied. The CMDENBL output is provided to indicate whether the above conditions are satisfied.
- 88 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Fig. 3.8.1 (b) Sequence of Automatic Operation by RSR
Set RSR for SETUP RSR/PNS on the RSR setting screen. Table 3.8.1 RSR Setting Items Description
Item RSR1 to 8 program number
Job prefix Base number Acknowledge function Acknowledge pulse width
Procedure 3-8
Specifies whether to enable or disable RSR1 to RSR8 and the RSR registration numbers. When an RSR signal is disabled and the specified signal is input, the program is not started. Setting whether to enable or disable each RSR is stored in system variable $RSR1 to $RSR8. Top character string of the name of the program to be started. By default, it is set to "RSR". Added to the RSR registration number to obtain the RSR program number. Sets whether to output RSR acknowledgment signals (ACK1 to ACK8). Sets the pulse output period (unit: msec) when the output of each RSR acknowledgment signal (ACK1 to ACK8) is enabled.
Setting RSR
Step 1 2 3 4
Press MENUS to display the screen menu. Select SETUP. Press F1, [TYPE] to display the screen switching menu. Select ”Prog Select.” The Prog Select screen appears.
- 89 -
3.SETTING UP THE HANDLING SYSTEM 5
B-82594EN-4/01
Position the cursor to ”Program select mode”. Press F4 [CHOICE] and select RSR, then press F3 DETAIL.
Prog select
Prog select
Job prefix
6 7
Position the cursor to the target item and enter a value. After changing Program select mode, to enable the change, turn the power off, then on again.
WARNING After the type of automatic operation function is changed, the power to the control unit must be turned off, then on again to enable the change. If not, the setting is not accepted.
3.8.2
Program Number Selection (PNS) The remote controller uses the program number selection (PNS) function to select or collate a program. Specify a desired PNS program number with the input signals, PNS1 to PNS8.
Step 1
The control unit reads the PNS1 to PNS8 input signals as a binary number by the PNSTROBE pulse input. When a program is being executed or is temporarily stopped, these signals are ignored. When the PNSTROBE pulse input is on, the selection of a program from the teach pendant is disabled.
NOTE In the initial status, the peripheral device input signal (UI) is disabled. To enable the signal, select TRUE for Enable UI signals on the system setting screen.
- 90 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
2
The data of signals PNS1 to PNS8 is converted into a decimal PNS number. The sum of the PNS number and the reference number is a PNS program number (four digits). (Program number)=(PNS number)+(Base number) The specified PNS+(Program number) program number is named as follows. When a zero is input by the PNS1 to PNS8 inputs, the system enters the status in which no program is selected on the teach pendant.
NOTE Specify the name of a program for automatic operation in ”PNS” + (program number) format. Enter a 4-digit number such as PNS0138, not PNS138. If not, the robot will not operate. The base number is set in $SHELL_CFG.$JOB_BASE and can be changed using Base number on the PNS setting screen or a program parameter instruction. 3 SNO1 to SNO8 are output to indicate a PNS number as a binary code as confirmation. An SNACK pulse is output simultaneously. If the PNS number cannot be represented as an 8-bit numeric value, SNO1 to SNO8 output a zero. 4 The remote control unit checks that the SNO1 to SNO8 output value is the same as the PNS1 to PNS8 input value when SNACK is output, and sends the automatic operation start input (PROD_START). 5 The control unit receives the PROD_START input and starts the program. Starting a program by PNS is enabled in the remote state. Starting a program involving an operation (group) is enabled when the operation enable conditions as well as the remote conditions are satisfied. The CMDENBL output is provided to indicate whether the above conditions are satisfied.
Fig. 3.8.2 (a) Program Number Selection
- 91 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Fig. 3.8.2 (b) Sequence of Automatic Operation by PNS
Setting the PNS function Set the PNS function on the PNS setting screen [6 (SETUP). RSR/PNS]. Refer to Table 3.8.2. Table 3.8.2 Setting the PNS function Descriptions
Items Job prefix Base number Acknowledge pulse width (msec)
Procedure 3-9
Top character string of the name of the program selected. By default, it is set to "PNS". The reference number is added to the PNS number to obtain a PNS program number. Sets the pulse output period (unit: msec) of the PNS acknowledgment signal (SNACK).
Setting the PNS function
Step 1 2 3 4
Press the MENUS key. The screen menu is displayed. Select “6 (SETUP).” Press the F1 key, TYPE. The screen change menu is displayed. Select “Prog Select”. Prog Select screen is displayed.
- 92 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
5
Position the cursor to ”Program select mode”. Press F4 [CHOICE] and select RSR, then press F3 DETAIL.
Prog select
Job prefix
Prog select
6 7
Place the cursor on a desired field and enter a value. After changing RSR to PNS, to enable the change, turn the power off, then on again.
WARNING After the type of automatic operation function is changed, the power to the control unit must be turned off, then on again to enable the change. If not, the setting is not accepted.
- 93 -
3.SETTING UP THE HANDLING SYSTEM
3.8.3
B-82594EN-4/01
Prog Select Screen
Overview On the "Prog Select" screen, the following can be performed: • As program selection methods, it is now possible to select , PNS, RSR, STYLE, and OTHER . • As program start methods, it is now possible to select UOP, DIN[ ], and OTHER. • Various checks are performed at a program start or resumption. Prog Select screen
Prog Select 1/14 1 Program select mode: 2 Production start method: Production checks: 3 At home check: 4 Resume position toler.: 5 Simulated I/O: 6 General override < 100%: 7 Prog override < 100%: 8 Machine lock: 9 Single step: 10 Process ready: General controls: 11 Heartbeat timing: 12 Low TEMP DRAM memory: 13 Low PERM CMOS memory:
[ TYPE ]
PNS UOP ENABLED ENABLED DISABLED DISABLED DISABLED DISABLED DISABLED DISABLED 1000 MS 100 KB 50 KB
HELP
Program selection methods It is now possible to select PNS, RSR, STYLE, and OTHER. • • •
RSR See Subsection 3.8.1, “Robot Service Request (RSR).” PNS See Subsection 3.8.2, “Program Number Selection (PNS).” STYLE The program associated with the STYLE number specified in group input (GI) is selected. GI for use in program selection can be set with the "Initiate Style" item on the I/O Cell screen (MENUS → "I/O" → F1 ([TYPE]) → "Cell Interface"). Associations between STYLE numbers and programs can be established on the Style table setup screen (Fig. 1), which appears by pressing F3 (DETAIL) on the Prog Select screen. A program selection is made when a program is started with the method specified by following "Automatic operation start methods", described later.
- 94 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
•
For example, if the automatic operation start method is UOP, a program is selected and executed with UI[6:START] or UI[18:PROD_START]. If the program is pausing, no program selection is made and execution is resumed. OTHER The program specified for the system variable $SHELL_WRK. $CUST_NAME is selected. A program selection is made when a program is started with the method specified by following "Automatic operation start methods", described later. If the program is pausing, no program selection is made and execution is restarted. Usually, do not use this function because it is for special purposes.
Prog Select Style Table Setup 1/32 Style ProgName Valid Comment 1 JOB123 YES 2 door 2 RSR001 YES 4 door 3 JB7 YES Hatchback 4 YES 5 YES Power OFF then ON to enable changes.
[ TYPE ]
CLEAR
CONFIG
[CHOICE]
>
Fig. 3.8.3 Style table setup screen
Automatic operation start methods If the program selection method is "STYLE" or "OTHER", it is possible to select a program start method from UOP, DIN[], and OTHER. • •
•
UOP A program is started with UI[6:START] or UI[18:PROD_START]. DIN[ ] A program is started at the startup of DI. DI for use in a program start can be set with the "Start DIN" item on the I/O Cell screen (MENUS → "I/O" → F1 ([TYPE]) → "Cell Interface"). This method cannot be selected if the program selection method is either RSR or PNS. OTHER A program is started by changing the system variable $SHELL_WRK. $CUST_START from FALSE to TRUE. This method cannot be selected if the program selection method is either RSR or PNS. Usually, do not use this function because it is for special purposes.
- 95 -
3.SETTING UP THE HANDLING SYSTEM *
B-82594EN-4/01
If the program selection method is either STYLE or OTHER and the automatic operation start method is UOP, it is possible to select and start a program with either UI[6:START] or UI[18:PROD_START], provided that a program is terminated. In this case, the program is started at the first line. If a program is pausing, the program can be resumed with either UI[6:START] or UI[18:PROD_START]. In this case, no program selection is made. Note that if the program selection method is either RSR or PNS, the effects of UI[6:START] and UI[18:PROD_START] are the same as those in the past.
List of program selection methods and automatic operation start methods Automatic operation start method UOP RSR
Program selection method
PNS
Style
Other
Program selection/start: RSR 1 to 8 Program selection: PNS1 to 8, PNSTROBE Program start: UI[18:PROD_START] or UI[6:START] Program selection:GI[#] Program start: UI[18:PROD_START] or UI[6:START] Program selection: $SHELL_WRK.$CUST_NAM E Program start: UI[18:PROD_START] or UI[6:START]
DIN
Other
Not available.
Not available.
Not available.
Not available.
Program selection:GI[#] Program start:DI[#]
Program selection:GI[#] Program start: $SHELL_WRK.$CUST_START
Program selection: Program selection: $SHELL_WRK.$CUST_NAM $SHELL_WRK.$CUST_NAME Program start: E $SHELL_WRK.$CUST_START Program start:DI[#]
- 96 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Automatic operation check It is possible to specify whether to enable or disable each of the automatic operation check items on the Prog Select screen. Check item At home check
Explanation Checks to see if the robot is in its home position. Home position refers to the reference position for which "Is a valid HOME" is set to ENABLE on the Reference Position Set up screen (MENUS → "SETUP" → F1 [TYPE] → "Ref. Position"). If At home check is enabled, "Is a valid HOME" must be set to ENABLE for at least one reference position of group 1. REF POSN Reference Position 1/13 Ref.Position Number: 1 1 Comment: [****************] 2 Enable/Disable: DISABLE 3 Is a valid HOME: ENABLE 4 Signal definition: SDO[0] 5 J1: 0.000 +/0.000 :
Resume position toler. Simulated I/O General override < 100% Prog override < 100% Machine lock Single step Process ready
If "Is a valid HOME" is set to ENABLE on the Reference Position Set up screen, the "HOME_IO" program will be started when the robot reaches that position. If not using "HOME_IO", delete all contents of the "HOME_IO" program. NOTE The "HOME_IO" program is configured not to accept a forced termination request so that it can always be executed to the end. Checks to see if the robot is near the position at which the program paused. Suppresses a program start/resumption if I/O is simulated. Suppresses a program start/resumption if the general override is less than 100%. Suppresses a program start/resumption if $MCR_GRP[].$PRGOVERRIDE is less than 100. Suppresses a program start/resumption if robot operation is disabled. Suppresses a program start/resumption in case of a single step. Enables the user to check whether to make a program start/resumption depending on the status of the cooling machine, cooling water, welding transformer, etc. (The process ready conditions differ from one application to another). Selections are displayed allowing the user to continue the program, recheck the I/O status, and stop the program.
By positioning the cursor on each item and pressing F3 (DETAIL), it is possible to make detailed settings for that check item. For some check items, it is not possible to make some of the settings on the Detailed Setup screen. * It is not possible to specify whether to enable or disable the Resume position toler. check item on the Prog Select screen. Specify this on the Resume tolerance check screen (MENUS → "SETUP" → F1 [TYPE] → "Resume Tol.").
- 97 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Automatic operation check detailed setting screen (At home check as an example)
Prog Select DETAIL 1/3 Check: At home check 1 Check when run: 2 Check when resume: 3 Prompt if failure: 4 Post error if failure: 5 Post warning if forced: 6 Force condition:
[ TYPE ]
ENABLED DISABLED
Detailed setting Check when run Check when resume Prompt if failure
Post error if failure
Post warning if forced
Force condition
ENABLED DISABLED DISABLED ENABLED DISABLED DISABLED
Explanation Checks specified items at a program start. For the Resume position toler. check, this item cannot be enabled. Checks specified items at a program resumption. For the At home check, this item cannot be enabled. Displays a prompt message on the screen if Check when run or Check when resume is set to ENABLED and the check causes a program start or resumption to be interrupted. At this time, it is possible to select whether to continue or stop the program. The text of the prompt message differs depending on the check item. Generates the alarms below if Check when run or Check when resume is set to ENABLED and the check causes a program start or restart to be interrupted. "SYST-011 Failed to run task" "SYST-079 Startup check failed" Effective only if Force condition is enabled. If enabled, this item displays a warning in the event of Force condition. The text of the warning differs depending on the check item. If Check when run or Check when resume is set to ENABLED, this item causes that check item to be forcibly satisfied. This item takes precedence over all other detailed settings. For the check items of At home check, Resume position toler., and Machine lock, it is not possible to set Force condition to ENABLED. The action performed with Force condition differs depending on the check item.
The details of Prompt if failure, Force condition, and Post warning if forced for each check item are as follows:
- At home check Condition Prompt if failure
Action in the event of an error The prompt below appears. Robot arm is not at home. Jog or move robot to a home position. [OK]
Force condition Post warning if forced
- 98 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
- Resume position toler. Condition Prompt if failure
Action in the event of an error The prompt below appears. Robot arm moved too far. ANSWERING CONTINUE WILL INITIATE MOTION. CONTINUE
[STOP]
When "CONTINUE" is selected, the program is executed with the warning "SYST-104 Resume tolerance ignored". Force condition Post warning if forced
- Simulated I/O Condition Prompt if failure
Action in the event of an error The prompt below appears. Simulated I/O ports exist (set from the I/O screens) CONTINUE
Force condition Post warning if forced
FORCE
[CANCEL]
• When "CONTINUE" is selected, the program continues to run. • If "FORCE" is selected, simulated I/O is forcibly canceled and the program is executed. • When "CANCEL" is selected, the program does not start but stops. Simulated I/O is automatically forcibly canceled and the program runs. Simulated I/O is automatically forcibly canceled and the program runs, and the message below appears. "SYST-084 I/O forced unsimulated"
- General override < 100% Condition Prompt if failure
Action in the event of an error The prompt below appears. General override (set from teach pendant hardkeys) is less than 100% CONTINUE
Force condition
FORCE
[STOP]
• When "CONTINUE" is selected, the program continues to run. • When "FORCE" is selected, the program runs at an override of 100%. • When "STOP" is selected, the program does not start but stops. The program automatically runs at an override of 100%.
- 99 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
- Prog override < 100% Condition Prompt if failure
Action in the event of an error The prompt below appears. Program override is less than 100% CONTINUE
Force condition Post warning if forced
FORCE
[STOP]
• When "CONTINUE" is selected, the program continues to run. • When "FORCE" is selected, the program runs by setting $MCR_GRP[].$PRGOVERRIDE to 100. • When "STOP" is selected, the program does not start but stops. The program automatically runs by setting $MCR_GRP[].$PRGOVERRIDE to 100. The program automatically runs by setting $MCR_GRP[].$PRGOVERRIDE to 100, and the message below appears. "SYST-088 Prog override forced to 100%"
- Machine lock Condition Prompt if failure
Action in the event of an error The prompt below appears. Motion is disabled CONTINUE
[STOP]
• When "CONTINUE" is selected, the program starts with the warning below. "SYST-108 Machine lock ignored" • When "STOP" is selected, , the program does not start but stops. Force condition Post warning if forced
- Single step Condition Prompt if failure
Action in the event of an error The prompt below appears. Single step is enabled (set from STEP TP key) CONTINUE
Force condition Post warning if forced
RECHECK
[STOP]
• When "CONTINUE" is selected, the program starts with the warning "SYST-109 Single step ignored". • When "RECHECK" is selected, the single step check is performed again, and in case of other than a single step, the program is started. • When "STOP" is selected, the program does not start but stops. A program start is made in the same way as when "CONTINUE" is selected and, at the same time, the single step is automatically canceled. Single step is automatically canceled with the warning below, and the program start. "SYST-092 Single step forced off"
- 100 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
- Process ready Condition Prompt if failure
Action in the event of an error The prompt below appears. Application process error. Please check process peripheral equipment. CONTINUE
RECHECK
[STOP]
• When "CONTINUE" is selected, the program starts with the warning "SYST-110 Process ready ignored". • When "RECHECK" is selected, the process ready check is performed again, and if the conditions are met, the program is started. • When "STOP" is selected, the program does not start but stops. Force condition Post warning if forced
General settings It is possible to make general settings for program selections and starts. • Heartbeat timing : Enables the user to specify the output cycle of the heartbeat signal for cell output. The heartbeat signal is an output signal that switches between ON and OFF at "n" millisecond intervals. PLC uses this signal to check that the robot is operating normally. This item specifies a heartbeat signal ON/OFF switching interval. An output signal can be allocated using the I/O cell output menu. If the timing is zero or if no input is allocated, the heartbeat signal is disabled. • Low TEMP DRAM memory : Enables the user to check the minimum temporary DRAM memory. If the memory is less than the minimum memory, a warning appears. • Low PERM CMOS memory : Enables the user to check the minimum permanent CMOS memory. If the memory is less than the minimum memory, a warning appears. • RESET when DEADMAN press : Specifies a method with which the system is recovered from the cancellation of the deadman switch when the teach pendant is ON. If this setting is enabled, it is possible to cancel the alarm by turning the deadman switch to OFF and back ON.
- 101 -
3.SETTING UP THE HANDLING SYSTEM
3.8.4
B-82594EN-4/01
Cell Interface I/O
Cell interface I/O Cell interface I/O signals are used for communication between the robot and the cell controller (PLC).
Cell interface input signals By using the cell interface input screen, it is possible to perform the following: • Display the status of an input signal. • Set an input signal to a simulated status. • Allocate an input signal. Cell interface input signals are explained in Table 3.8.4 (a). To configure cell interface I/O, use Procedure 3-10.
input signal Start (Only when Style is selected) Initiate Style (Only when Style is selected) Tryout Mode (Effective to the material handling/gripper option only)
User in n
User GIN n
Table 3.8.4 (a) Cell interface input signals Explanation When this signal is received, the execution of a style program starts.
This signal is used to set a GI[] signal number for selecting a style program.
This signal is to be allocated if tryout mode is used. The robot enters tryout mode under the conditions below. Signal = ON TP disabled $shell_wrk.$isol_mode = FALSE SI[REMOTE]＝ON If the signal is allocated and TP is disabled, it is possible to change tryout mode from the soft panel. The value of User in n is assumed as the value of the system variable $CELLIO.$DI_UCFGn_I. By creating a TP program such as that shown below, the same TP program can be shared with a system having different I/O allocation. 1: R[1] = $CELLIO.$DI_UCFG1_I ; 2: IF DI[R[1]] = ON,JMP LBL[1] ; The value of User GIN n is assumed as the value of the system variable $CELLIO.$GI_UCFGn_I. It can be used in the same way as User DI, described above.
- 102 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Cell interface output signals By using the cell interface output screen, it is possible to perform the following: • Display the status of an output signal. • Set an output signal to a simulated status. • Forcibly send an output signal. • Allocate an output signal. Cell interface output signals are explained in Table 3.8.4 (b). To configure cell interface I/O, use Procedure 3-10.
Output signal Style Ack (Only when Style is selected) Style Req./Echo (Only when Style is selected) Input Simulated OVERRIDE=100 Robot ready
Tryout Status Heartbeat MH Fault (*) MH Alert (*) Refpos1[n] User out n
User GOUT n
Table 3.8.4 (b) Cell interface output signals Explanation Posts the timing at which Style Req./Echo output is to be read.
Group output signal for posting the Initiate Style signal (input) received by the robot to the outside. This output is used to notify PLC that there is a simulated input signal. This output is used to notify PLC that the override for the teach pendant is at 100%. This output is used to notify PLC whether the CMDENBL, SYSRDY, and other conditions (whether each group operation is enabled, whether welding is enabled, and user-specified DI/O[] and RI/O[] conditions) are acceptable to a production start. The conditions contained in the signal must be previously set with "Status screen/robot ready". It is possible to check the status of each condition on this status screen. The function for outputting this signal is optional. Used to notify PLC of the tryout mode status. ON = Tryout mode enabled This signal switches between ON and OFF after each heartbeat signal cycle. This signal is used to check the status of communication between the robot and PLC. If the controller is not in tryout mode, this signal turns ON if an alarm of the material handling function is generated. FAULT RESET causes this output to turn OFF. This output turns ON if a disabled alarm is generated within 20 cycles. FAULT RESET causes this output to turn OFF. If REF POS is enabled, this output turns ON if the robot is at reference position n of operation group 1. The value of User out n is assumed as the value of the system variable $CELLIO.$DO_UCFGn_I. By creating a TP program such as that shown below, the same TP program can be shared with a system having different I/O allocation. 1: R[1] = $CELLIO.$DO_UCFG1_I ; 2: DO[R[1]] = ON ; The value of User GOUT n is assumed as the value of the system variable $CELLIO.$GO_UCFGn_I. It can be used in the same way as User DO, described above.
NOTE The item marked with an asterisk (*) is effective to the material handling/gripper option only.
- 103 -
3.SETTING UP THE HANDLING SYSTEM Procedure 3-10
B-82594EN-4/01
Configuring cell interface I/O
Step 1 2 3
Press the MENUS key and select [I/O]. Press F1 [TYPE]. Select [Cell Interface]. The cell input screen or cell output screen appears. The cell input screen is shown below as an example. The display contents differ depending on the program start method. I/O
Cell
Inputs
JOINT 50 % 1/7 TYPE # SIM STATUS UI[ 6] U OFF GI[ 0] U ***** DI[ 0] U ***
INPUT SIGNAL 1 Start 2 Initiate Style 3 Tryout Mode [TYPE ]
CONFIG
IN/OUT SIM
UNSIM
>
To switch between the input screen and the output screen, press F3 [IN/OUT]. The cell output screen is shown below. The display contents differ depending on the program start method. I/O Cell Outputs
1 2 3 4 5 6 7 8 9
OUTPUT SIGNAL Style Ack Style Req./Echo Input Simulated OVERRIDE = 100 Robot ready Tryout Status Heartbeat MH Fault MH Alert
[ TYPE ]
4
5
JOINT
CONFIG
50 % 1/21 TYPE # SIM STATUS DO[ 0] U *** GO[ 0] U ***** DO[ 0] U *** DO[ 0] U *** DO[ 0] U *** DO[ 0] U *** DO[ 0] U *** DO[ 0] U *** DO[ 0] U ***
IN/OUT SIM
UNSIM
>
To specify whether to place an I/O signal in a simulated status, position the cursor on the SIM field for that I/O signal. To specify whether to place an I/O signal in a simulated status, position the cursor on the SIM field for that I/O signal. • To place the signal in a simulated status, press F4 [SIM]. The signal is placed in a simulated status. • To release a signal from a simulated status, press F5 [UNSIM]. The signal is released from a simulated status. To forcibly turn an I/O signal ON or OFF, position the cursor on the STATUS field for that I/O signal. • To turn the I/O signal ON, press F4 [ON]. • To turn the I/O signal OFF, press F5 [OFF]. - 104 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
6
To allocate the signal, press F2 [CONFIG]. The screen below appears. I/O Cell Outputs
JOINT
50 %
Output Signal Details 1/2 Signal name: Style Ack 1 Output type/no: DO[ 0] [ TYPE ] PREV_IO NEXT-IO [CHOICE] VERIFY
CAUTION If $SHELL_CFG.$SET_IOCMNT = TRUE, and a signal number is input on this input screen or output screen, the comments on the corresponding signal on the I/O digital screen or I/O group screen is updated with the signal name displayed here. • • •
• •
If the type of a signal can be changed and is required to be changed, move the cursor to the TYPE field for that signal, press F4 [CHOICE], select an I/O type, and press [ENTER]. To change the number of a non-UOP I/O signal, place the cursor on [Number], input a signal number, and press the [ENTER] key. To check whether allocation is enabled, press F5 [VERIFY]. → If the signal exists and allocation is enabled, the message "Port assignment is valid" appears. → If allocation is not enabled, the message "Port assignment is invalid" appears. Re-input is necessary. → VERIFY does not perform a double allocation check. To display the detailed information for the previous I/O signal, press F2 [PREV_IO]. To display the detailed information for the next I/O signal, press F3 [NEXT-IO].
About the cell output signal, Robot ready (This function is optional.) The cell output signal, Robot ready, notifies PLC whether the robot is a production start ready status. The Robot ready output signal does not turn ON unless the various check items listed in Table 4-3 result in OK. The check items are performed with Robot ready on the status screen. It is necessary to set monitor items in advance in accordance with the actual system. The display and change procedure is explained in Procedure 4-2.
- 105 -
3.SETTING UP THE HANDLING SYSTEM
Check item CMENABLE SYSRDY General
User
Procedure 3-11
B-82594EN-4/01
Table 3.8.4(c) Check items with Robot ready Explanation Indicates whether the CMENABLE-related items are OK or NG. NG appears if UI allocation is not correct. Indicates whether the SYSRDY-related items are OK or NG. NG appears if UI allocation is not correct. Indicates whether the robot operation, welding enable/disable, pressurization enable/disable, and other items are OK or NG. To set the items and check whether they are enabled or disabled, press F2 [CONFIG] to display the display screen. Indicates the status of the I/O signals necessary for a production start, such as DI/DO and RI/RO. NG appears if UI allocation is not correct. To set the items and check whether they are enabled or disabled, press F2 [CONFIG] to display the display screen.
Displaying the status check screen
Step 1 2
Press the MENUS key and select [STATUS]. Press F1 [TYPE] and select [Robot ready].
STATUS Robot ready JOINT Output: Robot ready DO[0]
50 %
1 CMDENBL TP disabled 2 CMDENBL SI[2] = ON 3 CMDENBL SFSPD = ON 4 CMDENBL ENBL = ON 5 CMDENBL $RMT_MASTER=0 6 CMDENBL SYSRDY=ON 7 CMDENBL No active alarms 8 CMDENBL Not in single step 9 SYSRDY ENBL = ON 10 SYSRDY GRP1 Servo ready 11 SYSRDY GRP2 Servo ready 12 GRP1 Motion enabled 13 GRP2 Motion enabled 14 DO[0: ] 15 DO[0: ] 16 DO[0: ] [TYPE ] CONFIG
3
NG OK NG OK OK NG NG OK NG OK OK NG NG ----
>
If any settings have been changed, press the NEXT key and then F1 [REDO] button to check the current status.
- 106 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Changing monitor items (CMDENBL and SYSRDY conditions not changeable) - Step 1 2 3
Position the cursor to a desired item and press F2 CONFIG. To monitor the item, select YES. Otherwise, select NO. To return to the list, press F2 LIST.
1 2
Position the cursor on a DO[] field and press F2 CONFIG. Change the SIGNAL type, number, OK condition (ON, OFF), as desired. To monitor it, select YES. Otherwise, select NO. To return to the list, press F2 LIST.
Adding monitor signals - Step
3 4
- 107 -
3.SETTING UP THE HANDLING SYSTEM
3.9
B-82594EN-4/01
SETTING COORDINATE SYSTEMS A coordinate system defines the position and attitude of the robot. The system is defined for the robot or in a work space. A joint coordinate system and a Cartesian coordinate system are used.
Joint coordinate system The joint coordinate system is defined for robot joints. The position and attitude of the robot are defined by angular displacements with regard to the joint coordinate system of the joint base.
Fig. 3.9 (a) Joint Coordinate System
Cartesian coordinate system The position and attitude of the robot in the Cartesian coordinate system are defined by coordinates x, y, and z from the origin of the space Cartesian coordinate system to the origin (tool tip point) of the tool Cartesian coordinate system and angular displacements w, p, and r of the tool Cartesian coordinate system against the X-, Y-, and Z-axis rotations of the space Cartesian coordinate system. The meaning of (w, p, r) is shown below.
Fig. 3.9 (b) Meaning of (w, p, r)
- 108 -
B-82594EN-4/01
3.SETTING UP THE HANDLING SYSTEM
To operate the robot in a user-specified environment, use a corresponding Cartesian coordinate system. The following five coordinate systems are available:
Mechanical interface coordinate system ( Coordinate system fixed to the tool ) A standard Cartesian coordinate system defined for the mechanical interface of the robot (the surface of wrist flange). The coordinate system is fixed at a position determined by the robot. On the basis of the coordinate system, a tool coordinate system is specified.
Tool coordinate system A coordinate system that defines the position of the tool center point (TCP) and the attitude of the tool. The tool coordinate system must be specified. If the coordinate system is not defined, the mechanical interface coordinate system substitutes for it.
World coordinate system ( Coordinate system fixed in the work space ) A standard Cartesian coordinate system fixed in a work space. The coordinate system is fixed at a position determined by the robot. On the basis of the coordinate system, a user coordinate system and a jog coordinate system are specified. The world coordinate system is used for specifying position data and executing the corresponding instruction. Refer to the Appendix B.6 ”World Frame Origin” for the origin of the world frame.
Fig. 3.9 (c) World and Tool Coordinate Systems
User coordinate system A Cartesian coordinate system defined by the user in each work space. It is used to specify a position register, execute the corresponding position register instruction and position compensation instruction, etc. If the coordinate system is not defined, the world coordinate system substitutes for it.
- 109 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
WARNING If the tool or user coordinate system is changed after program teaching, the programmed points and ranges should be reset. Otherwise, the equipment would be damaged.
Jog coordinate system A coordinate system defined by the user. The jog coordinate system is used to efficiently move the robot by jog feed. You need not take care of the jog frame origin, since it is used only when the jog frame is selected as the manual-feed coordinate systems. If the coordinate system is not defined, the world coordinate system substitutes for it.
3.9.1
Setting a Tool Coordinate System A tool coordinate system is a Cartesian coordinate system that defines the position of the tool center point (TCP) and the attitude of the tool. On the tool coordinate system, the zero point usually represents the TCP and the Z-axis usually represents the tool axis. When the tool coordinate system is not defined, the mechanical interface coordinate system substitutes for it. Tool coordinates include (x, y, z) indicating the position of the tool center point (TCP), and (w, p, r) indicating the attitude of the tool. Coordinates x, y, and z indicate the position of TCP on the mechanical interface coordinate system. Coordinates w, p, and r indicate the attitude of the tool and the angular displacement around the X-, Y-, and Z-axes of the mechanical interface coordinate system. The tool center point is used to specify the position data. The attitude of the tool is required to perform tool attitude control.
Fig. 3.9.1 (a) Tool Coordinate System
The tool coordinate system is defined by using the frame setup screen or changing the following system variables. Ten tool coordinate systems can be defined. The desired one can be selected. ● $MNUTOOL [ 1, i ] (Frame number i = 1 to 10) is set the value. ● $MNUTOOLNUM [ group ] is set the used tool frame number. The tool frame can be set by three following methods.
- 110 -
B-82594EN-4/01
3.SETTING UP THE HANDLING SYSTEM
Three Point Method (TCP auto set) [Optional function] Use the three point method to define the tool center point(TCP).The three approach points must be taught with the tool touching a common point from three different approach statuses. As a result, the location of TCP is automatically calculated. To set the TCP accurately, three approach directions had better differ from others as much as possible. In the three point method, only the tool center point (x,y,z) can be set. The setting value of the tool orientation (w, p, r) is the standard value(0,0,0). The tool orientation should be defined by the six point method or direct list method after the location is set.
Fig. 3.9.1 (b) TCP auto set by the three point method
Six Point Method The tool center point can be set in the same method as the three point method. Then, set the tool attitude (w, p, r). Teach the robot so that w, p, and r indicate a given point in space, a point in the positive direction of the X-axis parallel to the tool coordinate system, and a point on the XZ plane. Also, teach the robot using Cartesian or tool jog so that the tilt of the tool does not change.
Fig. 3.9.1 (c) Six point method
- 111 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Direct list method The following values can be entered directly. One is the value (x,y,z) of the TCP position. The other is the rotating angle (w,p,r), which specifies the tool frame orientation, around the x-,y-,and z-axis of the mechanical interface frame.
Fig. 3.9.1 (d) Meaning of (w, p, r) used in direct teaching method
Procedure 3-12
TCP auto set (Three Point Method)
Step 1 2 3 4 5
Press the MENUS key. The screen menu is displayed. Select “6 (SETUP).” Press the F1 key, TYPE. The screen change menu is displayed. Select Frames. Press F3, OTHER and then select Tool Frame. Tool frame list screen is displayed.
- 112 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
6 7
Move the cursor to the line of the tool frame number you want to set. Press F2,DETAIL.The tool frame setup screen of the selected frame number is displayed.
8
Press F2,METHOD and then select Three Point.
9
To add a comment: a Move the cursor to the comment line and press the ENTER key.
b c d 10
Select the method of naming the comment. Press the appropriate function keys to add the comment. When you are finished, press ENTER key.
Record each approach point: a Move the cursor to each Approach point. b Jog the robot to the position you want to record. c Press and hold the SHIFT key and press F5,RECORD to record the data of current position as the reference position. As for the taught reference point, RECORDED is displayed.
NOTE Move the tool in three different directions to bring the tool tip to an identical point. Then, record the three reference points.
- 113 -
3.SETTING UP THE HANDLING SYSTEM
d
B-82594EN-4/01
When all the reference points are taught, USED is displayed. The tool frame has been set.
11
To move the robot to a recorded position, press and hold the SHIFT key and press F4,MOVE_TO.
12
To see each recorded position data, move the cursor to each reference position item and press the ENTER key. The position detail screen of each position data is displayed. To return to the previous screen, press the PREV key.
- 114 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
13
To display the tool frame list screen, press the PREV key. You can see the settings (x, y, z, and comment) for all tool frames.
14
To use the set tool frame as an effective tool frame now, press F5,SETIND.
CAUTION 1 If you do not press F5, SETIND, the tool frame will not be effective. 2 After all coordinate systems are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Subsection 5.2.3 ”Moving the Robot Jog Feed.” 15
To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR.
- 115 -
3.SETTING UP THE HANDLING SYSTEM Procedure 3-13
B-82594EN-4/01
Setting Up Tool Frame Using the Six Point Method
Step 1
Display the tool frame list screen (Refer to the three point method).
2 3
Move the cursor to the tool frame number line you want to set. Press F2,DETAIL. The tool frame setup screen of the selected frame number is displayed. Press F2,METHOD. Select Six Point. The tool frame setup / six point screen is displayed.
4 5
- 116 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
6
Add a comment and teach the reference point. For details, refer to TCP auto set (Three Point Method). a Press and hold the SHIFT key and press F5,RECORD to record the data of current position as the reference position. As for the taught reference point, RECORDED is displayed.
b
7
When all the reference points are taught, USED is displayed. The tool frame has been set.
Press the PREV key. The tool frame list screen is displayed. You can see all the tool frame settings.
- 117 -
3.SETTING UP THE HANDLING SYSTEM 8
B-82594EN-4/01
To make the set tool frame effective, press F5 (SETIND), then enter the frame number.
CAUTION 1 If you do not press F5, SETIND, the tool frame will not be effective. 2 After all coordinate systems are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Subsection 5.2.3 ”Moving the Robot Jog Feed.” To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR.
- 118 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Procedure 3-14
Setting Up Tool Frame Using the Direct List Method
Step 1
Display the tool frame list screen (Refer to the three point method).
2 3
Move the cursor to the tool frame number line you want to set. Press F2,DETAIL or press the ENTER key. The tool frame setup screen of the selected frame number is displayed. Press F2,METHOD. Select Direct Entry. Tool Frame Setup / Direct Entry screen is displayed.
4 5
6
Add a comment. Refer to TCP auto set (Three Point Method) for details.
- 119 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
7
Enter the coordinate values of the tool frame. a Move the cursor to each component. b Enter a new numerical value by using numerical keys. c Press the ENTER key. A new numerical value is set.
8
To display the tool frame list screen, press the PREV key. You can see the settings of all the tool frame.
9
To make the set tool frame effective, press F5 (SETIND), then enter the frame number.
CAUTION 1 If you do not press F5, SETIND, the tool frame will not be effective. 2 After all coordinate systems are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed. - 120 -
B-82594EN-4/01
3.SETTING UP THE HANDLING SYSTEM
NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Subsection 5.2.3 ”Moving the Robot Jog Feed.” To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR.
3.9.2
Setting a User Coordinate System A user coordinate system is a Cartesian coordinate system defined for each work space by the user. If the coordinate system is not defined, the world coordinate system substitutes for it. Define the user coordinate system by (x, y, z) indicating the position of the zero point and (w, p, r) indicating the angular displacement around the X-, Y-, and Z-axes on the world coordinate system. The user coordinate system is used to specify a position register and execute the corresponding position register instruction and position compensation instruction. For the specification of the position register, see Section 7.4, “Position Register.” For the execution of the position register instruction, see Subsection 4.3.2, “Position Data.” For the execution of the position compensation instruction, see Subsection 4.3.5, “Additional Motion Instruction.”
CAUTION If teaching is made by joint coordinates, changing the user coordinate system does not affect the position variables and position registers. When the robot is taught in the Cartesian format and the user coordinate system input option is not used, the position variables are not affected by the user coordinate systems. Note that both position variables and registers are affected by the user coordinate systems in other cases.
- 121 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Fig. 3.9.2 (a) World and User Coordinate Systems
The following system variables are changed by defining the user frame with the frame setup screen. Nine user coordinate systems can be defined. The desired one can be selected ● $MNUFRAME [ 1, i ] (Frame number i = 1 to 9 ) is set the value. ● $MNUFRAMENUM [ 1 ] is set the user frame number you want to use. The user frame can be defined by the following three methods.
Three Point Method Teach the following three points: the origin of the x-axis, the point which specifies the positive direction of the x-axis, and the point on the x-y plane.
Fig. 3.9.2 (b) Three Point Method
- 122 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Four Point Method Teach the following four points: the origin of the x-axis parallel to the frame, the point which specifies the positive direction of the x-axis, a point on the x-y plane, and the origin of the frame.
Fig. 3.9.2 (c) Four Point Method
Direct List Method Enter the following values directly: the value (x,y,z) which specifies the origin of the user frame and is the coordinate values of the world frame and the rotating angle (w,p,r) around the x-,y-,and z-axis of the world frame.
Fig. 3.9.2 (d) Meaning of (w,p,r) used in direct list method
Procedure 3-15
Setting Up User Frame Using Three Point Method
Step 1 2 3 4
Press the MENUS key. The screen menu is displayed. Select “6 (SETUP).” Press the F1 key, TYPE. The screen change menu is displayed. Select Frames.
- 123 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
5
Press F3, OTHER and then select User Frame. The user frame list screen is displayed.
6
Move the cursor to the line of the user frame number you want to set. Press F2,DETAIL. The user frame setup screen of the selected frame number is displayed.
7
8
Press F2,METHOD and then select Three Point.
- 124 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
9
To add a comment: a Move the cursor to the comment line and press the ENTER key.
b c d
10
Select the method of naming the comment. Press the appropriate function keys to add the comment. When you are finished, press ENTER key.
Record each approach point: a Move the cursor to each Approach point. b Jog the robot to the position you want to record. c Press and hold the SHIFT key and press F5, RECORD to record the current position as the approach point. As for the taught reference point, RECORDED is displayed.
d
When all the reference points are taught, USED is displayed. The user frame has been set.
- 125 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
11
To move to a recorded position, press and hold the SHIFT key and press F4,MOVE_TO.
12
To see each recorded position data, move the cursor to each reference position item and press the ENTER key. The position detail screen of each position data is displayed. To return to the previous screen, press the PREV key. To display the user frame list screen, press the PREV key. You can see the settings for all user frames.
13
14
To make the set user frame effective, press F5 (SETIND), then enter the frame number.
CAUTION 1 If you do not press F5, SETIND, the user frame will not be effective. 2 After all coordinate systems are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed.
- 126 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Subsection 5.2.3 ”Moving the Robot Jog Feed.” 15
Procedure 3-16
To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR.
Setting User Frame Using Four Point Method
Step 1
Display the user frame list screen (Refer to the three point method)
2 3
Move the cursor to the user frame number line you want to set. Press F2,DETAIL. The user frame setup screen of the selected frame number is displayed.
4
Press F2,METHOD
- 127 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
5
Select Four Point. The user frame setup / four point screen is displayed.
6
Add a comment and teach the reference point. For details, refer to TCP auto set ( Three Point Method ).
7
Press the PREV key. The user frame list screen is displayed. You can see all the user frame settings.
- 128 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
8
To make the set user frame effective, press F5 (SETIND), then enter the frame number.
CAUTION 1 If you do not press F5, SETIND, the tool frame will not be effective. 2 After all coordinate systems are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Subsection 5.2.3 ”Moving the Robot Jog Feed.” 9
Procedure 3-17
To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR.
Setting User Frame Using Direct List Method
Step 1
Display the user frame list screen (Refer to the three point method).
- 129 -
3.SETTING UP THE HANDLING SYSTEM
2 3 4 5
6
B-82594EN-4/01
Move the cursor to the user frame number line you want to set. Press F2,DETAIL or press the ENTER key. The user frame setup screen of the selected frame number is displayed. Press F2,METHOD. Select Direct List. The user frame setup / direct list is displayed.
Add a comment and enter the coordinate values. For details, refer to tool frame (Direct List Method).
- 130 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
7
To display the user frame list screen, press the PREV key. You can see the settings of all the user frame.
8
To get the set user frame as effective, press F5,SETIND.
CAUTION 1 If you do not press F5, SETIND, the tool frame will not be effective. 2 After all coordinate systems are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Subsection 5.2.3 ”Moving the Robot Jog Feed.” 9
To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR.
- 131 -
3.SETTING UP THE HANDLING SYSTEM
3.9.3
B-82594EN-4/01
Setting a Jog Coordinate System A jog coordinate system is a Cartesian coordinate system defined in a work space by the user. It is used to efficiently move the robot by Cartesian jog in the work space. (See Subsection 5.2.3.) The jog coordinate system is defined by (x, y, z) indicating the position of the zero point, and (w, p, r) indicating the angular displacement around the X-, Y-, and Z-axes on the world coordinate system.
NOTE You need not take care of the jog frame origin, since it is used only when the jog frame is selected as the manual-feed coordinate system. The zero point of the jog coordinate system has no special meaning. Select any convenient position for defining the jog coordinate system.
Fig. 3.9.3 Jog Coordinate System
The following system variables are changed by setting the jog frame with the frame setup screen. ● $JOG_GROUP [ 1 ] . $JOGFRAME is set the jog frame you want to used. Five jog frames can be set and they can be switched according to the situation. It is substituted by the world frame when undefined. Jog frame can be set by two methods.
Three Point Method Three reference points need be taught. They are the start point of the x-axis, the positive direction of the x-axis, and one point on the x-y plane. The start point of the x-axis is used as the origin of the frame. Refer to Fig. 3.9.2 (b).
- 132 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Direct List Method The origin position x, y and z of the jog frame in the world frame and the rotating angle w, p, and r around the x-,y-,and z-axis of the world frame can be input directly. Refer to Fig. 3.9.2 (d).
Procedure 3-18
Setting Up Jog Frame Using Three Point Method
Step 1 2 3 4 5 6
Press the MENUS key. The screen menu is displayed. Select 6 (SETUP). Press the F1 key, [TYPE]. The screen change menu is displayed. Select Frames. Press F3, OTHER Select Jog Frame. Jog frame entry screen is displayed.
7
Move the cursor to the line of the jog frame number you want to set. Press F2,DETAIL. The jog frame setup screen of the selected frame number is displayed.
8
9
Press F2,METHOD.
- 133 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
10
Select Three Point.
11
Add a comment and teach the reference point. For details, refer to TCP auto set (Three Point Method).
12
Press the PREV key. The jog frame list screen is displayed. You can see all the jog frame settings. To display the user frame list screen, press the PREV key. You can see the settings for all user frames.
13
14
To make the set jog frame effective, press F5 (JGFRM), then enter the frame number.
- 134 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
CAUTION 1 If you do not press F5, JGFRM the jog frame will not be effective. 2 After all coordinate systems are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Subsection 5.2.3 ”Moving the Robot Jog Feed.” 15
Procedure 3-19
To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR.
Setting Up Jog Frame Using the Direct List Method
Step 1
Display the jog frame list screen (Refer to the three point method).
2 3
Move the cursor to the jog frame number line you want to set. Press F2,DETAIL or press the ENTER key. The jog frame setup screen of the selected frame number is displayed. Press F2,METHOD.
4
- 135 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
5
Select Direct Entry.
6
Add a comment and teach the reference point. For details, refer to TCP auto set (Three Point Method).
7
Press the PREV key. The jog frame list screen is displayed. You can see all the jog frame settings.
- 136 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
8
To make the set jog frame effective, press F5 (JGFRM), then enter the frame number.
CAUTION 1 If you do not press F5, JGFRM the jog frame will not be effective. 2 After all coordinate systems are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Subsection 5.2.3 ”Moving the Robot Jog Feed.” 9
To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR.
- 137 -
3.SETTING UP THE HANDLING SYSTEM
3.10
B-82594EN-4/01
SETTING A REFERENCE POSITION A reference position is a fixed (predetermined) position that is frequently used in a program or when the robot is moved by jog feed. The reference position is a safe position, which is usually distant from the operating area of the machine tool or peripheral equipment. Three reference positions can be specified.
Fig. 3.10 Reference Position
When the robot is at the reference position, a predetermined digital signals, DO, is output. If the reference position is invalidated, the DO signal is not output. When the robot is at reference position 1, the reference position output signal (ATPERCH) of the peripheral device I/O is output. For this function, the reference position settings can be disabled so that the signal is not output. To make the robot move to the reference position, make the program which specifies the return path and execute this program. At this time, also specify the order in which axes returns to the reference position in the program. Moreover, it is convenient to set the return program as a macro instruction.(See Section 9.1, ”MACRO INSTRUCTION”) Specify the reference position on the reference position setting screen [6 (SETUP). Ref Position].
Procedure 3-20
Setting a reference position
Step 1 2 3
Press the MENUS key. Select SETUP. Press the F1 key, TYPE.
- 138 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
4
Select “Ref Position.” The reference position selection screen is displayed.
5
Press the F3 key, DETAIL. The detailed reference position screen is displayed.
Is a valid HOME:
6
FALSE
To enter a comment, follow these steps: a Place the cursor on the comment line and press the ENTER key. b Determine whether the comment is entered by words, alphabetic characters, or katakana. c Press the corresponding function key and enter the desired comment. d After entering the comment, press the ENTER key.
- 139 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
7
In the “Signal definition” line, specify the digital output signal to be output when the tool is at the reference position.
8
To teach the reference position, place the cursor on the setting fields J1 to J9. While pressing the SHIFT key, press the F5 key, RECORD. The current position is recorded as the reference position.
9
To enter the numeric value of the reference position directly, place the cursor on the setting fields J1 to J9 and enter the coordinates of the reference position. Enter the coordinates in the left column and allowable errors in the right column. Moreover, the value entered to the setting field which specifies an unused axis is ignored.
Is a valid HOME:
- 140 -
FALSE
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
10
After the reference position is specified, press the PREV key. The reference position selection screen is displayed again.
11
To enable or disable the reference position output signal, place the cursor on the ENABLE/DISABLE field and press the corresponding function key.
- 141 -
3.SETTING UP THE HANDLING SYSTEM
3.11
B-82594EN-4/01
JOINT OPERATING AREA The software restricts the operating area of the robot according to a specified joint operating area. The standard operating area of the robot can be changed by specifying the joint operating area. Specify the joint operating area at [6 SYSTEM Axis Limits] on the joint operating area setting screen.
WARNING 1 The robot operating area should not be controlled only by the joint moving range function. Limit switches and mechanical stoppers should be used together with the function. Otherwise, injury or property damage would occur. 2 The mechanical stoppers should be adjusted to the software settings. Otherwise, injury or property damage would occur. CAUTION Changing the joint moving range will affect the robot operating area. Before the joint moving range is changed, the expected effect of the change should be carefully studied in order to prevent possible trouble. Otherwise, the change would produce unpredictable results. For example, an alarm might occur at a position programmed earlier.
UPPER Specifies the upper limit of the joint operating area, which is the limit of the motion in the positive direction.
LOWER Specifies the lower limit of the joint operating area, which is the limit of the motion in the negative direction.
Enabling the new setting After a new joint operating area is specified, turn the controller off and on again to enable the new setting.
Procedure 3-21
Setting the joint operating area
Step 1 2 3
Press the MENUS key. The screen menu is displayed. Select 6 (SYSTEM). Press F1 (TYPE). The screen change menu is displayed.
- 142 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
4
Select Axis Limits. The joint operating area setting screen is displayed.
WARNING The robot operating area should not be controlled only by the joint moving range function. Limit switches and mechanical stoppers should be used together with the function. Otherwise, injury or property damage would occur. NOTE A setting of 0.000 indicate that the robot does not have the corresponding axis. 5
Place the cursor on the target axis limits field, and enter a new value from the teach pendant.
6 7
Repeat the above step for all the axes. To make the set information effective, turn the controller off and on again in cold start mode (Subsection 5.2.1).
WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage would occur.
- 143 -
3.SETTING UP THE HANDLING SYSTEM
3.12
B-82594EN-4/01
USER ALARM In the user alarm setup screen, the message displayed when the user alarm is generated is set. The user alarm is the alarm which is generated when the user alarm instruction is executed. (See Subsection 4.14.2 ”User Alarm Instruction”) Settings for user alarm is done in the user alarm setup screen [6 SETUP. User Alarm].
Procedure 3-22
Setting Up the User Alarm
Step 1 2 3 4
Select the MENUS key. The screen menu is displayed. Select 6(SETUP). Press the F1 key, TYPE. The screen change menu is displayed. Select User Alarm. The user alarm setup screen is displayed.
5
Move the cursor to the line of the user alarm number you want to set and press the ENTER KEY. Enter the message with the function keys.
- 144 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
6
When you are finished to input the message of the user alarm, press the ENTER key. The user alarm message has been set.
- 145 -
3.SETTING UP THE HANDLING SYSTEM
3.13
B-82594EN-4/01
VARIABLE AXIS AREAS On the variable axis area setting screen, multiple (up to three) sets of stroke limits can be set for the J1 axis and an additional axis. The variable axis area function allows the user to switch from one set of stroke limits to another during program execution. * This function is offered by the specific robot only.
Upper limit Indicates the upper limit for a joint operating area. Operating area in the plus direction.
Lower limit Indicates the lower limit for a joint operating area. Operating area in the minus direction. After changing an upper or lower limit, turn off the power to the control unit and then turn it on with a cold start. With a cold start, the new upper or lower limit takes effect and the selected joint operating area is returned to the standard value ($PARAM_GROUP.$SLMT_**_NUM).
CAUTION Changing a joint operating area affects the operating area of the robot. To avoid problems, it is necessary to thoroughly consider the effect of a change in the joint operating area before making the change. Procedure 3-23
Setting a variable axis area
Step 1 2 3 4
Press MENUS. The screen menu appears. Select SETUP. Press F1 ”TYPE.” The screen switching menu appears. Select Stroke limit. The variable axis area setting screen appears.
- 146 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
5
6
Procedure 3-24
Position the cursor to the desired axis area. Enter new values using the numeric keys on the teach pendant. ● The upper and lower limits must be within the stroke limits of the system. (->Section 3.11, ”Joint Operating Area”). If an attempt is made to set a value outside the limits, the upper or lower limit is fixed to the system default value. ● To switch from one motion group to another, use the F2 key (group #). ● To set an additional axis, press the F3 key (axis #) to switch to the additional axis setting screen. To make the settings effective, turn off the power and then back on. When the power is turned on for the first time after the settings have been changed, a cold start is automatically performed.
Using a variable axis area
Condition ■
A proper axis area has been set and is effective.
1
To switch to the joint operating area that has been set on the variable axis area setting screen during program execution, use the parameter instruction (→ Subsection 4.14.7, ”Parameter instruction”). For example, after the following program has been executed
Step
Value No.1 is used for the joint operating area for the J1 axis. To switch to another joint operating area for the additional axis, use the following command:
- 147 -
3.SETTING UP THE HANDLING SYSTEM
3.14
B-82594EN-4/01
SPECIAL AREA FUNCTION The special area function is a function that automatically stops the robot when a move instruction that causes the robot to enter the preset interference area is issued, the robot will stop if another robot or peripheral device is located in that interference area and, after confirming that the other robot or peripheral device has moved out of the interference area, automatically releases the robot from the stopped state to restart its operation. Communication between a robot and a peripheral device is accomplished with a set of interlock signals (one signal for each of input and output). One set of interlock signals is allocated to one interference area. Up to three interference areas can be defined. The relationship between the interlock signals and the robot is as described below.
Output signal The output signal is off when the tool endpoint is located inside the interface area. It is on when it is located outside the area. State Safe (tool endpoint located outside the interference area) Dangerous (tool endpoint located inside the interference area)
Output signal On Off
Input signal When the input signal is off, and the robot attempts to enter the interference area, the robot enters the hold state. When the input signal is turned on, the robot is released from the hold state, automatically restarting its operation.
CAUTION The robot decelerates to stop at the point where the tool endpoint enters the interference area, so that the robot actually stops at a position inside the interface area. The faster the operating speed of the robot, the deeper the robot enters the interference area. Consider this and other factors, such as the tool size, to ensure that a sufficiently large interface area is set. To set up the special area function, use the SETUP Space function.
- 148 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
To set up the following items, use the Rectangular Space/DETAILED screen.
Item Enable/disable Comment Output signal Input signal Driority
Table 3.14 (a) Items of the Special Area Function (Area Details Screen) Description Enables and disables this function. To change the settings of the other items, this function must be disabled for the area for which the settings of the items are to be changed. Allows the user to enter a comment of up to 10 characters. Sets up the output signal. Sets up the input signal. When two robots use this function, this item specifies which robot is to enter the interference area first if the two robots attempt to enter the interference area at the same time. The robot for which High is set enters the interface area first. When the robot completes its operation and moves out of the interference area, the robot for which Low is set enters the interference area. The setting for one robot must be different from that for the other. NOTE If High or Low is set for both robots, and the robots attempt to enter the interference area at the same time, they both enter the stopped (deadlock) state. If this occurs, perform the recovery operation described below and check that the settings are correct. 1 Perform an emergency stop on both robots.
WARNING If an emergency stop is not performed on both robots, one robot will automatically start its operation when the other moves out of the interference area. This is very dangerous.
inside/outside
2 Check that there are no objects or by standers that a robot could hit. 3 Disable this function. 4 Move either robot out of the interference area, using a jog operation. Specifies whether the inside or outside of a rectangular parallelepiped is to be an interference area.
To set up the following items, use the Rectangular Space/SPACE SETUP screen.
Item BASIS VERTEX SIDE LENGTH/SECOND VERTEX
Procedure 3-25
Table 3.14 (b) Items of the Special Area Function (Area Setting Screen) Description Position of the vertex of a rectangular parallel pipe that is to become the reference. If SIDE LENGTH is selected, specify the lengths of the sides of a rectangular parallelepiped from the reference vertex along the X, Y, and Z axes in the user coordinate system. (The sides of the rectangular parallel pipe must be parallel to the respective axes of the user coordinate system.) If SECOND VERTEX is selected, the rectangular parallel pipe having the reference vertex and the diagonal vertex, specified here, becomes an interference area.
Setting up the special area function
Step 1 2 3
Press MENUS. The screen menu appears. Select SETUP. Press F1 ”TYPE.” The screen switching menu appears.
- 149 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
4
Select Space fnct. The area list screen appears.
5
The area list screen allows the user to enable and disable each interface area with the appropriate function key. To enter a comment, use the procedure below: a. Move the cursor to the desired comment line and press the Enter key. b. Specify which of alphabetic or katakana characters are to be used to enter a comment. c. Press the appropriate function key to enter a comment. d. When a comment is entered, press the Enter key.
6
To set up an item other than Enb/Dsbl or Comment, press F3 (DETAIL). The details screen appears.
7
Position the cursor to the desired item. Change the setting of the item using the function or numeric keys. - 150 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
8
To set an area, press SPACE. The area setting screen appears.
9
The reference vertex and the side lengths or diagonal vertex can be set in either of two ways: a. Position the cursor to the X, Y, and Z coordinate fields and enter the desired coordinates directly using the numeric keys. b. Move the robot to a vertex of a rectangular parallelepiped, then read the current position of the robot with SHIFT key +F5 RECORD.
NOTE 1 If UF or UT is to be changed, perform operation b first. By means of this operation, the current UF or UT value is selected. 2 When the user coordinate system values are changed, the spatial position of the interference area does not change. When the user coordinate system values have been changed and an interference area is to be defined in the new user coordinate system, use SHIFT key +F5 RECORD to set an interference area again. 10
After setting the area, press PREV. The area details screen reappears. To return to the area list screen, press PREV again.
- 151 -
3.SETTING UP THE HANDLING SYSTEM
3.15
B-82594EN-4/01
SYSTEM CONFIG MENU The System Config Menu includes some important components which should be set when the system is established. In the system config menu, the following items can be set.
Items Use HOT START (Hot Start) I/O power fail recovery
Table 3.15 System config menu Descriptions When the hot start is set to TRUE, hot start is done at turning on the controller. (Default setting = FALSE) Specifies whether or how to perform I/O power failure recovery if the hot start function is enabled and how to perform simulated recovery if the hot start function is disabled. There are four power failure recovery modes, as described below. - NOT RECOVER I/O power failure recovery is not performed regardless of whether the hot start function is enabled. All outputs are turned off, and the simulated state is reset. - RECOVER SIM Simulated-state recovery is performed regardless of whether the hot start function is enabled, and the simulated state is reset, but all actual outputs and simulated inputs/outputs are turned off. - UNSIMULATE I/O power failure recovery is performed, but all the simulated states are reset. This is equivalent to NOT RECOVER if the hot start function is disabled, because the output states are not recovered. - RECOVER ALL I/O power failure recovery is performed if the hot start function is enabled. The output and simulated states are recovered to the states that existed immediately before the power is turned off. If the hot start function is disabled, RECOVER ALL is equivalent to RECOVER SIM, because the output states are not recovered.
CAUTION Even if power failure handling is enabled, the output signal is turned off without being recovered in the following cases: ● When the I/O allocation is changed before the power is turned off. ● When the fuse of an I/O unit blows, or when an I/O unit is turned off. ● When the I/O unit configuration is changed.
- 152 -
B-82594EN-4/01
3.SETTING UP THE HANDLING SYSTEM
Items
Descriptions
Autoexec program for Cold start Autoexec program for Hot start
Specifies the name of the auto-start program for the hot start. The specified program is executed immediately after the power is turned on. If it does not end within 15 seconds, it will be aborted.
CAUTION The program automatically executed at power of is executed just before the servo power is turned on. Therefore the robot can not be moved by this program. Set the program which initializes the condition of setup and I/O of the system. You should set the name of program which sets up the system, initializes I/O...etc. Moreover, the attributes should be set as follows on the program detail screen. Group Mask: [*,*,*,*,*] Ignore pause: [ON] HOT START done signal Restore selected program
Disable UI signals START for CONTINUE only CSTOPI for ABORT Abort all programs by CSTOPI
Specifies the digital signal (DO) that is to be output at the hot start. If the hot start is not performed, the digital signal is turned off. This function is disabled if 0 is specified. Specifies whether the program selected at turning off the controller is selected after turning on the controller when the cold start is done. When this is set to TRUE, the program selected at the power off is selected after the power on again. When this is set to FALSE, the program is not selected after power on again. This is set to TRUE in standard setting. Selects whether a UI signal is valid or invalid. When this is set to FALSE, the peripheral input signals (UI[1 to 8]) is disabled. See Section 3.3 ”PERIPHERAL I/O”. If this item is enabled, the external start signal (START) starts only those programs that have been paused. → See Section 3.3 ”PERIPHERAL I/O”. If this item is enabled, those programs that are currently running are forcibly terminated immediately upon the input of CSTOPI. → See Section 3.3 ”PERIPHERAL I/O”. Specifies whether all programs are to be forcibly terminated with the CSTOPI signal in a multitasking environment. If this item is set to TRUE, the CSTOPI input signal functions as follows: ● If RSR is selected for the RSR/PNS item, all programs are forcibly terminated. ● If PNS is selected for the RSR/PNS item, the selected program is forcibly terminated. If no program is selected, however, all programs are forcibly terminated.
If this item is set to FALSE, the CSTOPI input signal causes only the currently selected program to be forcibly terminated. (Default setting)
- 153 -
3.SETTING UP THE HANDLING SYSTEM Items PROD-START depend on PHSTROBE Detect FAULT_RESET signal Use PPABN signal
WAIT timeout RECEIVE timeout Return to top of program
Original program name (F1 to F5) Default logical command
Maximum of ACC instruction Minimum of ACC instruction WJNT for default motion
Auto display of alarm menu
Force Message
B-82594EN-4/01
Descriptions If this item is enabled, the PROD_START input is enabled only when the PNSTROBE input is on. By enabling this item, it is possible to prevent a program that should not be started from being started accidentally due to noise or a sequence error when that program is displayed on the teach pendant. Specifies whether the reset signal is detected the instant it rises or falls. When this setting is changed, turn the controller off and on again to use the new information. At this time the cold start is done automatically. The falling edge is detected by standard setting. Specifies if the pneumatic pressure alarm(*PPABN) is detected for each motion group. Move the cursor to this line and press ENTER key. The setup screen for each motion group is displayed. When *PPABN signal is not used, set this invalid. When this setting is changed, turn off the controller, and turn on the controller to use the new information. At this time it start when HOT START is disable. Specifies the period of time used in the conditional wait instruction(WAIT ..., TIMEOUT LBL[...] ). The period of time is 30 second. For this item, set the limit time for register receive instruction RCV R[...] LBL[...] (can be specified only when the sensor interface option is specified). Specifies whether the cursor is moved to the top of the program or not when it is finished to be executed. When this setting is TRUE, the cursor stays at the last line without returning to the top of the program when the program is finished to be executed. The default setting is TRUE. It is effective in the standard. Specifies the words which is displayed as the soft key at registering a program. It is convenient to set the words used many times as the program name to this. It is possible to enter the screen to which standard instruction function key is set by pushing the input key from the condition that there is a cursor in setting a standard instruction. - Name Specifies the name which is displayed as the function key title.(Up to 7 characters) - Lines Specifies the number of the logic command registered in on function key. The default logical command up to four can be registered in one function key. When the Lines is set to 0,the function of teaching the default logical command is invalid. Specifies the maximum of the override value used in the acceleration override motion option(ACC ...). The default value is 150. Specifies the minimum of the override value used in the acceleration override motion option(ACC ...). Adds the Wjnt motion option to all linear and circular default motion instructions or delete it from them. - Pressing the F4 (ADD) key adds the Wjnt motion option to all the linear and circular default motion instructions and changes the screen display from ”DELETE” (or ******) to ”ADD.” - Pressing the F5 (DELETE) key deletes the Wjnt motion option from all the linear and circular default motion instructions and changes the screen display from ”ADD” (or ******) to ”DELETE.” Toggles the function for automatically displaying the alarm screen between FALSE and TRUE. The default setting is FALSE. If the setting of this item is changed, the power must be turned off and then back on. ● FALSE : Does not display the alarm screen automatically. ● TRUE : Displays the alarm screen automatically. Specifies whether the user screen is to appear automatically when a message instruction is executed in a program.
- 154 -
B-82594EN-4/01
3.SETTING UP THE HANDLING SYSTEM
Items Hand broken
Reset CHAIN FAILURE detection
Remote / Local setup
External I/O (ON : Remote) Allow force I/O in AUTO mode
Allow chg. ovrd. in AUTO mode
Signal to set in AUTO mode Signal to set in T1 mode Signal to set in T2 mode Signal to set if E-STOP
Descriptions Enables and disables hand breakage (*HBK) detection. When multiple robots are used, hand breakage detection can be enabled and disabled for two robots. Press the Enter key with the cursor positioned on this line. Then, the screen for enabling or disabling hand breakage detection for each robot appears. On this screen, move the cursor to ENABLE or DISABLE, then press the ENABLE (F4) or DISABLE (F5) key to enable or disable hand breakage detection. When hand breakage detection is enabled, and the *HBK signal is off, alarm ”-SRVO-006 Hand broken” is issued. See Appendix D.2, ”RECOVERY FROM THE HAND BREAKAGE ALARM,” and release the alarm. When the *HBK signal is off, and this signal is not to be used, disable the hand breakage detection. When hand breakage detection is disabled although a hand is installed, and the *HBK signal is used, ”SRVO 302 Set hand broken to ENABLE” is displayed if the *HBK signal is on. Enable hand breakage detection. If the *HBK signal is turned off when hand breakage detection is disabled, ”SRVO 300 Hand broken / HBK disabled” is issued. In this case, this alarm can be released by pressing the reset key. By default, hand breakage detection is enabled. Resets a chain abnormality alarm (servo 230 or 231) when it is issued. For details on the chain abnormality alarm and for how to make hardware checks, refer to the maintenance manual.
1) Check for any hardware problem. 2) Press the emergency stop button on the teach pendant. (Input an emergency stop signal other than the emergency stop signal currently generated.) 3) Turn the emergency stop button on the teach pendant to release the emergency stop condition. 4) Move the cursor to this line, then press the F4 (TURE) key. 5) Press the reset button on the teach pendant. Select the method for setting the remote signal (SI[2]) that switches between remote mode and local mode of the system. - Remote : Keeps SI[2] on (remote mode) at all times. - Local : Keeps SI[2] off (local mode) at all times. - External I/O : Reflects the external signal status on SI[2]. When selecting this item, specify an external signal for External I/O (ON : Remote) on the next line. - OP panel key : When the R-J3i MODEL B controller is used, this item cannot be selected. When External I/O (ON : Remote) is selected in Remote / Local setup above, specify an external signal to be used here. Choose from DI, DO, RI, RO, UI, and UO. Enables or disables signal setting from TP when AUTO mode is set. By default, setting is enabled. - Yes : Enables signal setting. - No : Disables signal setting. Enables or disables override change from TP when AUTO mode is set. By default, change is enabled. - Yes : Enables override change. - No : Disables override change. If the three-mode switch is set to AUTO mode, a specified DO is turned on. When 0 (default) is set, this function is disabled. When the setting has been changed, the power must be turned off then back on. If the three-mode switch is set to T1 mode, a specified DO is turned on. When 0 (default) is set, this function is disabled. When the setting has been changed, the power must be turned off then back on. When the three-mode switch is set to T2 mode, a specified DO is turned on. When 0 (default) is set, this function is disabled. When the setting has been changed, the power must be turned off then back on. When an emergency stop (TP external emergency stop, operator’s panel) is applied, a specified DO is output. When 0 (default) is set, this function is disabled. When the setting has been changed, the power must be turned off then back on.
- 155 -
3.SETTING UP THE HANDLING SYSTEM Items Hand broken
Remote/Local setup
External I/O (ON : Remote) Simulated status signal (Set if INPUT SIMULATED) Simulated input wait time (Sim. Input Wait Delay) Setting to be assumed when the simulated signal skip function is enabled (Set if Sim. Skip enabled) Signal to be output at an override of 100% (Signal if OVERRIDE= 100) Multiple-program selection (Multi Program Selection)
B-82594EN-4/01
Descriptions Enables and disables hand breakage (*HBK) detection. When multiple robots are used, hand breakage detection can be enabled and disabled for two robots. Press the Enter key with the cursor positioned on this line. Then, the screen for enabling or disabling hand breakage detection for each robot appears. On this screen, move the cursor to ENABLE or DISABLE, then press the ENABLE (F4) or DISABLE (F5) key to enable or disable hand breakage detection. When hand breakage detection is enabled, and the *HBK signal is off, alarm "SRVO-006 SERVO Hand broken" is issued. See Appendix C.2, "ALARM CODES", and release the alarm. When the *HBK signal is off, and this signal is not to be used, disable the hand breakage detection. When hand breakage detection is disabled although a hand is installed, and the *HBK signal is used, "SRVO-302 SERVO Set Hand broken to ENABLE" is displayed if the *HBK signal is on. Enable hand breakage detection. If the *HBK signal is turned off when hand breakage detection is disabled, "SRVO-300 SERVO Hand broken/HBK disabled" is issued. In this case, this alarm can be released by pressing the reset key. By default, hand breakage detection is enabled. Select the method for setting the remote signal (SI[2]) that switches between remote mode and local mode of the system. • Remote : Keeps SI[2] on (remote mode) at all times. • Local : Keeps SI[2] off (local mode) at all times. • External I/O : Reflects the external signal status on SI[2]. When selecting this item, specify an external signal for "External I/O (ON : Remote)" on the next line. • OP panel key : When the R-30iA controller is used, this item cannot be selected. When "External I/O" is selected in "Remote/Local setup" above, specify an external signal to be used here. Choose from "DI, DO, RI, RO, UI, and UO". Monitors to see if an input signal set as a simulated one exists and outputs it as an output signal. For this item, set the number of the output signal that will turn on when a digital, group, robot, or analog input signal is set as a simulated one. When the setting has been changed, the power must be turned off then back on. Sets the time after which a wait command causes a timeout if the simulated signal skip function is enabled. When the setting is changed, the change is immediately applied.
Monitors to see if there is any input signal for which the simulated signal skip function is enabled and outputs the signal as an output signal. For this item, set the number of the output signal that will turn on when the simulated signal skip function is enabled for a digital or robot input signal. When the setting has been changed, the power must be turned off then back on.
Sets the number of the digital output signal for notifying that the override is set to 100%. For the digital output, on is output if the override is 100% and otherwise, off is output. When the setting has been changed, the power must be turned off then back on. This setting is for switching the program selection method between single task mode and multitask mode. If this setting is enabled, multitask mode is selected, and if it is disabled, single task mode is selected. If the R651 standard settings are ordered, the setting is disabled by default, and if the R650 North America only settings are ordered, it is enabled by default. When the setting is changed, the change is immediately applied.
- 156 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
Procedure 3-26
Setting The System
Step 1 2 3 4
Select the MENUS key. The screen menu is displayed. Select 6(SYSTEM) in the next page. Press the F1 key, [TYPE]. The screen change menu is displayed. Select Config. The system configuration screen is displayed.
Set if INPUT SIMULATED Sim. Input Wait Delay Set if Sim. Skip Enabled Set if OVERRIDE=100
UOP auto assignment Multi Program Selection
- 157 -
Full FALSE
3.SETTING UP THE HANDLING SYSTEM 5
B-82594EN-4/01
Move the cursor to the field you want to set and enter the new value by using the numerical key or using the function key on the teach pendant. As for the field which should be set character string, move the cursor to it and press the ENTER key. Then the character input becomes possible.
NOTE As for the setting of ”Use PPABN signal:”, ”Hand Broken:” or ”Default logical command:”, move the cursor to ”<*GROUPS*> or ”<*DETAIL*>” and press the ENTER key. Then each setting screen is displayed. Press the PREV key to get out of these screens.
6
When you change the setting that the cold start must be done after a setting is changed, the following message is displayed. In that case perform the cold start. (See Section 5.2,”TURNING ON THE POWER AND JOG FEED”)
- 158 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
3.16
SETTING THE GENERAL ITEMS [6 SETUP General] has the following items. ● Break on hold ● Current language ● Ignore Offset command ● Ignore Tool-offset
Items Break on hold
Table 3.16 Setting the general items Descriptions Specifies whether to issue an alarm and turn off the servo alarm when the HOLD key is pressed. • If the function is DISABLED, no alarm is issued when the operation is halted by the HOLD key (standard setting). • If the function is ENABLED, an alarm is issued and the servo power is turned off, when the operation is halted by the HOLD key. To be ENABLE this function power need to be on again.
WARNING Not all axes are equipped with a brake. The brake on hold function has no effect on an axis without brake even if the function is enabled. Before the brake on hold function is enabled, it should be checked which axis has a brake. Otherwise, injury would occur. Current language Ignore Offset command
Ignore Tool-offset
The current language is set to ”DEFAULT” by standard setting. Changing the current language requires special work. Usually, the standard setting should be used. Specifies whether to ignore the offset command (Subsection 4.3.5 ”Additional motion instructions”). • If the function is DISABLED, the robot moves to the position for which the offset command has been executed (standard setting). • If the function is ENABLED, the robot moves to the taught position (for which the offset command has not been executed). See Subsection 4.3.5 ”Additional Motion Instructions” for details of the Offset command. Specifies whether to ignore the tool offset command (Subsection 4.3.5 ”Additional motion instructions”). • If the function is DISABLED, the robot moves to the position for which the tool offset command has been executed (standard setting). • If the function is ENABLED, the robot moves to the taught position (for which the tool offset command has not been executed). See Subsection 4.3.5 ”Additional Motion Instructions” for details of the Tool-offset command.
- 159 -
3.SETTING UP THE HANDLING SYSTEM Procedure 3-27
B-82594EN-4/01
Setting the general items
Step 1 2 3 4
Press the MENUS key. The screen menu is displayed. Select 6 (SYSTEM). Press F1 [TYPE]. The screen change menu is displayed. Select General.
5
Place the cursor on the target field, and select the function key menu. If the value for the break on hold function is re-set, to make the new setting effective, turn the controller off and on again in cold start mode. The setting of the other functions is made effective immediately when they are reset.
6
- 160 -
3.SETTING UP THE HANDLING SYSTEM
B-82594EN-4/01
3.17
OTHER SETTINGS The other settings are specified at [6 SYSTEM Variables] on the system variable screen. ● Override restore function
Override restore function The override restore function is a function that decreases the speed override to a prescribed value when a safety fence is opened and the *SFSPD input is turned off, but restores the speed override immediately when the safety fence is closed. This function is effective under the following conditions: ■ $SCR.$RECOV_OVRD = TRUE. (A control start is required.) ■ The system is in remote control state. ■ The speed override is not changed while the safety fence is open. Other items are set up on the system variable screen, [6 SYSTEM Variables]. To specify system variables, see the appropriate appendix (→ Appendix D, ”SYSTEM VARIABLES”).
- 161 -
4 PROGRAM STRUCTURE
4
B-82594EN-4/01
PROGRAM STRUCTURE This chapter describes the program structure and program instructions. Contents of this chapter 4.1 PROGRAM DETAIL INFORMATION ..................................165 4.2 LINE NUMBER, PROGRAM END SYMBOL, AND ARGUMENT ..................................................................171 4.3 MOTION INSTRUCTIONS ....................................................174 4.4 PALLETIZING INSTRUCTIONS...........................................202 4.5 REGISTER INSTRUCTIONS .................................................204 4.6 I/O INSTRUCTIONS ...............................................................212 4.7 BRANCH INSTRUCTIONS....................................................217 4.8 WAIT INSTRUCTIONS ..........................................................233 4.9 SKIP CONDITION INSTRUCTION.......................................237 4.10 OFFSET CONDITION INSTRUCTION .................................240 4.11 TOOL OFFSET CONDITION INSTRUCTIONS ...................241 4.12 FRAME INSTRUCTIONS.......................................................242 4.13 PROGRAM CONTROL INSTRUCTIONS .............................244 4.14 OTHER INSTRUCTIONS .......................................................245 4.15 MULTIAXIS CONTROL INSTRUCTIONS...........................252 4.16 OPERATION GROUP INSTRUCTIONS ...............................253
- 162 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
A robot application program consists of commands described by the user for the robot to perform operations and other incidental information. In addition to program information that describes how the robot should perform operations, a program contains program detail information that defines program attributes.
Fig. 4 (a) Program Information Screen
Program detail information consists of the following information items: • Attribute-related information items such as a creation date, modification date, a copy source file name, presence/absence of position data, and program data size. • Information items related to an execution environment such as a program name, subtype, comment, group mask, write protection and interruption disable.
Fig. 4 (b) Program Selection Screen
- 163 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Fig. 4 (c) Program Edit Screen
A program consists of the following information: • Line number assigned to each program command • Motion instructions specifying how and where the robot is to move • Program instructions including the following: Palletizing instructions for performing the palletizing function Instructions for storing numerical data in registers (register instructions) Instructions for storing robot position data in position registers (position register instructions) I/O instructions to output and input signals to and from peripheral devices Branch instructions for changing the flow of program control when a defined condition is satisfied (IF, JMP/LBL, CALL/END) Wait instructions for suspending program execution Skip condition instruction for operating the robot until a signal is received. If the signal is not received, a branch to a specified command occurs. If the signal is received, the next command is executed, canceling the operation. Program comments Other instructions • Program end symbol indicating that the program contains no more instructions Program detail information is set on the program information screen. (See Subsection 5.3.1 and 5.5.) A program is registered on the program registration screen (See Subsection 5.3.1.) A program is created and changed on the program edit screen. (See Sections 5.3 and 5.4.)
- 164 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.1
PROGRAM DETAIL INFORMATION Program detail information names a program and defines the attributes of the program. Program detail information consists of the following items: • Attribute-related information items such as a creation date, modification date, a copy source file name, presence/absence of position data, and program data size. • Information items related to an execution environment such as a program name, subtype, comment, group mask, write protection and interruption disable. The program information screen is used to set program detail information. The program information screen is displayed by selecting F2 (DETAIL) on the program selection screen. (For program detail information setting, see Subsection 5.3.1 and 5.5) Moreover, program comment, a write protection, a modification date, a memory size of the program, and a copy source settings, can be displayed on the selection screen by pressing F5,[ATTR] and selecting the item from a pull up menu.
4.1.1
Program Name A program name is specified to identify a program stored in the memory of the control unit. A single control unit cannot contain two or more programs with the same program names.
Length A program name must consist of one to eight characters. A unique name must be assigned to each program.
Usable characters Character: Alphabetic characters, Number: 0 to 9. No program name can start with a number. Symbol: Underscore (_) only. The at mark (@) and asterisk (*) cannot be used.
- 165 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Informative name A program should be named so that purpose or function of the program can be known from its name. When a program for spot workpiece A is to be named, for example, “HAND-A” is a good name to assign to the program since it indicates the function of the program.
NOTE Observe the following when writing a program for automatic operation using RSR or PNS. Otherwise, the program will not run. • A program using RSR must be named RSRnnnn, where nnnn is a 4-digit number. Example: RSR0001. • A program using PNS must be named PNSnnnn, where nnnn is a 4-digit number. Example: PNS0001.
4.1.2
Program Comment When a new program is created, a program comment can be added to the program name. A program comment is used to describe additional information to be displayed on the selection screen together with the program name.
Length A program comment must consist of one to sixteen characters.
Usable characters Character: Alphabetic characters, Number: 0 to 9 Symbol: Underscore (_), at mark (@), and asterisk (*)
Informative comment A program comment should describe the purpose or function of the program.
4.1.3
Subtype Subtype is used to set a type of program. The following subtypes are available: • Job (JB): This represents a main program that can be started using a device such as a teach pendant. Process programs are called in a main program for execution. • Process (PR): This represents a subprogram that is called by a job program for execution of a particular job.
- 166 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
•
•
4.1.4
Macro (MR): This represents a program for executing a macro instruction. The subtype of a program registered on the macro instruction setting screen is automatically set to MR. State: Specify this when creating a conditional program with the state monitoring function.
Group Mask A motion group sets up an operation group of a program. An operation group represents a group of different axes (motors) used for independent robots, positioning tables, and other jigs.
NOTE A motion group must be set before the program is executed. The Robot control unit can divide up to 40 axes (when a multifunction board is inserted) into up to five operation groups and control those groups simultaneously. A single group can control up to nine axes (multimotion function). If the system has only one operation group, the default motion group is group 1 (1, *, *, *, *). For a program that has no motion group (that is, a program involving no robot motion), this item is to be specified as (*, *, *, *, *). A program that has no motion group can be started even when the system is not ready for operation. The system is ready for operation when the following ready conditions are satisfied: ■ The peripheral I/O, ENBL input, is on. ■ The peripheral I/O, SYSRDY output, is on (With the servo power is on).
4.1.5
Write Protection Write protection specifies whether the program can be modified. • When this item is set to ON, no data can be added to the program, and the program cannot be modified; that is, the program is write protected. When a program has been created, and its operation is confirmed, the user can set this item to ON to prevent the program from being modified by the user or someone else.
NOTE When this item is set to ON, other items in the program detail information (Program name, Comment, Sub Type, Group Mask, Ignore pause) cannot be changed.
- 167 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
•
4.1.6
When this item is set to OFF, the program can be modified; that is, program instructions can be added to the program, and existing instructions can be modified. Write protection is normally set to OFF as standard.
Interruption Disable Interruption disable (ignore pause) prevents a program being executed and not having the motion group from being interrupted by an alarm (with a severity of SERVO or lower), emergency stop, or halt. When these signals are to be ignored, set interruption disable to ON. When interruption disable is set to ON, a program being executed can only interrupted by an abort instruction in the program or an alarm with a severity higher than SERVO. (See Subsection 4.13.2.)
WARNING When interruption disable is set to ON, a program being executed cannot be interrupted by pressing the emergency stop or halt button on the teach pendant or operator’s panel. Procedure 4-1 Program Detail Information
Step 1 2
Press the MENUS key. The screen menu is displayed. Select 1(SELECT). The program selection screen is displayed. The program selection screen can be displayed by pressing the SELECT key without using above steps.
- 168 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
- Switching the screen using sub type 3
To specify the program to be displayed for the sub type, press F1,[TYPE] and select the sub type of the program you want to display. All : All the programs are displayed. Job : Only job programs are displayed. Process : Only process programs are displayed. Program : All the programs except the macro are displayed. Macro : Only macro programs are displayed.
- Switching the display using the attribute 4
To specify the program attribute to be displayed, press F5,[ATTR] and select the attribute type of the program you want to display. Comment : The comment is displayed. Protection : The setting of the write protection is displayed. Last Modified : The latest date of the modification is displayed. Size : The number of the line and the program size are displayed. Copy Source : The name of the copy source program is displayed.
- 169 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
- Program Detail Screen 5
Press NEXT, > and press F2,DETAIL in the next page. The program detail screen is displayed.
6
When you finish setting the program header information, press F1,END.
- 170 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.2
LINE NUMBER, PROGRAM END SYMBOL, AND ARGUMENT
Line number A line number is automatically inserted in front of an instruction when it is added to a program. When an instruction is deleted, or an instruction is moved to another location, the lines of the program are renumbered in ascending order; that is, the first line is numbered as 1, the second line is numbered as 2, and so forth. When a program is to be modified, the cursor can be used to specify a line or a range of lines for movement or deletion by line number. The user can make the cursor move to a desired line number by specifying a line number (with the ITEM key).
Program end symbol The program end symbol ([End]) is automatically displayed on the line after the last instruction of a program. Whenever a new instruction is added, the program end symbol moves downward on the screen. As a result, it is always displayed on the last line. When the execution of a program reaches the program end symbol after the last instruction in the program is executed, the program execution automatically returns to the first line of the program for termination. However, when the setting of ”Return to top of program” is FALSE, the cursor stays at the last line of the program after program execution is completed. (See Section 3.15 ”SYSTEM CONFIG MENU”.) A description of the program instructions required to create and change a program follows. (For how to create a program, see Section 5.3. For how to change a program, see Section 5.4.)
Argument i Argument i is an index used in teaching control instructions (program instructions other than motion instruction). Some arguments are specified directly; others are specified indirectly. In direct specification, an integer from 1 to 32767 is usually specified. The range of values used depends on the type of instruction. In indirect specification, the register number of a register is specified.
Fig. 4.2 Format of Argument i
- 171 -
4 PROGRAM STRUCTURE Procedure 4-2
B-82594EN-4/01
Program Edit Screen
Condition ■
The teach pendant must be enabled.
1 2
Display the program selection screen. Move the cursor to the program you want to edit and press ENTER key. The program edit screen is displayed.
3
To move the cursor, use the arrow keys such as up, down right, and left. To move quickly through the information, press and hold the SHIFT key and press the down or up arrow keys. To select the line number, press the ITEM key and enter the line number you want to move the cursor.
Step
- Moving the cursor
4
- Entering the numerical value 5
To enter the numerical value, move the cursor to the argument and press the numerical value keys. When you are finished, press the ENTER key.
- 172 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
6
To use the indirect addressing with the register, press F3,INDIRECT.
- 173 -
4 PROGRAM STRUCTURE
4.3
B-82594EN-4/01
MOTION INSTRUCTIONS A motion instruction moves a robot tool to a specified point within the operating area at a specified feedrate and in a specified traveling mode. The items listed below must be specified in a motion instruction. The format of a motion instruction is shown in Fig. 4.3. • Motion format: Specifies how to control the path of motion to a specified position. • Position data: Teaches a position to which the robot is to move. • Feedrate: Specifies the feedrate of the robot. • Positioning path: Specifies whether to position the robot at a specified point. • Additional motion instruction: Specifies the execution of an additional instruction while the robot is in motion.
Fig. 4.3 Motion Instructions
In teaching a motion instruction, a standard motion instruction is selected using either the F1 or F5 function key. (For modifying a standard motion instruction, see Subsection 5.3.2. For teaching a motion instruction, see Subsection 5.3.3. For changing a motion instruction, see Subsection 5.4.2.)
• •
Press F1 POINT to program an operation instruction. Press F5 TOUCHUP to re-program programmed position data.
- 174 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.3.1
Motion Format For the motion format, the path of motion to a specified position is specified. Three options are available: joint motion, which does not exercise path/attitude control and linear motion and circular motion, which exercise path/attitude control. • Joint motion (J) • Linear motion (including the rotation motion)(L) • Circular motion (C)
Joint motion J The joint motion mode is the basic mode for moving the robot to a specified position. The robot accelerates along or about all axes, moves at a specified feedrate, decelerates, and stops at the same time. The path of motion is usually non-linear. The motion format is specified to teach an end point. A percentage of a maximum feedrate is specified as the feedrate of joint motion. The attitude of a tool being moved is not controlled.
Fig. 4.3.1 (a) Joint Motion
- 175 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Linear motion L The linear motion mode controls the path of tool center point (TCP) motion from a start point to an end point; the tool center point moves linearly. The motion format is specified to teach an end point. For linear feedrate specification, a desired option must be chosen from mm/sec, cm/min, and inch/min. The attitude of a tool being moved is controlled by distinguishing the attitude at a start point from the attitude at a target point.
Fig. 4.3.1 (b) Linear Motion
Rotary operation is a method of travel in which the tool is rotated about the tool endpoint from the start position to the end position by using linear operation. The orientation of the tool during travel is controlled by dividing the orientation at the start position and that at the destination position. The feedrate is specified in deg/sec. The focus is controlled linearly (if the tool endpoint moves).
Fig. 4.3.1 (c) Rotation Motion
- 176 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Circular motion The circular motion mode controls the path of tool center point motion from a start point to an end point through a passing point. Both a passing point and a target point are taught in one instruction. For circular feedrate specification, a desired option must be chosen from mm/sec, cm/min and inch/min. The attitude of a tool being moved is controlled by distinguishing the attitude at a start point from the attitude at a target point.
Fig. 4.3.1 (d) Circular motion
4.3.2
Position Data Position data includes the positions and attitudes of the robot. When a motion instruction is taught, position data is written to the program at the same time. Position data is classified into two types. One type consists of joint coordinates in a joint coordinate system. The other type consists of Cartesian coordinates representing tool positions and attitudes in work space. Standard position data uses Cartesian coordinates.
Cartesian coordinates Position data consisting of Cartesian coordinates is defined by four elements: the position of the tool center point (origin of the tool coordinate system) in a Cartesian coordinate system, the inclination of the axis along which the tool moves (tool coordinate system), configuration, and a Cartesian coordinate used. A Cartesian coordinate system may be a world coordinate system. How to select the coordinate systems is explained later in this subsection.
Fig. 4.3.2 (a) Position Data (Cartesian Coordinates)
- 177 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Position and attitude • •
The position (x,y,z) represents the three-dimensional position of the tool center point (origin of the tool coordinate system) in the Cartesian coordinate system. The attitude (w,p,r) represents angular displacements about the X-axis, Y-axis, and Z-axis in the Cartesian coordinate system.
Fig. 4.3.2 (b) World Coordinate System/Tool Coordinate System
Configuration A configuration represents the attitude of the robot. Several configurations are available which meet the condition of Cartesian coordinates (x,y,z,w,p,r). The turn number and joint placement of each axis must be specified.
Fig. 4.3.2 (c) Configuration
- 178 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
- Joint placement Joint placement specifies the placement of the wrist and arm. This specifies which side the control point of the wrist and arm is placed on against the control plane. When a control point is placed on the control plane, the robot is said to be placed at a singular, or to be taking a peculiar attitude. At the singular, since the configuration can not be decided to one by the specified cartesian coordinate values, the robot can not move. • An operation that ends at a singular point cannot be programmed. (In some cases, the most feasible configuration can be selected.) To specify such an operation, define the axial coordinate values. • During linear or circular motion, the tool cannot pass through a singular point (the joint placement cannot be changed). In this case, execute a joint motion. To pass through a singular point on the wrist axis, a wrist joint motion (Wjnt) can also be executed.
Fig. 4.3.2 (d) Joint Placement
Turn number Turn number represents the number of revolutions of the wrist axis (J4, J5, J6). Each axis returns to the original position after one revolution. So, specify how many turns have been made. Turn number is 0 when each axis is at an attitude of 0. The turn numbers for up to three axes can be displayed. The axis number to correspond to each field is specified with system variable $SCR_GRP[i].$TURN_AXIS[j] (where i is a group number), as follows: Left field : Axis number specified with $SCR_GRP[i].$TURN_AXIS[1] Middle field : Axis number specified with $SCR_GRP[i].$TURN_AXIS[2] Right field : Axis number specified with $SCR_GRP[i].$TURN_AXIS[3] When programmed linear motion or circular motion is executed, the robot tool moves toward the target point while adopting an attitude very similar to that at the start point. The number of revolutions performed at the target point is selected automatically. The actual number of revolutions performed at the target point may differ from the number specified in the position data.
- 179 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Cartesian coordinate system reference In playback of position data consisting of Cartesian coordinates, a Cartesian coordinate system reference checks the coordinate system number of a Cartesian coordinate system to be used. If the coordinate system number (a number from 0 to 10) specified in the position data does not match the coordinate system number currently selected, the program is not executed for safety, and an alarm is issued. A coordinate system number is written into position data in position teaching. To change a coordinate system number after it has been written, use the tool replacement/coordinate replacement shift function.
Tool coordinate system number (UT) The tool coordinate system number specifies the coordinate system number of a mechanical interface coordinate system or tool coordinate system. Thus, the coordinate system of the tool is determined. • 0 : The mechanical interface coordinate system is used. • 1 to 10 : The tool coordinate system of a specified tool coordinate system number is used. • F : The coordinate system of the tool coordinate system number currently selected is used.
User coordinate system number (UF) The user coordinate system number specifies the coordinate system number of a world coordinate system or user coordinate system. Thus, the coordinate system of work space is determined. • 0 : The world coordinate system is used. • 1 to 9 : The tool coordinate system of a specified tool coordinate system number is used. • F : The coordinate system of the tool coordinate system number currently selected is used.
Detail position data To display the detail position data, position the cursor to the position number, then press the F5 (POSITION) key.
- 180 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Switching the coordinate system check function The coordinate system check function allows the user to perform FWD/BWD execution easily between two points with different coordinate system numbers. By changing the setting of the following system variable, this function can be switched to one of three specifications. Setting of the system variable $FRM_CHKTYP = -1
$FRM_CHKTYP = -2 $FRM_CHKTYP = 2
Description Disables FWD/BWD execution between two points having different coordinate system numbers. Enables FWD/BWD execution between two points having different numbers. Enables FWD/BWD execution between two points having different numbers, and changes the current coordinate system number ($MNUFRAME_NUM or $MNUTOOL_NUM) to the number specified in the position data in the program.
The system variable is explained, using a specific program as an example. Example 1: UTOOL_NUM = 1 2: JP [1] 100% FINE (specified with P [1] UT = 1) 3: JP [2] 100% FINE (specified with P [2] UT = 2) • If $FRM_CHKTYP = -1, FWD: An alarm is generated if the coordinate system numbers differ on the third line. BWD: If the currently selected tool coordinate system number is 2, an alarm is generated when the second line is executed after BWD execution on the third line. • If $FRM_CHKTYP = -2, FWD: An alarm is not generated on the third line. The third line is executed with a tool coordinate system number of 2. (Operation is performed at the specified position.) BWD: As with FWD, an alarm is not generated. • If $FRM_CHKTYP = 2, An alarm is not generated in the same way as for $FRM_CHKTYP = -2. FWD: An alarm is not generated on the third line. The third line is executed with a tool coordinate system number of 2. Immediately after the start of the operation for the third line, the tool coordinate system number of the system is changed to 2. BWD: An alarm is not generated on the second line. Immediately after the start of the operation for the second line, the tool coordinate system number of the system is changed to 1.
NOTE Regardless of the value of $FRM_CHKTYP, BWD operation between arcs having different coordinate system numbers result in an alarm. - 181 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Joint coordinates Position data consisting of joint coordinates is defined using angular displacements with respect to the joint coordinate system on the base side of each articulation.
Fig. 4.3.2 (e) Position Data (Joint Coordinates)
Fig. 4.3.2 (f) Joint Coordinate System
Detail position data Detailed position data is displayed when F5 POSITION is pressed. You can chose between Cartesian coordinates and axial coordinates by pressing F5 [REPRE].
Position variable and position register In a motion instruction, position data is represented by a position variable (P[i]) or position register (PR[i]). Usually, a position variable is used.
Fig. 4.3.2 (g) Position Variable and Position Register
- 182 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Example
1: J 2: L 3: L
P[12] 30% FINE PR[1] 300mm/s CNT50 PR[R[3]] 300mm/s CNT50
- Position variable The position variable is the variable usually used to hold position data. In motion instruction teaching, position data is automatically saved. When Cartesian coordinates are taught, the following Cartesian coordinate system and coordinate system number are used: • Coordinate system of the tool coordinate system number currently selected (UT = 1 to 10) • World coordinate system (UF = 0)(When $USE_UFRAME is FALSE) In playback, the following Cartesian coordinate system and coordinate system number are used: • Coordinate system of the user coordinate system number currently selected (UF = 0 to 9) (When $USE_UFRAME is TRUE)
NOTE The system variable $USE_UFRAME cannot be used if the user coordinate system input function option is not provided. When a position is copied, • Coordinate system with the specified tool coordinate system number (UT = 1 to 10) • Coordinate system with the specified user coordinate system number (UF = 0 to 9)
- Position register The position register functions as a general-purpose register for holding position data. (For position teaching using a position register, see Section 7.4.) When Cartesian coordinates are taught, the following Cartesian coordinate system and coordinate system number are used: • Coordinate system of the tool coordinate system number currently selected (UT = F) • Coordinate system of the user coordinate system number currently selected (UF = F) In playback, the following Cartesian coordinate system and coordinate system number are used: • Coordinate system of the tool coordinate system number currently selected (UT = F) • Coordinate system of the user coordinate system number currently selected (UF = F)
- 183 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
- Position number The position number is used to reference a position variable. A position number is automatically assigned each time a motion instruction is taught and it is reflected in the program. For example, the first position number assigned is P[1], the second P[2], and so on. When a motion instruction is added, it is assigned the position number obtained by incrementing the position number assigned to the most recently added motion instruction by one, regardless of where the newly added instruction is placed in the program. However, this is not the case when a position number is changed. When a position is deleted, the position numbers of other taught points remain unchanged. However, this is not the case when a position number is changed. (For changing a position number, see Section 5.4 ”Changing a Program”.) A comment consisting of up to 16 characters can be described for a position number or position register number. To add a comment, press the ENTER key when the cursor is at the position number or position register number. Example 4: J 5: L
4.3.3
P[11: APPROACH POS ] 30% FINE PR[1: WAIT POS ] 300mm/s CNT50
Feedrate The feedrate specifies the speed at which the robot moves. During program execution, the feedrate is controlled by feedrate overriding. A feedrate override value of 1% to 100% can be used. The unit used to specify a feedrate depends on the motion format taught with a motion instruction.
NOTE The programmed traveling speed cannot exceed the allowable range of the robot. If a speed exceeding the range is programmed, a warning alarm would be issued.
J P[1] 50% FINE When the motion type is joint, a feedrate is specified as the following: • A percentage from 1% to 100% of the maximum feedrate is to be specified. • When the unit is sec, specify the value from 0.1 to 3200sec as the time took for motion. This specification is required, when the time took for motion is important. An operation cannot sometimes takes place in a specified time. • When the unit is msec, specify the value from 1 to 32000msec as the time took for motion.
- 184 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
L P[1] 100mm/sec FINE If the specified motion format is linear motion or circular motion, specify a feedrate as follows: • When the unit is mm/sec, specify a feedrate from 1 to 2000 mm/sec. • When the unit is cm/min, specify a feedrate from 1 to 12000 cm/min. • When the unit is inch/min, specify a feedrate from 0.1 to 4724.4 inch/min. • When the unit is sec, specify the value from 0.1 to 3200sec as the time took for motion. • When the unit is msec, specify the value from 1 to 32000msec as the time took for motion.
L P[1] 50deg/sec FINE When the mode of motion is rotation about the tool center point, specify an angular displacement as follows: • When the unit is deg/sec, specify an angular displacement from 1 to 272 deg/sec. • When the unit is sec, specify the value from 0.1 to 3200sec as the time took for motion. • When the unit is msec, specify the value from 1 to 32000msec as the time took for motion.
Specifying the feedrate with a register The feedrate can be specified with a register. This allows the user to specify the feedrate for an operation instruction after calculating the feedrate using a register. The feedrate can also be specified externally, using group input (GI) or data transfer, for example.
CAUTION This function allows the user to change the feedrate of a robot freely by setting a register. This means that the robot may operate at an unexpected speed depending on the specified register value. When using this function, therefore, specify the register value with great care during both teaching and operation. Format in which an operation instruction is displayed when the feedrate is specified with a register • Joint J P[1] R[i]% FINE • Linear L P[1] R[i]mm/sec FINE • Arc C P[1] P[2] R[i]mm/sec FINE • Pallet operation instruction J PAL_1[A_1] R[i]% FINE J PAL_1[BTM] R[i]% FINE J PAL_1[R_1] R[i]% FINE
- 185 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
NOTE The pallet operation instruction is a software option of palletizing. •
Pallet operation instruction J PAL_1[A_1] R[i]% FINE J PAL_1[BTM] R[i]% FINE J PAL_1[R_1] R[i]% FINE
NOTE The pallet operation instruction is a software option of palletizing. Operation group instruction Asynchronous operation group GP1 JP[1] R[i]% FINE GP2 JP[1] R[i]% FINE
NOTE The operation group instruction is a software option of multimotion. The feedrate for a standard operation instruction is also supported. Search/replace functions Search function The search function is not supported. Search using register items cannot be performed. Replace function Replacement is possible with the operation statement modification item. Replacement using register items cannot be performed. The additional axis feedrate for an operation addition instruction is not supported. In program editing, a range check is not performed on the feedrate (register value). The feedrate (register value) is not automatically converted when the feedrate unit is changed. If the feedrate specification for an operation statement is made with a register, the read-ahead of execution is stopped. (It is possible to specify whether to stop read-ahead using a system variable. This is described later.) If the value entered in the register is not within the upper and lower limits, or if the value is of a type other than those appropriate to a feedrate (integer/real), an alarm is generated during execution. Unit % Sec Msec mm/sec cm/min
Allowable range 1 to 100 0.1 to 3200.0 1 to 32000 1 to 2000 1 to 12000
- 186 -
Integer (*1) Real/effective up to the first decimal place. (*1) Integer (*1) Integer (*1) Integer
4 PROGRAM STRUCTURE
B-82594EN-4/01
Unit inch/min deg/sec
Allowable range 0.1 to 4724.2 1 to 272
(*2) Real/effective up to the first decimal place. (*3) Integer
The allowable range (maximum value) differs depending on the robot type. *1: System variable $MPR_GRP.$SPPEDLIM *2: System variable $MPR_GRP.$SPPEDLIM/10 *3: System variable $MPR_GRP.$ROTSPEEDLIM * 180/3.1415 Read-ahead can be enabled. If the feedrate specification for an operation statement is made with a register, the read-ahead of execution is stopped. It is possible to specify whether to stop read-ahead using the following system register. The default is FALSE (read-ahead is stopped). $RGSPD_PREXE = TRUE: Enables read-ahead. = FALSE: Disables read-ahead.
NOTE If the read-ahead of the register feedrate is enabled with the above system variable, it is possible that the new value is not reflected in the operating speed, causing the robot to move with the old value, depending on the timing at which the register value is changed. If read-ahead of the register feedrate is enabled, it is necessary to take appropriate measures such as interlocking or not changing the value of the register used for the feedrate during program execution. 10: R [1] = 100 11:J P[5] R[1]% FINE 12:R[1]=10 14:J P[6] R[1]% FINE If read-ahead is enabled, 100 on line 10, not 10 on line 12, is used for the operating speed on line 14.
4.3.4
Positioning Path The positioning path defines the method of ending robot operation in a motion instruction. Three positioning path modes are available: • FINE positioning path • CNT positioning path • Corner distance specification: Available only when the high-precision focus function is ordered. For an explanation of corner distance specification, see Subsection 4.3.6.
- 187 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
FINE positioning path J P[i] 50% FINE When the FINE positioning path is specified, the robot stops at a target point before moving to the next target point.
CNT positioning path J P[i] 50% CNT50 When the CNT positioning path is specified, the robot approaches a target point but does not stop at the point and moves to the next point. How closely the robot must approach a target point can be defined by specifying a value from 0 to 100. When 0 is specified, the robot moves the nearest path to the destination position but moves to the next target point without stopping at the target point. When 100 is specified, the robot moves along the farthest path to the target point because the robot does not decelerate near the target point and it starts to move to the next target point soon.
NOTE 1 When an instruction such as a wait instruction is taught, the robot stops at the target point to execute that instruction. 2 Several short-distance, high-speed motions that are performed continuously with CNT specified may be decelerated, even if the specified CNT value is 100.
Fig. 4.3.4 Robot motion path using continuous termination type
4.3.5
Additional Motion Instructions An additional motion instruction causes the robot to perform a particular job. The following additional motion instructions are available: • Wrist joint motion instruction (Wjnt) • Acceleration override instruction (ACC) - 188 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
• • • • • • • • • •
Skip instruction (Skip,LBL[i]) Offset condition instruction (Offset) Direct offset condition (Offset,PR[i]) Tool offset instruction (Tool_Offset) Direct tool offset instruction (Tool_Offset, PR[i]) Incremental instruction (INC) Simultaneous EV instruction (EV i%) Independent EV instruction (Ind.EV i%) Path instruction (PTH) Pre-execution instruction (pre-execution/post-execution) (→Section 9.8, ”Pre-execution Instruction”) • Corner speed ratio add instruction For an explanation of the corner speed ratio add instruction, see Subsection 4.3.6. When teaching an additional motion instruction, move the cursor after the motion instruction, then press the F4 [CHOICE] to display the list of additional motion instructions. Then select a desired additional motion instruction.
Wrist joint motion instruction L P[i] 50% FINE Wjnt
The wrist joint motion instruction specifies a path control operation that does not control the attitude of the wrist. (In the standard mode, the attitude of the wrist is controlled until the end of the motion.) The wrist joint motion instruction is used when a linear motion or circular motion is specified. When the wrist joint motion instruction is used, the attitude of the wrist changes during the motion. However, the tool center point can move along a programmed path without causing the wrist axis to invert due to a wrist axis singular point.
- 189 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Acceleration override J P[1] 50% FINE ACC80
This instruction specifies the percentage of the acceleration/deceleration rate during motion. When the acceleration override is reduced, acceleration time will be long (Acceleration and deceleration are done slowly). To perform a potentially dangerous operation such as hot water scooping, use a value of less than 100%. When acceleration override is raised, acceleration time will be short (Acceleration and decelerate are done quickly). For portions where the operation is felt to be very slow, use a value greater than 100%. The time used for motion from a starting point to a destination point depends on the acceleration override. The acceleration override value ranges from 0 to 150%. Acceleration override is programmed at the destination position.
Fig. 4.3.5 (a) Acceleration Override
CAUTION If the acceleration override value is large, awkward movement and vibration may occur. This may cause a servo alarm. If this occurs with an operation instruction to which an acceleration/deceleration override instruction is added, either reduce the acceleration/deceleration override value or delete the accelerate/deceleration override instruction.
- 190 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Skip instruction SKIP CONDITION [I/O] = [value]
J P[1] 50 FINE Skip,LBL[3]
A skip instruction causes a jump to a branch destination label if the skip condition is not satisfied. If the skip condition is satisfied while the robot is moving to a target point, the robot cancels the motion and program execution proceeds to the program statement on the next line. If the skip condition is not satisfied, program execution skips (jumps) to the line of the branch destination label after completion of the robot motion. The skip condition instruction specifies, in advance, a skip condition (condition for executing a skip instruction) to be used with it. Before a skip instruction can be executed, a skip condition instruction must be executed. A skip condition once specified is valid until the execution of the program is completed, or the next skip condition instruction is executed. (For the branch instructions, see Section 4.7. For the skip condition instruction, see Section 4.9.)
Fig. 4.3.5 (b) Skip Instruction
Example
1: 2: 3: 4: 5: 6:
SKIP CONDITION DI[1] = ON J P[1] 100% FINE L P[2] 1000mm/sec FINE Skip, LBL[1] L P[3] 50% FINE LBL[1] J P[4] 50% FINE
High-speed skip - Function outline (1) The position of the robot when the skip conditions are met can be stored in programmed position registers. (2) Digital servo control stops the robot quickly by developing the maximum torque of the motor when the robot detects that the skip conditions are met. - 191 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
- Use method The high-speed skip function can be used in program teaching. There is no need to set system variables.
Program teaching a) b)
Teaching skip conditions The skip conditions for the high-speed skip function are taught in the same way as the ordinary skip function. Teaching a high-speed skip instruction (an additional operation instruction) In the same way as the ordinary line skip instruction, select the high-speed skip instruction from the additional operation instruction menu.
Motion modify 1 Skip, LBL, PR 3 Skip, LBL,
JOINT 30%
High-speed skip instruction Ordinary skip instruction
c. Specify the label, position register, and position storage format. Skip, LBL[10], PR[5]=LPOS or JPOS
[Sample program]
: 8: SKIP CONDITION DI[3]=ON : 10: LP[2]500mm/sec FINE 11: LP[3]100mm/sec : SKIP, LBL[10], PR[5]=LPOS : : 30: LBL[10]
Explanation of the execution example When DI[3] is turned on during execution of the 11th line, the current position is stored in a form of Cartesian coordinates. When DI[3] is not turned on during execution of the 11th line, a branch to LBL[10] is made after the execution of the 11th line ends. In this case, no position data is stored in PR[5].
- Limitations and notes <1> Position read error As the programmed operation speed is slower, the position read accuracy under skip conditions becomes higher. (As a guideline, an error of about 1.5 mm is generated for 100 mm/sec. The error is proportional to the speed.)
- 192 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
OFFSET instruction Offset,PR[2] (UFRAME [1]) J P[1] 50% FINE Offset
The OFFSET instruction alters positional information programmed at the destination position by the offset amount specified by a position register, and moves the robot to the altered position. The offset condition is specified by the OFFSET CONDITION instruction. The OFFSET CONDITION instruction specifies the offset amount used by the OFFSET instruction in advance. The OFFSET CONDITION instruction has to be specified before the OFFSET instruction is executed. The specified offset condition is available until the program is finished or the next OFFSET CONDITION instruction is executed: As for the offset condition, the following elements should be specified: • The position register specifies the shifting direction and the shift amount. • When the positional information is expressed in the joint frame, the shift amount of each axis is applied. • When the positional information is expressed in the Cartesian coordinate system, the user frame by which the offset condition is decided should be specified.(See Section 4.12, ”FRAME INSTRUCTION) When it is not specified, the user frame (UF) being selected now is used.(See Section 4.10, ”OFFSET CONDITION INSTRUCTION”)
CAUTION If teaching is made by joint coordinates, changing the user coordinate system does not affect the position variables and position registers. If teaching is performed in cartesian coordinates, and the user coordinate system input option is not used, the position variable is not influenced by the user coordinate system. In other cases, both the position variable and position register are influenced by the user coordinate system. The setting values of the tool frame number (UT) and the configuration (CONF:) are ignored. When you teach or edit the positional information of the motion instruction with the OFFSET option, you teach the position minus the offset amount. - 193 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
When you teach or edit the positional information of the motion instruction with the OFFSET option, the following prompt message is displayed. • Subtract offset data from current pos? Yes The positional information subtracted the offset data is taught. No The positional information is directly taught. • Enter PR index of offset data : Enter the number of the position register specified in the OFFSET CONDITION instruction. • Enter uframe no of offset data : Enter the number of the user frame which is used when the offset amount is subtracted. When the positional information is manually edited with the numerical keys, you can not teach the positional information minus the offset amount. Moreover, even if the position teaching by which the amount of the subtracted correction is effective, the current position will be taken in the following cases. • The specified position register is non-initialization. • ”Ignore Offset command” is set to ENABLED. (See Section 3.15 ”SETTING THE GENERAL ITEMS”) When ”Ignore Offset command” is set to ENABLED, the current position is directly taught as the positional information (The prompt message is not displayed) and the robot stops at the teaching position even if the OFFSET instruction is executed. When the offset amount is changed after the program is paused while the OFFSET instruction is in progress, this change is reflected to the motion after the program is resumed. But, when you change the number of a position register in the OFFSET CONDITION instruction, this change is not reflected in the motion. The robot moves to the offset position at the backward execution.(See Subsection 6.3.2,”Step Test”) This is the same as the following explanation for the direct offset condition instruction.
Direct offset condition instruction J P[1] 50% FINE Offset,PR[2]
The direct offset condition instruction alters positional information by the offset amount directly specified in the position register without using the offset condition specified in the OFFSET CONDITION instruction. The reference frame is specified by the number of the user frame currently selected. - 194 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
CAUTION If teaching is made by joint coordinates, changing the user coordinate system does not affect the position variables and position registers. If teaching is performed in cartesian coordinates, and the user coordinate system input option is not used, the position variable is not influenced by the user coordinate system. In other cases, both the position variable and position register are influenced by the user coordinate system. When you change or edit the motion instruction with the direct offset condition option, you can teach the positional information minus the offset amount. When you teach or edit the motion instruction with the direct offset condition option, the following prompt message is displayed: • Subtract offset data from current pos? Yes Subtract the offset data from the taught position. No The positional information from the directly taught position. When the positional information is manually edited with the numerical keys, you can not teach the positional information minus the offset amount. Moreover, even if the position teaching by which the subtracted offset amount is effective, the current position will be taught as it is in the following cases: • The specified position register is non-initialized. • The position register number used by direct offset condition instruction is non-initialized. • ”Ignore Offset command” is set to ENABLED.(See Section 3.15 ”SETTING THE GENERAL ITEMS”) When ”Ignore Offset command” is set to ENABLED, the current position is directly taught as the positional information (The prompt message is not displayed) and the robot stops at the teaching point even if the offset instruction is executed.
Fig. 4.3.5 (c) Offset Instruction
- 195 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Example 1
1: OFFSET CONDITION PR[1] 2: J P[1] 100% FINE 3: L P[2] 500mm/sec FINE Offset
Example 2
1: J 2: L
P[1] 100% FINE P[2] 500mm/sec FINE Offset, PR[1]
Tool offset instruction TOOL_OFFSET_CONDITION PR[2] ( UTOOL[1] ) J P[1] 50% FINE Tool_offset
A tool offset instruction moves the robot to the position shifted from the target position, recorded in the position data, by the offset specified in the tool offset conditions. The condition when the offset is applied is specified by a tool offset condition instruction. A tool offset condition instruction specifies the offset condition used in a tool offset instruction. Execute a tool offset condition instruction before executing the corresponding tool offset instruction. Once the tool offset condition has been specified, it remains effective until the program terminates or the next tool offset condition instruction is executed. Note the following when specifying tool offset conditions. • The position register specifies the direction in which the target position shifts, as well as the amount of the shift. • The tool coordinate system is used for specifying offset conditions. • When the number of a tool coordinate system is omitted, the currently selected tool coordinate system is used. When a motion statement which includes a tool offset instruction is taught or a certain position is modified, the position to which the offset is not to be applied can be taught. When a motion statement which includes a tool offset instruction is taught or a certain position is modified, the system prompts the operator to respond to enter data in response to the following messages. • Subtract tool offset data? Pressing the YES soft key subtracts the tool offset from the position data and the robot is taught the new position. Pressing the NO soft key stores the current position as the position data. • Enter PR index of tool offset data? Specify the position-register number specified by the tool offset condition instruction. • Enter tool no. of tool offset data? Specify the number of the tool coordinate system in which the offset is to be specified. - 196 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
When the position data is manually modified with the numeric keys, the position is taught without subtracting the offset. Even when teaching of the position from which the offset is subtracted is enabled, the current position is stored in the following cases. • When the specified position register has not yet been initialized • When ”Ignore Tool-offset” is set to ENABLED. (See Section 3.16 ”SETTING THE GENERAL ITEMS”.) When ”Ignore Tool-offset” is set to ENABLED, the current position is taught as position data (no prompt messages are output) and the robot is moved to the taught position, even if a tool offset instruction is executed. When the robot is temporarily stopped during the execution of a tool offset instruction and the shift distance is modified, the modified distance is used in the resumed movement. When a position register number specified by a tool offset condition instruction is modified, the modified number is not used. In backward execution (See Subsection 6.3.2, ”Step Test”), the robot is moved to the position to which the offset has been applied. This also applies to the direct tool offset instruction, described next.
Direct tool offset instruction J P[1] 50% FINE Tool_Offset, PR[2]
The robot moves according to the offset stored in the specified position register, ignoring the tool offset conditions specified by the tool offset condition instruction. The currently selected tool coordinate system is used. When a motion statement which includes a direct tool offset instruction is taught or a certain position is modified, the position to which the offset is not to be applied can be taught. When a motion statement which includes a direct tool offset instruction is taught or a certain position is modified, the system prompts the operator to enter data in response to the following messages. • Subtract tool offset data? Pressing the YES soft key subtracts the tool offset from the position data and the robot is taught the new position. Pressing the NO soft key stores the current position as position data. When the position data is manually modified with the numeric keys, the position is taught without subtracting the offset. When teaching of the position from which the offset is subtracted is enabled, the current position is stored in the following cases. • When the specified position register has not yet been initialized - 197 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
•
When the direct tool offset instruction has not specified the number of a position register • When ”Ignore Tool-offset” is set to ENABLED. (See Section 3.16 ”SETTING THE GENERAL ITEMS”.) When ”Ignore Tool-offset” is set to ENABLED, the current position is taught as position data (no prompt messages are output) and the robot is moved to the taught position even if a tool offset instruction is executed.
Fig. 4.3.5 (d) Tool Offset Instruction
Example 1
1: TOOL_OFFSET CONDITION PR[1] 2: J P[1] 100% FINE 3: L P[2] 500mm/sec FINE Tool_Offset
Example 2
1: J P[1] 100% FINE 2: L P[2] 500mm/sec FINE Tool_Offset, PR[1]
Incremental instruction J P[1] 50% FINE INC
The incremental instruction uses the positional data in the motion instruction as the incremental amount from the current position, and causes the robot to move to the destination position that the incremental amount is added to the current position. This means that the incremental motion amount from the current position is recorded in the positional data in the motion instruction. The incremental condition is specified by the following elements: • When the positional data is joint frame value, the incremental amount of each axis is applied.
- 198 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
•
• •
When the positional variable (P[]) is used as the positional data, the reference user frame is specified by the number of the user frame which is specified in the positional data. However, the frame is verified.(Cartesian coordinate system reference) When the position register is used as the position data, the reference frame is the current user frame. When the INC instruction is used with the OFFSET instruction, the type of the positional data in the motion instruction should be corresponding to the type of the positional register for the offset. In this case, the offset amount is used as the offset amount of the specified incremental amount.
Fig. 4.3.5 (e) Incremental instruction
Example 1
1: J 2: L
P[1] 100% FINE P[2] 500mm/sec FINE INC
Note the following when teaching the incremental instruction (See Subsection 5.3.4, ”Teaching an Supplementary Motion Instruction”): • Adding the INC option causes the positional data to be non-initialized. • When the motion instruction with the INC option is taught, the positional data is set to be non-teaching. • Editing the position in the motion instruction with the INC option removes the INC option automatically. When the motion instruction with the INC option is paused and the position data is changed, that changes is not immediately reflected. To move the robot to the changed position, resume the program from the just previous motion instruction.
- 199 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Simultaneous EV instruction J P[1] 50% FINE EV 50%
The additional axis speed instruction (synchronous) moves the robot in sync with the additional axis. When this instruction is used, the robot and additional axis operations are synchronized as follows: • If the robot operation time is longer than the additional axis operation time, the additional axis operation is synchronized with the robot operation. • If the additional axis operation time is longer than the robot operation time, the robot operation is synchronized with the additional axis operation. The extended axis speed is specified as a ratio (1% to 100%) to the maximum travel speed of the extended axis.
Independent EV instruction (Ind.EV i%) J P[1] 50% FINE Ind.EV 50%
The additional axis speed instruction (asynchronous) moves the robot synchronously with the additional axis. When this instruction is used, the robot and the additional axis start moving at the same time, but stop at different times because they are not synchronized. The extended axis speed is specified as a ratio (1% to 100%) to the maximum travel speed of the extended axis. If a motion statement is not accompanied with either extended axis speed instruction, the extended axis moves in synchronization with the speed of the robot.
- 200 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Path instruction J P[1] 50% Cnt10 PTH
This function is designed to improve the performance of continuous motion (the termination type is Cnt1 to Cnt100) when the robot moves through a short distance. In a motion where the robot moves through a short distance, the robot speed cannot be increased to the speed specified by a motion statement. For this reason, in an operation statement for which the positioning format is ”FINE,” operation planning for such an operation must be based on the ”attainable speed,” the speed that the robot can actually attain, rather than the specified speed. (Motion planning entails calculating the path along which the robot will travel, before actual operation.) By using this instruction, operation planning is performed using the ”attainable speed” in a CNT operation. The use of this function enables the following effects in normal operation: • Improvement in cycle time • Improvement in path accuracy This function is more effective as the movement distance is shorter and the Cnt value is smaller (the value n in Cntn is smaller). When using this function, note the following: In the following cases, use of the PTH instruction may actually incur a longer cycle time: Before using this function, therefore, confirm its effect. • A large Cn t value is specified in a motion statement. • A motion statement causes the robot to move through a long distance. • Successive Cnt motion statements appear.
CAUTION Some motion instructions that use the PTH switch might cause jerky motion or vibration. If the motion is attached to PTH has a vibration, delete the PTH motion option.
- 201 -
4 PROGRAM STRUCTURE
4.4
B-82594EN-4/01
PALLETIZING INSTRUCTIONS Palletizing is a function for orderly stacking of workpieces by only teaching several representative points. (See Section 10.1.)
Fig. 4.4 Palletizing
The following palletizing instructions are available: • Palletizing instruction PALLETIZING-B, BX, E, EX • Palletizing motion instruction L PAL_i [BTM] 100 % FINE • Palletizing end instruction PALLETIZING-END-_i
4.4.1
Palletizing Instruction Based on the value held in the palletizing register, the palletizing instruction calculates the position of the current stack point from a stacking pattern and the position of the current path from a path pattern. It then writes the found values into the position data of a palletizing motion instruction.
Fig. 4.4.1 Palletizing Instruction
Palletizing is divided into four palletizing patterns according to the piling and path patterns (See Section 10.2).
- 202 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Palletizing patterns For pallet instructions, palletizing is divided into the following palletizing patterns. Table 4.4.1 Palletizing Patterns Allowable palletizing
Pattern B BX E EX
4.4.2
Simple piling pattern and single path pattern Simple piling pattern and multiple path patterns Complex piling pattern and single path pattern Complex piling pattern and multiple path patterns
Palletizing Motion Instruction The palletizing motion instruction is a motion instruction that uses three path points - an approach point, stack point, and retraction point - as position data. This instruction is dedicated to palletizing. Each palletizing instruction rewrites such position data.
Fig. 4.4.2 Palletizing Motion Instruction
4.4.3
Palletizing End Instruction The palletizing end instruction increments or decrements the palletizing register.
Fig. 4.4.3 Palletizing End Instruction
Example
1: 2: L 3: L 4: 5: L 6:
- 203 -
PALLETIZING-B_3 PAL_3[ A_1 ] 100mm/sec CNT10 PAL_3[ BTM ] 50mm/sec FINE HAND1 OPEN PAL_3[ R_1 ] 100mm/sec CNT10 PALLETIZING-END_3
4 PROGRAM STRUCTURE
4.5
B-82594EN-4/01
REGISTER INSTRUCTIONS The register instructions perform arithmetic operations on registers. The following register instructions are available:
• Register instructions • Position register instructions • Position register axis instructions • Palletizing register instructions In register operations, polynomial operations such as those shown below are possible: Example 1: R[2]=R[3]-R[4]+R[5]-R[6] 2: R[10]=R[2]*[100/R[6] The following restrictions are imposed: • Up to five operators can be written on a single line. Example 1: R[2]=R[3]+R[4]+R[5]+R[6]+R[7]+R[8] Up to five operators • The ”+” and ”-” operators can be mixed on a single line. So can the ”*” and ”/” operators. ”+” and ”-” cannot, however, be mixed with ”*” and ”/”.
- 204 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.5.1
Register Instructions A register instruction performs an arithmetic operation on registers. A register is a variable for holding an integer or a decimal fraction. (For registers, See Section 7.3.) Two hundred registers are provided.
R[i] = (value) The instruction, R[i] = (value), loads a value into a specified register.
Fig. 4.5.1 (a) Instruction R[i] = (value)
Example
1: R[1] = RI[3] 2: R[R[4]] = AI[R[1]]
R[i] = (value) + (value) The instruction, R[i] = (value) + (value), loads the sum of two values into a specified register.
R[i] = (value) - (value) The instruction, R[i] = (value) - (value), loads the difference between two values into a specified register.
R[i] = (value) * (value) The instruction, R[i] = (value) * (value), loads the product of two values into a specified register.
R[i] = (value) / (value) The instruction, R[i] = (value) / (value), loads the quotient of two values into a specified register. - 205 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
R[i] = (value) MOD (value) The instruction, R[i] = (value) MOD (value), loads the remainder (value after decimal point) of the quotient of two values into a specified register.
R[i] = (value) DIV (value) The instruction, R[i] = (value) DIV (value), loads the integer of the quotient of two values into a specified register. R [ i ] = ( x - ( x MOD y ) ) / y
Fig. 4.5.1 (b) Arithmetic Register Instruction
Example
3: R[3:flag] = DI[4]+PR[ 1, 2 ] 4: R[ R[4] ] = R[1]+1
- 206 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.5.2
Position Register Instructions A position register instruction performs an arithmetic operation on position registers. A position register instruction can load position data, the sum of two values, or the difference of two values, into a specified position register. A position register instruction uses the same format as a register instruction. A position register is a variable for holding position data (x,y,z,w,p,r). (For position registers, See Section 7.4.) Ten position registers are provided.
NOTE Before using position register instructions, lock position registers by specifying LOCK PREG. When position register instructions are used with the position registers unlocked, operation may become tight. For the LOCK PREG instruction, see Section 9.6, ”POSITION REGISTER LOOK-AHEAD EXECUTION FUNCTION.”
PR[i] = (value) The instruction, PR[i] = (value), loads position data into a specified position register.
Fig. 4.5.2 (a) Instruction PR[i] = (value)
Example
1: PR[1] = Lpos 2: PR[ R[4] ] = UFRAME[ R[1] ] 3: PR[9] = UTOOL[1]
- 207 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
PR[i] = (value) + (value) The instruction, PR[i] = (value) + (value), loads the sum of two values into a specified register. The instruction, PR[i] = (value) - (value), loads the difference of two values into a specified register.
Fig. 4.5.2 (b) PR[i] Arithmetic Instruction
Example
4.5.3
4: PR[3] = PR[3]+Lpos 5: PR[4] = PR[ R[1] ]
Position Register Axis Instructions A position register axis instruction performs an arithmetic operation on position register elements. i of PR[i,j] represents a position register number, and j of PR[i,j] represents a position register element number. The position register axis instructions can load the value of one position data element, or the sum, difference, product, or quotient of two values into a specified position register element. A position register axis instruction uses the same format as a register instruction.
Fig. 4.5.3 (a) Format of PR[i,j]
- 208 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
PR[i,j] = (value) The instruction, PR[i,j] = (value), loads the value of a position data element into a position register element.
Fig. 4.5.3 (b) Instruction PR[i,j] = (value)
Example
1: PR[ 1, 2 ] = R[3] 2: PR[ 4, 3 ] = 324.5
PR[i] = (value) + (value) The instruction, PR[i,j] = (value) + (value), loads the sum of two values into a specified position register element.
PR[i] = (value) - (value) The instruction, PR[i,j] = (value) - (value), loads the difference of two values into a specified position register element.
PR[i] = (value) * (value) The instruction, PR[i,j] = (value) * (value), loads the product of two values into a specified position register element.
PR[i] = (value) / (value) The instruction, PR[i,j] = (value) / (value), loads the quotient of two values into a specified position register element.
R[i] = (value) MOD (value) The instruction, R[i] = (value) MOD (value), loads the remainder (value after decimal point) of the quotient of two values into a specified register. - 209 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
R[i] = (value) DIV (value) The instruction, R[i] = (value) DIV (value), loads the integer of the quotient of two values into a specified register. R [ i ] = ( x - ( x MOD y ) ) / y
Fig. 4.5.3 (c) PR[i,j] Arithmetic Instruction
Example
4.5.4
1: PR[ 3, 5 ] = R[3]+DI[4] 2: PR[ 4, 3 ] = PR[ 1, 3 ]-3.528
Arithmetic Palletizing Register Instructions An arithmetic palletizing register instruction performs an arithmetic operation on palletizing registers. The arithmetic palletizing register instructions are load position data, the sum of two values, or the difference between two values. An arithmetic palletizing register instruction uses the same format as a register instruction. A palletizing register holds palletizing register elements (j,k,l). A program can use up to 16 palletizing registers. (See Section 7.6.)
- 210 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Palletizing register element For palletizing register elements, elements to be loaded into a palletizing register, or elements to be operated on are specified. Three methods of element specification are available; - Direct specification: A numerical value is directly specified. - Indirect specification: The value of register [i] is specified. - Omitted: The asterisk (*) specifies that no modification is to be made.
Fig. 4.5.4 (a) Format of Palletizing Register Elements
PL[i] = (value) The instruction, PL[i] = (value), loads (assigns) palletizing register elements into a specified palletizing register.
Fig. 4.5.4 (b) Instruction PL [ i ] = (value)
Example
1: PL[1] = PL[3] 2: PL[2] = [ 1, 2, 1 ] 3: PL[ R[3] ]= [ *, R[1], 1 ]
PL[i] = (value) (operator) (value) The instruction, PL[i] = (value) (operator) (value), performs an arithmetic operation, then loads the result of the operation into a specified palletizing register.
Fig. 4.5.4 (c) Instruction PL [ i ] = (value) (operator) (value)
Example
1: PL[1] = PL[3]+[ 1, 2, 1 ] 2: PL[2] = [ 1, 2, 1 ]+[ 1, R[1], * ]
- 211 -
4 PROGRAM STRUCTURE
4.6
B-82594EN-4/01
I/O INSTRUCTIONS The I/O (input/output signal) instructions are used to change the state of a signal output to peripheral devices and read the state of an input signal.
• • • •
(System) digital I/O instruction Robot (digital) I/O instruction Analog I/O instruction Group I/O instruction
NOTE As for the I/O signal, the logical number need to be allocated to the physical number before using it.(For configuring I/O, See Section 3.1.)
4.6.1
Digital I/O Instructions The digital input signal (DI) and digital output signal (DO) are input/output signals that can be controlled by the user.
R[i] = DI[i] The instruction, R[i] = DI[i] loads, the state of a digital input signal (on = 1/off = 0) into a specified register.
Fig. 4.6.1 (a) Instruction R[i] = DI[i]
Example
1: R[1] = DI[1] 2: R[ R[3] ] = DI[ R[4] ]
DO[i] = ON/OFF The instruction, DO[i] = ON/OFF, turns on or off a specified digital output signal.
Fig. 4.6.1 (b) Instruction DO[i] = ON/OFF
- 212 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Example
3: DO[1] = ON 4: DO[ R[3] ] = OFF
DO[i] = PULSE,[WIDTH] The DO[i] = PULSE, [TIME] instruction inverts the current status of a specified digital output for a specified duration. When no duration is specified, pulse output is executed for the duration specified with $DEFPULSE (0.1-second units).
Fig. 4.6.1 (c) Instructions DO[i] = PULSE,(WIDTH)
Example
5: DO[1] = PULSE 6: DO[2] = PULSE, 0.2sec 7: DO[ R[3] ] = PULSE, 1.2sec
DO[i] = R[i] The instruction, DO[i]=R[i],turns on or off a specified digital output signal according to the value of a specified register. When the value of the specified register is 0, the digital output signal is turned off. When the value of the specified register is other than 0, the digital output signal is turned on.
Fig. 4.6.1 (d) Instruction DO[i] = R[i]
Example
4.6.2
7: DO[1] = R[2] 8: DO[ R[5] ] = R[ R[1] ]
Robot I/O Instructions The robot input signal (RI) and robot output signal (RO) are input/output signals that can be controlled by the user.
R[i] = RI[i] The instruction, R[i] = RI[i], loads the state of a robot input signal (on = 1/off = 0) into a specified register.
Fig. 4.6.2 (a) Instruction R[i] = RI[i]
Example
1: R[1] = RI[1] 2: R[ R[3] ] = RI[ R[4] ]
- 213 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
RO[i] = ON/OFF The instruction, ROD[i] = ON/OFF, turns on or off a specified robot digital output signal.
Fig. 4.6.2 (b) Instruction RO[i] = ON/OFF
Example
3: RDDO[1] = ON 4: RDDO[ R[3] ] = OFF
RO[i] = PULSE,[WIDTH] The RO[i] = PULSE,[TIME] instruction inverts the current status of a specified digital output for a specified duration. When no duration is specified, pulse output is executed for the duration specified with $DEFPULSE (0.1-second units).
Fig. 4.6.2 (c) Instruction of RO[i] = PULSE,[WIDTH]
Example
5: RO[1] = PULSE 6: RO[2] = PULSE, 0.2sec 7: RO[ R[3] ] = PULSE, 1.2sec
RO[i] = R[i] The instruction, RO[i] = R[i], turns on or off a specified robot output signal according to the value of a specified register. When the value of the specified register is 0, the robot output signal is turned off. When the value of the specified register is other than 0, the robot output signal is turned on.
Fig. 4.6.2 (d) Instruction RO[i] = R[i]
Example
7: RO[1] = R[2] 8: RO[ R[5] ] = R[ R[1] ]
- 214 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.6.3
Analog I/O Instructions Analog input (AI) and analog output (AO) signals indicate levels as a value on a continuum. Thus, the magnitude of a signal represents a temperature, voltage, or other data.
R[i] = AI[i] The R[i] = AI[i] instruction stores the value of an analog input signal in a register.
Fig. 4.6.3 (a) R[i] = AI[i] Instruction
Example
1: R[1] = AI[2] 2: R[ R[3] ] = AI[ R[4] ]
AO[i] = (value) The AO[i] = (value) instruction outputs a value as a specified analog output signal.
Fig. 4.6.3 (b) AO[i] = (value) Instruction
Example
3: AO[1] = 0 4: AO[ R[3] ] = 3276
AO[i] = R[i] The AO[i] = R[i] instruction outputs a register value as an analog output signal.
Fig. 4.6.3 (c) AO[i] = R[i] Instruction
Example
5: AO[1] = R[2] 6: AO[ R[5] ] = R[ R[1] ]
- 215 -
4 PROGRAM STRUCTURE
4.6.4
B-82594EN-4/01
Group I/O Instruction
R [ i ] = GI [ i ] The signal of the group input(GI) and the group output(GO) is that some digital input/output signals are grouped and this is controlled by one instruction. The instruction, R[i]=GI[i],converts the binary value of the specified group input signal to the decimal value and inputs it to the specified register.
Fig. 4.6.4 (a) Instruction R [ i ] = GI [ i ]
Example
7: R[1] = GI[1] 8: R[ R[3] ] = GI[ R[4] ]
GO [ i ] = (value) The GO[i]=(VALUE) instruction sends the binary equivalent of a value on the specified group output lines.
Fig. 4.6.4 (b) Instruction GO [ i ] = ( value)
Example
3: GO[1] = 0 4: GO[ R[3] ] = 32767
GO [ i ] = R [ i ] The GO[i]=R[i] instruction sends the binary equivalent of the contents of specified register on the specified group output lines.
Fig. 4.6.4 (c) Instruction GO [ i ] = R [ i ]
Example
5: GO[1] = R[2] 6: GO[ R[5] ] = R[ R[1] ]
- 216 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.7
BRANCH INSTRUCTIONS A branch instruction causes a branch from one line of a program to another. Four types of branch instructions are supported. • Label instruction • Program end instruction • Unconditional branch instruction • Conditional branch instruction
4.7.1
Label Instruction
LABEL[i] The label instruction (LBL[i]) is used to specify a program execution branch destination. A label is defined with a label definition instruction.
A comment can be added to explain a label. Once a label is defined, it can be used for either an unconditional branch or conditional branch. It is not possible to specify the label number as the indirect addressing. To add a comment, move the cursor to the label number and press the ENTER key.
Fig. 4.7.1 LBL[i] Instruction
Example
1: LBL[1] 2: LBL[ R[3] ]
- 217 -
4 PROGRAM STRUCTURE
4.7.2
B-82594EN-4/01
Program End Instruction
END The program end instruction indicates the end of a program. The execution of a program is terminated by this instruction. If a program is called from another main program, control is returned to the main program.
END Fig. 4.7.2 Program End Instruction
4.7.3
Unconditional Branch Instructions An unconditional branch instruction invariably causes a branch from one line to another in the same program. Two types of unconditional branch instructions are supported. • Jump instruction: Causes a branch to a specified label or program. • Program call instruction: Causes a branch to another program.
Jump instruction JMP LBL[i] The JMP LBL[i] instruction transfers program control to a specified label.
Fig. 4.7.3 (a) JMP LBL[i] Instruction
Example
3: JMP LBL[2:hand open] 4: JMP LBL[ R[4] ]
- 218 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Program call instruction CALL (program) The CALL (program) instruction transfers program control to the first line of another program (subprogram) in order to execute it. When a program end instruction (END) in a called program is executed, control is returned to the instruction immediately after the program call instruction in the calling program (main program). To enter the calling program name, select it with the sub-menu automatically displayed or press F5,STRINGS to enter characters directly.
Fig. 4.7.3 (b) CALL (program) Instruction
Example *)
4.7.4
5: CALL SUB1 6: CALL PROGRAM2
It is possible to set an argument for the program call instruction and use its value in a subprogram. See Subsection 4.7.5, ”Arguments” for Details.
Conditional Branch Instructions A conditional branch instruction causes a branch from one location in a program to another when some condition is satisfied. Two types of conditional branch instructions are available.
•
•
Conditional compare instruction: Causes a branch to a specified label or program when some condition is satisfied. The register conditional compare instruction and I/O conditional compare instruction are available. Conditional select instruction: Causes a branch to a specified jump instruction or subprogram call instruction according to the value of a register.
- 219 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Register conditional compare instruction IF R[i] (operator) (value) (processing) A register conditional compare instruction compares the value stored in a register with another value and, when the compare condition is satisfied, executes processing.
Fig. 4.7.4 (a) Register Conditional Compare Instruction
CAUTION When the contents of a register is compared with the real value using the operator ”=”,the contents does not always correspond to the real value because of the rounding-off error of the contents. To compare with the real value, use the operator without on equal sign.
I/O conditional compare instruction IF (I/O) (operator) (value) (processing) The I/O conditional compare instruction compares the value of an input/output signal with another value. When the comparison condition is satisfied, specified processing is executed.
Fig. 4.7.4 (b) I/O Conditional Compare Instruction 1
Example
7: IF R[1] = R[2], JMP LBL[1] 8: IF AO[2] >= 3000, CALL SUBPRO1 9: IF GI[ R[2] ] = 100, CALL SUBPRO2
- 220 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Fig. 4.7.4 (c) I/O Conditional Compare Instruction 2
Example
10: IF RO[2] <> OFF, JMP LBL[1] 11: IF DI[3] = ON, CALL SUB1
In a conditional branch instruction, multiple conditions can be specified on a single line in the condition statement, using the logical operators (”and” and ”or”). This simplifies the program structure, allowing the conditions to be evaluated efficiently. Instruction format • Logical product (and) IF and and , JMP LBL [3] • Logical sum (or) F or , JMP LBL [3] If the ”and” (logical product) and ”or” (logical sum) operators are used together, the logic becomes complex, impairing the readability of the program and case of editing. For this reason, this function prohibits the use of the logical operators ”and” and ”or” in combination. If multiple ”and” (logical product) or ”or” (logical sum) operators are specified for an instruction on a single line, and one of the operators is changed from ”and” to ”or” or from ”or” to ”and,” all other ”and” or ”or” operators are changed accordingly, and the following message appears: TPIF-062 AND operator was replaced to OR TPIF-063 OR operator was replaced to AND Up to five conditions can be combined with ”and” or ”or” operators on a single line. Example IF and and and and , JMP LBL [3]
- 221 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Pallet register conditional compare instruction IF PR [i] (operator) (value) (processing) The pallet register conditional compare instruction compares the value of the pallet register with the value of another pallet register element. When the comparison is true, specified processing is executed. If 0 is entered in each element, "*" appears. Only a numeric value or remainder specification ca be used for each element to be compared. For the pallet register element, specify the element whose value is to be compared with the value of the pallet register. There are four methods for specification. [i,j,k] Pallet register element Direct specification: Row, column, and stage number (1 to 127) Indirect specification: Value of R [i] Remainder specification: a-b: What results in a remainder of b when divided by a (a: 1 to 127, b: 0 to 127) No specification: * is any value.
Fig. 4.7.4 (d) Pallet Register Element Format
IF PR [i] (operator)(value) Pallet number (1 to 16)
= <>
(processing) JMP LBL [ i] CALL (program name)
PR [ i] [i,j,k] Fig. 4.7.4 (e) Pallet Register Conditional Compare Instruction
Example 12: IF PR[1] = R[2], JMP LBL［1］ 13: IF PR[2]<>［1, 1, 2］, CALL SUB1 14: IF PR[R[3]]<>［*, *, 2-0］, CALL SUB1
Conditional select instruction SELECT R[i] = (value) (processing) = (value) (processing) = (value) (processing) ELSE (processing) The conditional select instruction consists of several register compare instructions. The conditional select instruction compares the value of a register with one or more values, then selects a statement that satisfies the comparison condition. • If the value of a specified register matches one value, the jump instruction or subprogram call instruction corresponding to the value is executed. • If the value of a specified register does not match any of the values, the jump instruction or subprogram call instruction corresponding to ELSE is executed.
- 222 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Fig. 4.7.4 (f) Conditional Select Instruction
Example
4.7.5
11: SELECT R[1] = 1, JMP LBL[1] 12: = 2, JMP LBL[2] 13: = 3, JMP LBL[2] 14: = 4, JMP LBL[2] 15: ELSE, CALL SUB2
Arguments By using ”arguments” and ”argument registers,” it is possible to transfer data between two programs only. Example) In this example, the main program MAIN calls the subprogram PROC_1 with two arguments. PROC_1 can use the values of the arguments with the argument registers. The first argument corresponds to AR[1] while the second argument corresponds to AR[2].
Arguments can be used in macro instructions in the same way.
Argument types The following arguments are supported. Table 4.7.5 (a) Argument types Argument type Example Constant Character string Argument register Register
- 223 -
1, 3.5 ’Perch’ AR[3] R [6]
4 PROGRAM STRUCTURE
B-82594EN-4/01
*1 Available in KAREL programs only. *2 Used as argument registers in subprograms. CALL PROC_1 ( 1, AR[1], R[6]) PROC_1 :
R[1], AR[2], AR[3]
Instructions for which arguments can be set Table 4.7.5 (b) Instructions for Which Arguments Can be Set Instruction Example Program call instruction Macro instruction
CALL SUBPRG (1, R[3], AR[1]) Vacuum hand open (2.5)
CAUTION A program call used for branching with an instruction such as a conditional branch instruction cannot use arguments. This problem can be solved by programming as follows: (Arguments cannot be set) (Arguments can be set) IF R[1]=3, CALL PROC_5 → IF R[1]<>3, JMP LBL[1] CALL PROC_5 (1, R[2]) LBL[1]
Instructions that can use argument registers Table 4.7.5 (c) Instructions That Can Use Argument Registers Instruction Example Right side of an instruction and conditional expression having a register on the left side Right side of the analog output (AO[]) and group output (GO[]) instructions Right side of a conditional expression having analog input/output (AI[]/AO[]) or group input/output (GI[]/GO[]) on the left side Right side of the user coordinate system selection instruction and the tool coordinate system selection instruction Indirect index specification Argument of a program call instruction Argument of a macro instruction
- 224 -
R[1]=AR+R[2]+AR[4]I F R[1]=AR[1], JMP LBL[1] AO[1]=AR[2] GO[1]=AR[2] IF AO[1]=AR[1], JMP LBL[1] WAIT GI[1]<>AR[2], TIMEOUT, LBL[1] UTOOL_NUM=AR[4]
R[AR[1]]=R[AR[2]] DO[AR[1]]=ON CALL SUBPRG1 (AR[5]) hand 3 open (AR[1])
4 PROGRAM STRUCTURE
B-82594EN-4/01
Restrictions on arguments The following restrictions are imposed on arguments: • Up to 10 arguments can be set. • An argument of character string type can be one to sixteen characters in length. (An argument with 0 characters is regarded as being uninitialized.) • An indirect specification cannot be used for an already indirectly specified element of an index. c [AR[1]] ° [R[AR[1]]] • The value stored in an argument register cannot be changed in a subprogram.
Specifying arguments When a program call instruction or macro instruction is specified, the cursor stops at the end of the line. If no arguments need be specified, press the ENTER key or ”→” or ”↓” key to move the cursor to the next line. To display the argument selection submenu, press function key [CHOICE].
Specifying arguments of the constant type To specify an argument of the constant type, press the [CHOICE] function key and select ”1 Constant” from the submenu (see ”Specifying arguments”).
- 225 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Specifying arguments of character type To specify an argument of character type, press function key [CHOICE] and select String from the submenu (see ”Specifying arguments”). The character string type selection menu appears.
When a character string type is selected, the character string selection menu appears.
Select a character string from the menu. The character string is confirmed. 1: CALL PROC_1 (‘Parts ITEM2’) Select Parts ITEM2 from the menu To enter a character string directly, press function key STRINGS from the character type selection menu or the character string selection menu.
- 226 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Press the Enter key to confirm the character string. 1: CALL PROC_1 (‘Tool 12’ )
To change a character string, move the cursor to the character string and press the [CHANGE] function key. The character string type selection menu appears.
Specifying arguments of the argument register type To set an argument of the argument register type, press the [CHOICE] function key and select AR[] from the submenu (see ”Specifying arguments).
1: CALL PROC_1 (AR[ ... ]) Enter an index. 1: CALL PROC_1 (AR[1] ) To toggle between direct and indirect index specifications, press the [INDIRECT] function key. The display changes as follows: AR[R[...]] → AR[AR[...]] → AR[R[...]] → ...
Specifying arguments of the register type To set an argument of register type, press the [CHOICE] function key and select ”4 R[]” from the submenu (see ”Specifying arguments).
1: CALL PROC_1 (R[ ... ]) Enter an index. 1: CALL PROC_1 (R[1] )
- 227 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
To toggle between direct and indirect index specifications, press the [INDIRECT] function key. The display changes as follows: R[R[...]] → R[AR[...]] → R[R[...]] → ...
Adding arguments Move the cursor to ”)” at the end of the line. 1: CALL PROC_1 (1 ) Press function key CHOICE and select an argument type from the submenu (see ”Specifying arguments). A new argument can be added to the cursor position. 1: CALL PROC_1 (1, Constant ) Select an argument type and set a value. 1: CALL PROC_1 (1, Constant ) Select the constant type 1: CALL PROC_1 (1, 2 ) Set a value of ”2”
Inserting arguments Move the cursor to the argument for which an argument is to be inserted.
1: CALL PROC_1 (1, 2 ) Press function key [CHOICE] and select from the submenu (see ”Specifying arguments). A new argument can be inserted at the cursor position. 1: CALL PROC_1 (1..., 2) Select an argument type and set a value, index, and so on. 1: CALL PROC_1 (1, R[ ... ],2) Select the constant type 1: CALL PROC_1 (1, R[3], 2 ) Set a value of ”3”
NOTE An argument cannot be inserted when no argument has been set, and at ”)” at the end of a line. The same submenu reappears; select the argument type.
- 228 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Deleting arguments Position the cursor to the argument to be deleted.
1: CALL PROC_1 (1, 2 , 3) Press function key [CHOICE] and select from the submenu (see ”Specifying arguments”). The argument is deleted from the cursor position. 1: CALL PROC_1 (1, 3 )
NOTE Selecting when no argument has been set, and at ”)” at the end of a line, simply closes the submenu; no argument is deleted.
Specifying argument registers The following explanation uses a register instruction as an example. The selections for the right side of a register instruction are as follows:
To use an argument with the instruction, select AR[] from the menu. 1: R[1]=AR[ ... ] Specify the index. 1: R[1]=AR[ 1 ]
- 229 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
If function key F3 ”Indirect specification” is pressed twice at an element having an index, an argument register can be used for an indirect index specification. 1: WAIT R[R ... ]] When F3 is pressed once 1: WAIT R[AR ... ]] When F3 is pressed again
Notes on using arguments Note the following when specifying arguments: • The contents of an argument are not checked when the argument is specified. If the type of an argument does not match the type of the corresponding one in the subprogram, an error occurs during execution. Example In this example, although a value of AR[1] is assigned to the register in subprogram PROC_1, an argument of character string type is specified in the main program. An error occurs when line 5 of the subprogram is executed.
- 230 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
•
The number of arguments is not checked when arguments are specified. Even if the number of arguments is not correct, no errors occur if the arguments specified in the main program are not used in a subprogram. Example In this example, only one argument is specified in the main program, but two arguments are used in subprogram PROC_1. An error occurs when line 6 of PROC_1 is executed.
Notes on specifying arguments for a program call instruction • •
When the program name is changed, the arguments that have been set are kept intact. When the program call instruction itself is re-specified, not only the program name but all the arguments are deleted.
Notes on specifying arguments for a macro instruction •
When the macro name is changed, those arguments that have been set are kept intact.
Notes on execution As described in ”Notes on using arguments,” the contents and number of arguments to be passed between the calling program and the called program are not checked when they are specified. If an argument is set or used incorrectly, an error occurs on a line where a conflict is detected during program execution. • Check that the number of arguments specified in the main program is equal to that of the arguments used in the subprogram. • If the arguments specified in the main program are not used in the subprogram, an error does not occur. • Check that the contents of the arguments specified in the main program match the types of instructions in the subprogram that use those arguments. • Check that the indexes and values of the specified arguments are set correctly. 1: CALL PROC_1 ( Constant ) An error occurs because the value is uninitialized 2: CALL PROC_1 (R[ ... ]) The index is uninitialized - 231 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
When lines containing these are executed, the error ”INTP-201 Unspecified Statement” occurs.
System variables relating to arguments The argument-attached program call/macro instruction function displays, as selections, the character strings set as system variables when an argument of the character string type is to be selected. These system variables are given below. Table 4.7.5 (d) System Variables Relating to Arguments Item System variable Remarks Single character string type Two-character string Three-characte r string Four word at character entry
$STRING_PRM=TRUE/FALSE Standard value=FALSE
(Note)
$ARG_STRING[i].$TITLE (i = 1 to 10) $ARG_STRING[i].$ITEMJ (i = 1 to 10, j=1 to 20) $ARG_WORD [i](i = 1 to 5)
More than 1 and up to 16 characters(Note) Up to 16 characters(Note) Up to 7 characters(Note)
NOTE Arguments of character string is able to use on KAREL program only.
- 232 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.8
WAIT INSTRUCTIONS A wait instruction is used to stop program execution for a specified period of time or until a condition is satisfied. Two types of wait instructions are available.
• •
4.8.1
Time-specified wait instruction: Waits program execution for a specified period of time. Conditional wait instruction: Waits program execution until a specified condition is satisfied or a specified period of time has elapsed.
Time-specified Wait Instruction
WAIT (TIME) The time-specified wait instruction waits program execution for a specified period of time (in seconds).
Fig. 4.8.1 Time-Specified Wait Instruction
Example
4.8.2
1: WAIT 2: WAIT 10.5sec 3: WAIT R[1]
Conditional Wait Instructions
WAIT (condition) (processing) A conditional wait instruction waits program execution until a specified condition is satisfied or a specified period of time has elapsed. Two methods of specifying time-out processing are available: • If no processing is specified, program execution is waits until a specified condition is satisfied. • Timeout, LBL[i] is transferred to a specified label if the specified condition is not satisfied until the time specified in 14 WAIT timeout on the system configuration screen.
- 233 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Register conditional wait instruction The register conditional wait instruction compares the value of a register with another value, and waits until the comparison condition is satisfied,
Fig. 4.8.2 (a) Register Conditional Wait Instruction
Example
3: WAIT R[2] <> 1, TIMEOUT LBL[1] 4: WAIT R[ R[1] ]> = 200
I/O conditional wait instruction The I/O conditional wait instruction compares the value of an input/output signal with another value, and waits until the comparison condition is satisfied.
Fig. 4.8.2 (b) I/O Conditional Wait Instruction 1
Fig. 4.8.2 (c) I/O Conditional Wait Instruction 2
Example
5: WAIT DI[2] <> OFF, TIMEOUT LBL[1] 6: WAIT RI[ R[1] ] = R[1]
- 234 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
NOTE Off-: The falling edge of a signal is regarded as being a detection condition. The condition is not satisfied while the signal remains off. The detection condition is satisfied when the signal changes from the on state to the off state. On+: The rising edge of a signal is regarded as being a detection condition. The condition is not satisfied while the signal remains on. The detection condition is satisfied when the signal changes from the off state to the on state.
Error condition wait instruction The error condition wait instruction waits for the occurrence of an alarm having a specified error number.
Fig. 4.8.2 (d) Error condition wait instruction
NOTE An error number is specified with an alarm ID followed by an alarm number. Error number = aabbb where aa = alarm ID bbb = alarm number For an explanation of alarm IDs and numbers, refer to the alarm code table given in the operator’s manual. Example For SRVO-006 HAND broken, the servo alarm ID is 11, and the alarm number is 006. Thus, Error number = 11006 In the condition wait instruction, multiple conditions can be specified on a single line in the condition statement, using the logical operators (”and” and ”or”). This simplifies the program structure, allowing the conditions to be evaluated efficiently. Instruction format • Logical product (and) WAIT and and • Logical sum (or) WAIT or or - 235 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
If the ”and” (logical product) and ”or” (logical sum) operators are used in combination, the logic becomes complex, impairing the readability of the program and the ease of editing. For this reason, this function prohibits the use of the logical operators ”and” and ”or” in combination. If multiple ”and” (logical product) or ”or” (logical sum) operators are specified for an instruction on a single line, and one of the operators is changed from ”and” to ”or” or from ”or” to ”and,” all other ”and” or ”or” operators are changed accordingly, and the following message appears: TRIF-062 AND operator was replaced to OR TRIF-063 OR operator was replaced to AND Up to five conditions can be combined with ”and” or ”or” operators on a single line. Example) WAIT and and and and
- 236 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.9
SKIP CONDITION INSTRUCTION The skip condition instruction specifies, in advance, a skip condition (condition for executing a skip instruction) used with a skip instruction. Before a skip instruction can be executed, a skip condition instruction must be executed. A skip condition once specified is valid until the execution of the program is completed, or the next skip condition instruction is executed.
A skip instruction causes a jump to a branch destination label if the skip condition is not satisfied. If the skip condition is satisfied, a skip instruction causes the robot to suspend the current motion toward a target point, instead executing the program instruction on the next line. If the skip condition is currently not satisfied, a skip instruction causes a jump to a destination label upon the completion of the current motion.
Fig. 4.9 (a) Skip Condition Instruction (Register Condition)
Fig. 4.9 (b) Skip Condition Instruction (I/O condition 1)
- 237 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Fig. 4.9 (c) Skip Condition Instruction (I/O condition 2)
Example
1: 2: 3: 4: 5: 6:
SKIP CONDITION DI[ R[1] ] <> ON J P[1] 100% FINE L P[2] 1000mm/sec FINE Skip, LBL[1] J P[3] 50% FINE LBL[1] J P[4] 50% FINE
NOTE Off-: The falling edge of a signal is regarded as being a detection condition. The condition is not satisfied while the signal remains off. The detection condition is satisfied when the signal changes from the on state to the off state. On+: The rising edge of a signal is regarded to be a detection condition. The condition is not satisfied while the signal remains on. The detection condition is satisfied when the signal changes from the off state to the on state.
Fig. 4.9 (d) Skip Condition Instruction (Error condition)
- 238 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
NOTE An error number is specified with an alarm ID followed by an alarm number. Error number = aabbb where aa = alarm ID bbb = alarm number For an explanation of alarm IDs and numbers, refer to the alarm code table in the operator’s manual. Example For SRVO-006 Hand broken, the servo alarm ID is 11, and the alarm number is 006. Thus, Error number = 11006 In the skip condition instruction, multiple conditions can be specified on a single line in the condition statement, using the logical operators (”and” and ”or”). This simplifies the program structure, allowing the conditions to be evaluated efficiently. Instruction format • Logical product (and) SKIP CONDITION and and • Logical sum (or) SKIP CONDITION or or If the ”and” (logical product) and ”or” (logical sum) operators are used in combination, the logic becomes complex, impairing the readability of the program and case of editing. For this reason, this function prohibits the use of the logical operators ”and”and ”or” in combination. If multiple ”and” (logical product) or ”or” (logical sum) operators are specified for an instruction on a single line, and one of the operators is changed from ”and” to ”or” or from ”or” to ”and,” all other ”and” or ”or” operators are changed accordingly, and the following message appears: TRIF-062 AND operator was replaced to OR TRIF-063 OR operator was replaced to AND Up to five conditions can be combined with ”and” or ”or” operators on a single line. Example) SKIP CONDITION and and and and
- 239 -
4 PROGRAM STRUCTURE
4.10
B-82594EN-4/01
OFFSET CONDITION INSTRUCTION The OFFSET CONDITION instruction specifies the offset condition used in the OFFSET CONDITION instruction, in advance. The OFFSET CONDITION is needed to be executed before the OFFSET instruction is executed. The specified offset condition is effective until the program execution finishes or the next OFFSET CONDITION instruction is executed.(For the offset instruction, see Subsection 4.3.5.)
• • •
The position register specifies the shifting direction and the shift amount. When the positional information is expressed in the joint frame, the shift amount of each axis is applied. When the positional information is expressed in the Cartesian coordinate system, the number of user frame by which the offset condition is decided should be specified. When it is not specified, the user frame being selected now is used.
CAUTION If teaching is made by joint coordinates, changing the user coordinate system does not affect the position variables and position registers. If teaching is performed in cartesian coordinates, and the user coordinate system input option is not used, the position variable is not influenced by the user coordinate system. In other cases, both the position variable and position register are influenced by the user coordinate system. The OFFSET instruction shifts positional information programmed at the destination position by the offset amount specified by position register, and moves the robot to the shifted position. The shifting condition is specified by the OFFSET CONDITION instruction.
Fig. 4.10 Offset Conditional Instruction
Example
1: OFFSET CONDITION PR[ R[1] ] 2: J P[1] 100% FINE 3: L P[2] 500mm/sec FINE Offset
- 240 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.11
TOOL OFFSET CONDITION INSTRUCTIONS A tool offset condition instruction specifies the offset condition used in a tool offset instruction. Execute a tool offset condition instruction before executing the corresponding tool offset instruction. Once the tool offset conditions have been specified, they remain effective until the program terminates or the next tool offset condition instruction is executed. (For the tool offset instruction, see Subsection 4.3.5 ”Additional motion instructions”)
•
The position register specifies the direction in which the target position shifts, as well as the amount of shift. • The tool coordinate system is used for specifying offset conditions. • When the number of a tool coordinate system is omitted, the currently selected tool coordinate system is used. • When the position data is given as coordinates, an alarm is issued and the program stops temporarily. A tool offset instruction moves the robot to a position shifted from the target position, recorded in the position data, by the offset specified in the tool offset conditions. The condition when the offset is applied is specified by a tool offset condition instruction.
Fig. 4.11 Tool Offset Condition Instruction
Example
1: TOOL_OFFSET PR[1] 2: J P[1] 100% FINE 3: L P[2] 500mm/sec FINE Tool_Offset
- 241 -
4 PROGRAM STRUCTURE
4.12
B-82594EN-4/01
FRAME INSTRUCTIONS The FRAME instruction is used to change the setting of the Cartesian coordinate system by which the robot works. There are two kinds in the FRAME instruction.
• •
Frame setup instruction - The definition of the specified frame is changed. Frame select instruction - The frame number being selected now is changed.
The frame setup instruction The tool frame setup instruction changes the setting of the tool frame specified by the tool frame number in this instruction. The user frame setup instruction changes the setting of the user frame specified by the user frame number in this instruction.
Fig. 4.12 (a) Tool Frame Setup Instruction
Fig. 4.12 (b) User Frame Setup Instruction
Example
1: TOOL[1] = PR[1] 2: UFRAME[3] = PR[2]
- 242 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Frame select instruction The tool frame select instruction changes the current tool frame number. The user frame select instruction changes the current user frame number.
Fig. 4.12 (c) Tool Frame Select Instruction
Fig. 4.12 (d) User Frame Select Instruction
Example
1: 2: 3: 4: 5: 6:
UFRAME_NUM = 1 J P[1] 100% FINE L P[2] 500mm/sec FINE UFRAME_NUM = 2 L P[3] 500mm/sec FINE L P[4] 500mm/sec FINE
- 243 -
4 PROGRAM STRUCTURE
4.13
B-82594EN-4/01
PROGRAM CONTROL INSTRUCTIONS The program control instructions control program execution.
• •
4.13.1
Halt instruction Abort instruction
Halt Instruction
PAUSE The halt instruction stops program execution, causing the robot in motion to decelerate and stop: • If an operation instruction is being executed, the program stops before the operation is completed. • The cursor moves to the next line. When restarted, the program is executed from this line. • If the program timer is active, it is stopped. When the program is restarted, the program timer is activated. • If a pulse output instruction is being executed, the program stops after that instruction has been executed. • If an instruction other than a program call instruction is being executed, the program stops after that instruction has been executed. A program call instruction is executed when the program is restarted.
PAUSE Fig. 4.13.1 Halt Instruction
4.13.2
Abort Instruction
ABORT The abort instruction aborts program execution in the following way, causing the robot in motion to decelerate and stop: • If an operation instruction is being executed, the program stops before the operation is completed. • The cursor stops on the current line. • When the abort instruction is executed, the execution of the program cannot be continued. Information held by a program call instruction about the main program is lost.
ABORT Fig. 4.13.2 Abort Instruction
- 244 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.14
OTHER INSTRUCTIONS The following miscellaneous instructions are available:
• • • • • • • •
4.14.1
RSR instruction User alarm instruction Timer instruction Override instruction Comment instruction Message instruction Parameter instruction Maximum speed instruction
RSR Instruction
RSR [i] = (value) The RSR instruction alternately enables and disables the RSR function having a specified RSR number.
Fig. 4.14.1 RSR instruction
Example
RSR[2:Workproc.2.]=ENABLE
- 245 -
4 PROGRAM STRUCTURE
4.14.2
B-82594EN-4/01
User Alarm Instruction
UALM[i] The user alarm instruction displays the alarm message corresponding to an already set user alarm number on the alarm display line. The user alarm instruction pauses the program which is on progress. A user alarm is specified on the user alarm setting screen(See Section 3.12) and this setting is registered in the system variable $UALM_MSG . The total number of user alarms can be changed at a controlled start (See Section B.1, ”START MODE”).
Fig. 4.14.2 User Alarm Instruction
Example
4.14.3
1: UALM[1]
($UALRM_MSG[1] = WORK NOT FOUND
Timer instruction
timer [i] = (state) The timer instruction starts/stops the program timer. The operating state of the program timer can be viewed on program timer screen STATUS PRGTIMER (option).
Fig. 4.14.3 Timer instruction
Example
1: TIMER [1]=START TIMER [1]=STOP TIMER [1]=RESET
The value of the timer can be referenced in a program, using a register instruction. It is possible to determine whether the timer has overflowed by using a register instruction. The program timer overflows if it exceeds 2147483.647 seconds. [1]=TIMER [1] R[2]=TIMER_OVER FLOW[1] 0: Not over flow 1: Over flow
- 246 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.14.4
Override Instruction
OVERRIDE = (value)% The override instruction changes a feedrate override.
Fig. 4.14.4 Override Instruction
Example
4.14.5
1: OVERRIDE = 100%
Comment Instruction
!(Remark) The comment instruction adds a comment in a program. A comment has no effect on program execution. A comment specified in a comment instruction can consist of up to 32 characters including alphanumeric characters, asterisk s (*) underlines (_), and at marks (@). To add a comment, press the ENTER key.
Fig. 4.14.5 Comment Instruction
Example
4.14.6
1: !APPROACH POSITION
Message Instruction
MESSAGE[message statement] The message instruction displays a specified message on the user screen. (For the user screen, see Section 7.2.) A message can consist of up to 24 characters including alphanumeric characters, asterisks (*), underlines (_) , and at marks (@). To add a comment, press the ENTER key.
Fig. 4.14.6 Message Instruction
Example
1: MESSAGE[ DI[1] NOT INPUT ]
- 247 -
4 PROGRAM STRUCTURE
4.14.7
B-82594EN-4/01
Parameter Instruction
$(SYSTEM VARIABLE NAME) = (value) The parameter instruction changes the value of a system variable. This instruction can be used only for a system variable containing a numeric value (constant). You can enter the parameter name after pressing the ENTER key. It is possible to enter the parameter name up to 30 characters or less without the first character,”$”. There are two types of system variables, variable type and position type. A system variable of variable type can be assigned to a register. A system variable of position type can be assigned to a position register. System variables of position data type are divided into three data types, cartesian (XYZWPR type), joint type (J1-J6 type), and matrix type (AONL type). When a system variable of position data type is assigned to a position register, the data type of the position register is converted to the data type of the system variable. If a system variable of position type is assigned to a register, or if a system variable of variable type is assigned to a position register, the following alarm is generated during execution. INTP-240 Incomputible datatype
Fig. 4.14.7 (a) Parameter Instruction (Writing)
Example
1: $SHELL_CONFIG.$JOB_BASE = 100
Fig. 4.14.7 (b) Parameter Instruction (Reading)
Example
1: R[1] = $SHELL_CONFIG.$JOB_BASE
WARNING The operation of the robot and control unit is controlled with system variables. Only a person who is aware of how changes to the system variables will affect the system should set system variables. If a person without detailed knowledge attempts to set the system variables, the robot and control unit would malfunction, causing injury to personnel or damage to equipment.
- 248 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
Procedure 4-3 Specifying parameter instructions
Step 1
On the program edit screen, press function key [INST]. Select item Miscellaneous from the menu. Then, select item Parameter name from the menu.
2
Select item 2 ”... =$ ...”
3
Select item 1 ”R[ ]” and enter the desired register number.
- 249 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4
To display the system variable menu, press the [CHOICE] function key. To enter a character string, press the Enter key. When function key CHOICE is pressed
5
Select item 1 ”DEFPULSE.”
6
When ENTER is pressed
7
Enter the desired system variable name.
- 250 -
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.14.8
Maximum Speed Instructions A maximum speed instruction specifies the maximum operating speed of a program. There are two maximum speed instructions, the instruction for specifying the joint operation speed and that for specifying the path control operating speed. If a speed exceeding the speed specified with a maximum speed instruction is specified, the speed specified with the maximum speed instruction is assumed.
JOINT_MAX_SPEED[i]=(value)
Fig. 4.14.8 (a)
Example
JOINT_MAX_SPEED[3] = R[3]
LINEAR_MAX_SPEED= (value)
Fig. 4.14.8 (b)
Example
LINEAR_MAX_SPEED = 100
- 251 -
4 PROGRAM STRUCTURE
4.15
B-82594EN-4/01
MULTIAXIS CONTROL INSTRUCTIONS Multiaxis control instructions control the execution of a multitask program. These instructions can be specified and executed only when the multitask option is supported.
• • •
4.15.1
Semaphore instruction Semaphore wait instruction Program execution instruction
Program Execution Instruction During the execution of a program, the program execution instruction starts the execution of another program. • The difference from the program call instruction is that, with the program call instruction, those lines following the call instruction are executed after the called program has been executed, whereas with the program execution instruction, the program that starts the execution of another program continues concurrently. • To synchronize programs that are being executed simultaneously, use the register instruction and the register condition wait instruction. • If an attempt is made to execute a program for which the same motion group is specified, an alarm is generated. If this occurs, specify a different motion group.
Fig. 4.15.1 Program execution instruction
Example PROG1 1: R[1]=0 2: RUN PROG1 3: J P[1] 100% FINE 4: J P[2] 100% FINE 5: WAIT R1[1] MOTION GROUP[1,*,*,*,*]
- 252 -
PROG2 1: J P[3] 100% FINE 2: J P[4] 100% FINE 3: J P[5] 100% FINE 4: J P[6] 100% FINE 5: R[1]=1 MOTION GROUP[*,1,*,*,*]
4 PROGRAM STRUCTURE
B-82594EN-4/01
4.16
OPERATION GROUP INSTRUCTIONS The operation group instructions enable the following in single-line operation instructions in a program having multiple operation groups: • Specification of the operation format for each operation group (excluding the arc) • Specification of the feedrate for each operation group • Specification of the positioning format for each operation group This allows each operation group to operate asynchronously. These instructions can be specified and executed only when the multitask option is supported.
• Asynchronous operation group instruction • Synchronous operation group instruction With ordinary operation instructions for which these operation group instructions are not specified, all operation groups are executed with the same operation format, feedrate, and positioning format, and are synchronized with the operation add instructions. The operation group having the longest travel time is that with which the other operation groups are synchronized.
4.16.1
Asynchronous Operation Group Instruction The asynchronous operation group instruction controls operation groups asynchronously, with the operation formats, feedrates, and positioning formats specified separately for the individual operation groups.
Fig. 4.16.1 Asynchronous operation group instruction
- 253 -
4 PROGRAM STRUCTURE
4.16.2
B-82594EN-4/01
Synchronous Operation Group Instruction The synchronous operation group instruction controls operation groups synchronously, with the operation formats specified separately for the individual operation groups. • As with ordinary operation instructions, the operation group having the longest travel time is that with which the other operation groups are synchronized. Thus, the feedrate is not always the same as that specified in the program. • The positioning format for an operation group with the smallest CNT value (closest to FINE) is also applied to the other operation groups.
Fig. 4.16.2 Synchronous operation group instruction
- 254 -
5.PROGRAMMING
B-82594EN-4/01
5
PROGRAMMING This chapter describes how to create and change a program for moving the robot. Contents of this chapter 5.1 5.2 5.3 5.4 5.5 5.6 5.7
TIPS ON EFFECTIVE PROGRAMMING..............................257 TURNING ON THE POWER AND JOG FEED .....................261 CREATING A PROGRAM .....................................................277 CHANGING A PROGRAM ....................................................299 PROGRAM OPERATION.......................................................332 BACKGROUND EDITING .....................................................337 SINGULAR POINT CHECK FUNCTION..............................348
- 255 -
5.PROGRAMMING
B-82594EN-4/01
Various program instructions are issued with the robot and peripherals to specify robot and hand motions. When these instructions are combined together, they create what is called a hand application program. A hand application program for instance, can: • Move the robot to desired positions in the operating area along the specified path • Handle workpiece • Perform arc welding • Send output signals to the peripherals • Receive input signals from the peripherals Before programming, design the outline of a program. In the design, incorporate the most effective method for the robot to do the target work. This enables efficient programming and ensures that only the instruction s appropriate for the purpose are used. Instructions must be selected from menus displayed on the teach pendant during programming. To teach a target position to the robot, the robot must be moved to the target position by jog feed. After you have finished creating the program, change the program if necessary. To change, add, delete, copy, find, or replace an instruction, select the desired item from the menu displayed on the teach pendant. This chapter describes the following: • Tips on effective programming • Turning on the power and jog feed • Creating a program • Changing a program See Chapter 4 for the configuration of a program and the program instructions.
Fig. 5.1 Programming by Teaching
- 256 -
5.PROGRAMMING
B-82594EN-4/01
5.1
TIPS ON EFFECTIVE PROGRAMMING This section describes tips on effective programming. The following items are explained: • Motion instructions • Fixed positions
NOTE This section describes tips on programming, but does not describe tips on jog feed.
5.1.1
Motion Instructions Refer to the following instructions when teaching motions to the robot.
Workpiece hold position = FINE positioning Use FINE positioning for all workpiece hold positions. The robot stops exactly at the workpiece hold position. When CNT positioning is used (explained next), the robot does not stop at taught points.
Moving around workpieces = CNT positioning Use CNT positioning for moving around workpieces. The robot continuously moves to the next target point without stopping at taught points. If the robot moves near the workpieces, adjust the path of CNT positioning.
Fig. 5.1.1 (a) Adjusting the path of CNT Positioning
- 257 -
5.PROGRAMMING
B-82594EN-4/01
Fixing the attitude of the tool Cycle time is wasted when the robot motion considerably changes the attitude of the tool. The robot moves much faster when the attitude of the tool is changed smoothly and gradually. Teach positions so that the attitude of the tool changes as gradually as possible with respect to the robot. When the attitude of the tool must be changed considerably, teach one large motion by dividing it into several small motions. Namely, teach positions so that the attitude of the tool changes gradually.
Fig. 5.1.1 (b) Teaching Positions According to the Tool Attitude
To change the attitude of the hand as smoothly as possible: 1 Teach the first position of the work so that the robot has a normal attitude. 2 Move the robot to the last position of the work by jog feed. Then check that the robot has a normal attitude. 3 Teach the last position. 4 In accordance with the work, teach a position between the first and last positions. 5 Select a Cartesian coordinate system (World, user or jog coordinate system) and move the robot to the first position by jog feed. - 258 -
5.PROGRAMMING
B-82594EN-4/01
6 7
Select the Cartesian coordinate system, move the robot toward the last position by jog feed, then stop the robot at the next position to be taught. Correct the taught position so that the robot has a normal attitude.
WARNING If the J5 axis passes singular points (near 0 degrees) when the robot is operated by setting the move type to linear, the additional move instruction with no attitude must be used for these points, or the move type must be changed from linear to axial. 8
5.1.2
Repeat steps 6 and 7 for all the remaining positions to be taught between the first and last positions.
Predefined Position The predefined position is the position that is referenced many times in a program. The predefined positions that are used often are the pounce position and the home(perch) position. You should define these positions to program efficiently or delete cycle time.
Pounce position The pounce position is the reference position for all work. This is the safe position away from the motion area of the machine tool and peripheral device.
Home(perch) position The home position, or perch position, is a safety position away from the machine tool and the workpiece transfer area. The reference position digital output signal is turned on when the robot is at this position.(See Section 3.10, ”SETTING A REFERENCE POSITION)
NOTE HOME is a peripheral device I/O input signal, and does not represent a home position. A reference position is one of the home positions, but there is no utility used to move the robot to the reference position.
Other predefined position The pounce position, reference position, or any other position can be defined as a predetermined position. Specify those positions that are frequently used in a program as predetermined positions. When using the fixed position, use position registers (See Section 7.4) and macro instructions (See Section 9.1).
- 259 -
5.PROGRAMMING
B-82594EN-4/01
CAUTION If the position variable and position register are taught according to joint type, they are not affected when the user coordinate system is changed. If the position variable is taught according to cartesian coordinates, and the user coordinate system input option is not used, the position variable is not affected by the user coordinate system. In other cases, both of the position variable and position register are affected when the user coordinate system is changed. NOTE To move the robot to the same spatial position when the position register is shared by two programs, the two programs must have the same tool and user coordinate system.
- 260 -
5.PROGRAMMING
B-82594EN-4/01
5.2
TURNING ON THE POWER AND JOG FEED
5.2.1
Turning On the Power and Turning Off the Power Turning on the power starts up the robot system. Turning on the power normally executes internal processing called a cold start or hot start, then the system is started up. The special operation is necessary to perform processing with a control or initial start.(See Section B.1, ”START MODE”)
CAUTION Some systems require inspection before the robot is turned on. For the sake of safety, the system should be checked before the robot is turned on.
Hot start You can select hot start if the hot start is setup when you start the robot system. The hot start is the function that save the condition of the system just before power off and revives it after the next power on.(See Section 3.15, ”SYSTEM CONFIG MENU”) • If the hot start is set to disable($SEMIPOWERFL=FALSE), the system starts up with the cold start. In cold start mode, the system software of the controller is initialized during starting. When you change the setting of the system such as I/O configuration, you should start up in cold start mode. • If the hot start is set to be effective($SEMIPOWERFL=TRUE), the system starts up in hot start mode. In hot start mode, the system software of the controller is not initialized during starting up.
HOT START done signal You can set that the digital output signal(DO) is turned on when the hot start is finished. This function is set with the system configuration screen [6 SYSTEM.Config].(See Section 3.15, ”SYSTEM CONFIG MENU”)
Automatic start program An automatic start program can be specified. The program is automatically started when the power is turned on. If override and parameter instructions are specified in the program to be started, the system can be customized when the power is turned on. • In Autoexec program for Cold start of the system setting menu, register a program to be automatically started when power interrupt handling is disabled. Such a program, if not defined, is not started. The automatic start program cannot operate the robot. The automatic start program is used to set up the system or initialize the state of I/O, etc. (See Section 3.15, ”SYSTEM CONFIG MENU”)
- 261 -
5.PROGRAMMING
B-82594EN-4/01
Program selection after power on The condition of the program selection after the power on is the following: • When hot start is disable, it depends on the setting of the system variable,$DEFPROG_ENB. You can set $DEFPROG_ENG with the system config menu. TRUE : The program which had been selected at the power off is selected as it is. FALSE : No program is selected. • When hot start is effective, a program which had been selected at power off is selected as it is.
System condition The table below lists settings in different start modes. Table 5.2.1 System Statuses in Different Start Modes Hot start Effective Disable (default setting) Contents of register Overridef Selection program Execution line Condition of I/O TP screen
A: B: C:
A A A A A (NOTE 1) B (NOTE 2)
A C [10%] B (NOTE 3) C [First line] C [All off] C [Hint screen]
All values that are current at power-down are saved and restored at power-up. Only some of the values that are current at power-down are saved. The values that are current at power-down are not saved. At power-up, the default values are set.
- 262 -
5.PROGRAMMING
B-82594EN-4/01
NOTE 1 Generally, the status existing at power-down is restored, but digital output (DO), being performed by a pulse instruction at power-down, is turned off. To restore the I/O status, specify the desired restoration status in [6 SYSTEM Config] (see Section 3.15, ”SYSTEM CONFIG MENU”). Even if power interrupt handling is enabled, none of the output signals are resumed, but all output signals are turned off in the following cases: - The I/O allocation was changed before power-off. - The fuse of the I/O device blew, or the power to the I/O device was turned off. - The I/O device configuration was changed. 2 The screen type selected at power-down is restored, but the page, cursor, and other screen statuses are not restored. Instead, the screen is restored using the same page, cursor, and other screen statuses assumed immediately after a cold start. 3 The name of the main program that calls the subprogram is stored. CAUTION Before the power is turned on, system statuses in the corresponding start mode described above should be checked.
5.2.2
Three-Mode Switch The three-mode switch is a key operation switch installed on the operator’s panel or operation box. This switch is used to select an optimum robot operation mode according to the robot operation conditions and use status. There are operation modes AUTO, T1, and T2. See Fig. 5.2.2.
Fig. 5.2.2 Three-mode switch
- 263 -
5.PROGRAMMING
B-82594EN-4/01
When the three-mode switch is used to switch between operation modes, a message appears on the screen of the teach pendant, and the robot halts. When the key is removed from the switch, the switch setting position can be fixed. (For the DCS and dual chain specifications, when the switch is set to T2 mode, the key cannot be removed to fix the switch setting position.)
CAUTION For the DCS and dual chain specifications, if switching between T1 or T2 mode and AUTO mode is made with the deadman’s switch kept held, a system error occurs. In this case, selected mode is not set until the deadman’s switch is released. Release the deadman’s switch, then hold the deadman's switch again. - Connection Connect the *FENCE signal to the protective fence. Make a connection in such a way that, when the protective fence is open, the signal entered to the robot is off and, when it is closed, the signal is on. The *SFSPD signal can be used in accordance with the design of your system. The following explains the operation modes that can be selected using the three-mode switch:
T1 (<250 mm/s): Test mode 1 This mode is intended for use to teach the position of operation to the robot. It can also be used to check the robot path at low speed and the program sequence.
- Program execution A program can be executed only from the teach pendant.
- Robot speed at jogging •
The speeds at the tool tip and flange are both limited not to exceed 250 mm/sec.
- Robot speed at executing program •
The override value can be increased to up to 100%, but the speeds at the tool tip and flange surface are limited to 250 mm/sec or slower. For example, if the taught speed is 300 mm/sec, the speeds at the tool tip and flange surface are limited to 250 mm/sec. If the taught speed is 200 mm/sec, they are not limited. Even when the taught speed is 250 mm/sec or below, the speed on the flange surface may exceed 250 mm/sec in a portion (for example, a corner) where the posture of the tool changes. In this case, the actual operation speed is limited. The warning message MOTN - 231 T1 speed limit (G:i ) appears only if the operation speed is limited and the taught speed is 250 mm/sec or below. - 264 -
5.PROGRAMMING
B-82594EN-4/01
•
Speed limitation is performed based on the taught speed with an override value of 100%. Therefore, if the taught speed is, for example, 2000 mm/sec, the operation speed is limited to 250 mm/sec for an override value of 100%. However, the operation speed can be decreased further, for example, to 125 mm/sec by lowering the override value to 50%.
- Protective fence If you want to work with the protective fence kept open, it is necessary to set the three-mode switch to T1 or T2 before starting operating the robot. • It is possible to operate the robot only when the teach pendant is enabled and the deadman switch is pressed (gripped). • Disabling the teach pendant puts the robot in an emergency stop alarm condition, so the robot cannot run. • When the teach pendant is enabled, but the deadman switch is not pressed, the robot is in an emergency stop alarm condition, so it cannot run.
CAUTION When checking the program you created, be sure to follow the safety manual. - Fixing operation mode When the switch is set in the T1 mode position, the operation mode can be fixed to T1 mode by removing the key.
- Troubleshooting •
When the switch is set in the T1 mode position, turning off the teach pendant enable switch stops the robot and causes an error message to appear. To release the error, set the teach pendant enable switch to on, then press the RESET key.
T2 (100%): Test mode 2 The T2 mode is intended for use to make a final check of the program you created. In the T1 mode, it is impossible to verify the robot’s actual tool path and cycle time because the operation speed is limited. In the T2 mode, it is possible to verify them by running the robot at the production speed because there is basically no speed limitation(*). * Using a safety speed based on the *SFSPD signal can limit the operation speed of the robot even in the T2 mode by lowering the override value. (Reference) If *SFSPD is off, the override value is limited to within a value specified by $SCR.$SFRUNOVLIM (default: 30%).
- Program execution A program can be executed only from the teach pendant.
- 265 -
5.PROGRAMMING
B-82594EN-4/01
- Robot speed at jogging •
The speeds at the tool tip and flange are both limited not to exceed 250 mm/sec.
- Robot speed at executing program • •
The override value can be increased to up to 100%. There is no special speed limitation. When the switch is switched to T2 mode, the default override is limited to such a value that the speeds at the tool tip and flange are both equal to or less than 250mm/sec. The override can be changed with appropriate means such as the override key.
- Protective fence If you want to work with the protective fence kept open, it is necessary to set the three-mode switch to T1 or T2 before starting operating the robot. • It is possible to operate the robot only when the teach pendant is enabled and the deadman switch is pressed (gripped). • Disabling the teach pendant puts the robot in an emergency stop alarm condition, so the robot cannot run. • When the teach pendant is enabled, but the deadman switch is not pressed, the robot is in an emergency stop alarm condition, so it cannot run.
CAUTION When checking the program you created, be sure to follow the safety manual. - Fixing operation mode When the switch is set in the T2 mode position, the operation mode can be fixed to T2 mode by removing the key. (For the CE and RIA specifications, however, the key cannot be removed.)
- Troubleshooting •
When the switch is set in the T2 mode position, turning off the teach pendant enable switch stops the robot and causes an error message to appear. To release the error, set the teach pendant enable switch to on, then press the RESET key.
AUTO: Auto mode The AUTO mode is intended for use at production.
- Program execution A program can be executed from external devices and operator’s panel. Program execution from the teach pendant is impossible if the switch is set in the AUTO mode position.
- Robot speed The robot can be operated at a maximum speed. - 266 -
5.PROGRAMMING
B-82594EN-4/01
- Robot speed at jogging Jogging operation is not possible. • The speeds at the tool tip and flange are both limited not to exceed 250 mm/sec.
- Robot speed at executing program •
The robot can be operated at a maximum speed.
- Safety devices Close the protective fence. When the protective fence is opened during program execution, the robot responds as follows: • The robot decelerates and stops. After a certain time, the robot enters the emergency stop state. If the protective fence is opened while the robot is operating at a high speed, the robot may enter the emergency stop state during deceleration. In this case, the robot stops immediately at this point. • The robot stops immediately in the same manner as when another emergency stop signal is applied.
- Fixing operation mode When the switch is set in the AUTO mode position, the operation mode can be fixed to AUTO mode by removing the key.
- Troubleshooting •
When the switch is set in the AUTO mode position, turning on the teach pendant enable switch stops the robot and causes an error message to appear. To release the error, set the teach pendant enable switch to off, then press the RESET key.
- Three-mode switch and program operation The following table lists the relationships among the three-mode switch setting, protective fence status (*FENCE signal), teach pendant (TP) enabled/disabled, deadman switch setting, *SFSPD signal status, and program-specified robot operation speed.
- 267 -
5.PROGRAMMING
B-82594EN-4/01
Relationships between three-mode switch settings and program operations ThreeProtective TP enabled/ Mode fence(*1) *SFSPD disabled TP deadman switch Gripped Enabled Open
ON Disabled
AUTO Enabled Closed
Enabled ON
Emergency stop (fence open)
ON
Operable
External start(*2)
Programmed speed
Operable
External start(*2)
Programmed speed
Operable
TP only
T1 speed
TP only
T1 speed
TP only
Programmed speed(*3)
TP only
Programmed speed
Gripped Released
Gripped Released Gripped
Disabled Released Enabled Open
ON(*4)
Gripped Released Gripped
Disabled Released T2 Enabled Closed
ON
Gripped Released Gripped
Disabled Released
*1 *2 *3
Alarm and stop (deadman)
Released
Released
Closed
Alarm and stop (AUTO and TP enable)
Gripped
Disabled
Enabled
(deadman, fence open) Emergency stop (fence open)
Gripped
T1
Program-specified operation speed
Emergency stop (fence open)
Gripped
Gripped
Units that can be started
Emergency stop
Released
Released
ON Disabled
Open
Released
Robot status
Emergency stop (deadman) Emergency stop (T1/T2 and TP disabled) Emergency stop (T1/T2 and TP disabled) Operable Emergency stop (deadman) Emergency stop (T1/T2 and TP disabled) Emergency stop (T1/T2 and TP disabled) Operable Emergency stop (deadman) Emergency stop (T1/T2 and TP disabled) Emergency stop (T1/T2 and TP disabled) Operable Emergency stop (deadman) Emergency stop (T1/T2 and TP disabled) Emergency stop (T1/T2 and TP disabled)
Protective fence status Open: *FENCE is off. Closed: *FENCE is on. External speed Remote mode: Program start on the line control panel Local mode: Start button on the robot operation panel When the three-mode switch is in the T1 position and the fence is open, if you want to clamp a program-specified speed with the SFSPD override value, configure the system in such a way that the *SFSPD mentioned at *4 becomes off.
NOTE SFSPD override: When the program is executed with *SFSPD turned off, the override value is limited to within a value specified in $SCR.$SFRUNOVLIM (default value: 30%).
- 268 -
5.PROGRAMMING
B-82594EN-4/01
5.2.3
Moving the Robot by Jog Feed The robot moves by jog feed when the jog keys on the teach pendant are pressed. The robot must be moved to a target position when motion instructions are specified in the program. Jog feed depends on the following two factors: • Feedrate override: Robot motion speed (jog feedrate) • Manual-feed coordinate system: Coordinate system for robot motion (jog feed type)
Feedrate override A feedrate override is one of the two factors on which jog feed depends. The feedrate override is represented in percentage (%). The current feedrate override is displayed at the upper right corner of the screen of the teach pendant. Pressing the feedrate override key displays a pop up window in reverse video at the upper right of the screen to call the user’s attention. The popup window in reverse video automatically disappears after a few seconds or when another key is pressed.
Fig. 5.2.3 (a) Screen Display for Feedrate Override
Feedrate override 100% means that the robot moves at the maximum feedrate. The step feed-rate of FINE is specified by a system variable, $JOG_GROUP.$FINE_DIST in linear jog.(Standard : 0.1mm). In standard setting, each axis rotates at 0.001deg per step. The step width of VFINE is one-tenth of that of FINE.
NOTE If VFINE or FINE is used as the current speed override, the robot makes a motion of a single step at a time. To resume the robot motion, release and press the jog key.
- 269 -
5.PROGRAMMING
B-82594EN-4/01
Table 5.2.3 (a) shows the change in feedrate override when the override key is pressed. Table 5.2.3 (a) Feedrate Override When the override key is pressed
When the override key is pressed while pressing the SHIFT key (*1)
*1
VFINE → FINE → 1% → 5% → 50% → 100% In 1% In 5% increments increments VFINE → FINE → 5% → 50% → 100%
Enabled only when $SHFTOV_ENB is 1 To change the feedrate override, press the override key. Whenever the override key is pressed while the shift key is pressed, the feedrate changes sequentially in the order: FINE, VFINE, 5%, 50%, and 100%. However, the feedrate is changed in this way only when system variable $S HFTOV_ENB = 1.
Fig. 5.2.3 (b) Override Keys
A feedrate override must be determined according to the condition of the machining cell, type of the robot motion, or the skill of the operator. Therefore, an inexperienced robot operator should use a low feedrate override.
NOTE When the override key is pressed, a window indicating the manual feed coordinate system and speed override appears on the screen in reverse video. Pressing the override key again enables you to change the override value. If the override key is not pressed, the window closes automatically. This window is automatically closed if the override keys are not pressed for a while. When the safe speed signal (*SFSPD input) (→ Section 3.3) is turned off, the speed override is reduced to the value of $SCR.$FENCEOVRD. In this state, the speed override cannot be increased beyond the upper limit specified by $SCR.$SFJOGOVLIM (→ Section 3.3). A function is available which restores the speed override when the safety fence is closed (→ Section 3.16). - 270 -
5.PROGRAMMING
B-82594EN-4/01
Jog feedrate A jog feedrate is a speed at which the robot moves during jog feed. The jog feedrate is obtained by the following expression: If the following value exceeds the speed limit 250 mm/sec for the T1 or T2 mode described above, the operation speed is clamped at the one described earlier.
Fig. 5.2.3 (c) Jog Feedrate
- Manual-feed coordinate systems (Jog type) Manual-feed coordinate systems determine how the robot moves during jog feed. The manual-feed coordinate systems are classified into three types:
- Joint jog (JOINT) During joint jog, the robot moves independently around each axis according to each joint coordinate system. See Section 3.9 for the joint coordinate systems.
Fig. 5.2.3 (d) Joint Jog
- 271 -
5.PROGRAMMING
B-82594EN-4/01
- Cartesian jog (XYZ) During Cartesian jog, the tool center point of the robot moves along the X-, Y-, and Z-axes of the user or jog coordinate systems. You can not cause the robot to rotate the tool around x-,y-,and z-axis of the user frame or jog frame.(See Subsection 3.9.2, ”Setting a User Coordinate System”, and Subsection 3.9.3, ”Setting a Jog Coordinate System”)
Fig. 5.2.3 (e) Cartesian Jog
Tool jog (TOOL) During tool jog, the tool center point (TCP) moves along the X-, Y-, and Z-axes of the tool coordinate system defined for the wrist of the robot. You can not cause the robot to rotate the tool around x-,y-,and z-axis of the tool frame.(See Subsection 3.9.1, ”Setting a Tool Coordinate”)
Fig. 5.2.3 (f) Tool Jog
- 272 -
5.PROGRAMMING
B-82594EN-4/01
Selecting a manual-feed coordinate system The current manual-feed coordinate system is displayed at the upper right corner of the screen of the teach pendant. Pressing the COORD key displays a popup menu in reverse video at the upper right of the screen to call the user’s attention. The popup menu in reverse video automatically disappear after a few seconds or when another key is pressed.
Fig. 5.2.3 (g) Screen Display for Manual-Feed Coordinate Systems
Whenever the COORD key on the teach pendant is pressed, the selected manual-feed coordinate system change cyclically. When a manual-feed coordinate system changes sequentially in the order shown in Table 5.2. is selected, its corresponding LED lights. Table 5.2.3 (b) Jog type Selection Sequence Screen display LED state
JOINT → JGFRM → TOOL → USER → JOINT JOINT LED on → XYZ LED on → TOOL LED on → XYZ LED on → JOINT LED on
Enabling a wrist joint feed In wrist joint feed, the attitude of the tool is not held during linear feed (Cartesian jog feed) or circular feed (tool jog feed). • When wrist joint feed is disabled, the attitude of the tool is held during jog feed. (Standard setting) • When wrist joint feed is enabled, the attitude of the tool is not held during jog feed. In this case, [W/] is displayed on the screen. In linear feed (linear motion along the axes of the Cartesian coordinate system), the tool center point moves linearly while the wrist joint is fixed. The wrist axis is moved in axial movement while the position of the tool tip is held in rotational feed (attitude rotation about the wrist axis).
Fig. 5.2.3 (h) Indication that Wrist Joint Feed Is Enabled
- 273 -
5.PROGRAMMING
B-82594EN-4/01
NOTE When the motion instruction for linear or circular motion under path control is executed, wrist joint feed has the same function as the wrist joint motion additional instruction (WRIST JOINT).
Switching to additional axes In addition to the standard robot axes (usually 4 to 6 axes) in one operation group, up to three additional axes can be controlled as a subgroup.
NOTE The user can switch to a subgroup by using the auxiliary menu or jog menu described below.
Jog menu With the jog menu function, the following data related to jog operation can be displayed or updated easily: • Tool, jog, or user coordinate system number currently selected • Group number currently selected • Subgroup selection state (robot or additional axes) To display the jog menu, press the manual feed coordinate system key while holding down SHIFT key.
Operation
Table 5.2.3 (c) Operation Procedure Using the Jog Menu Procedure
Opening the menu Closing the menu
Moving the cursor Changing the coordinate system number Group switching (for a multi-group system only)
Press the manual feed COORD key while holding down SHIFT key. • Press the manual feed COORD key while holding down SHIFT key. • Press PREV key. • Value modification using numerical key (See the descriptions of coordinate system number change and group switching.) cursor key • Tool coordinate system, jog coordinate system 1 to 10 (Put the ”.” key to select 10.) • User coordinate system 0 to 9 Numeric key (valid for existing group numbers only)
- 274 -
5.PROGRAMMING
B-82594EN-4/01
Operation
Procedure
Subgroup switching (for a system with a subgroup)
After moving the cursor to the line containing Robot/Ext, switch between Robot and Ext by using the left/right cursor key. (The position of reverse video switches.)
WARNING 1 Be sure to remember the current coordinate system number/group number. Otherwise, in such a case, a robot may move in an unexpected direction at jog time, or a robot of an unexpected group may move, thus leading to a fatal accident. 2 After coordinate system number/group number switching, be sure to close the jog menu. If the jog menu is left open, the operator may change the coordinate system number or group number by touching a numeric key of the teach pendant unconsciously. In such a case, a robot may move in an unexpected direction at jog time, or a robot of an unexpected group may move, thus leading to a fatal accident. Procedure 5-1
Moving the robot by jog feed
Condition ■
Do not enter the operating area. Do not put any obstacles within the work area.
CAUTION Before you jog the robot be sure that all safety requirements for the work area are satisfied. Otherwise, injury or property damage could occur.
Step 1
Press the COORD key to display a desired manual-feed coordinate system on the teach pendant.
NOTE The feedrate override is automatically set to 10%. 2 3 4
Press the override key to adjust the jog feedrate displayed on the teach pendant. Hold the teach pendant and press the deadman switch on the back of the teach pendant. Continue pressing the deadman switch during jog feed. Turn on the teach pendant enable switch.
NOTE 1 If the deadman switch is released when the teach pendant enable switch is on, an alarm occurs. To reset the alarm, press and hold down the deadman switch again, then press the RESET key on the teach pendant. 2 If the operator is not accustomed to the operation of the robot or is not sure about the robot motions, low feedrate overrides should be set. - 275 -
5.PROGRAMMING
B-82594EN-4/01
WARNING The robot starts its motion in the next step. If the jog feed of the robot needs to be stopped in an emergency in order to avoid danger, the operator should release the deadman’s switch or press the emergency stop button. 5
To move the robot by jog feed, press the jog key corresponding to the desired robot motion direction while pressing the SHIFT key. When the jog key is released, the robot stops.
NOTE When the override is FINE or VFINE, press the jog key and release it every time for each motion.
Switch to wrist joint feed 6 7
Press the FCTN key. The function menu is displayed. Select 5,TOGGLE WRIST JOG. The mark,[W/],is displayed to show the wrist joint jog mode. To release this mode, select 5,TOGGLE WRIST JOG again.
8 9
Press the FCTN key. The function menu is displayed. Select 4,TOGGLE SUB GROUP. The jog control is switched from the robot standard axes to an extended axis. The control will be returned when it is done.
10
To terminate jog feed, turn off the teach pendant enable switch and release the deadman switch.
Switch to a extended axis
- 276 -
5.PROGRAMMING
B-82594EN-4/01
5.3
CREATING A PROGRAM To create a program, use the following procedure: • Register a program and specify program information • Modify standard instruction (standard motion instructions) • Teach motion instructions • Teach various control instructions including a palletizing instruction
Fig. 5.3 Creating and Changing a Program
Registering a program Create a null program with a new name.
Specifying program information Specify the attributes of the program.
Changing standard motion instructions Respecify the standard instructions to be used when teaching motion instructions.
Teaching motion instructions Teach a motion instruction and a supplementary motion instruction.
Teaching control instructions Teach control instructions including a palletizing instruction. Use the teach pendant to create a new program and correct an existing program. To do this, the teach pendant must be enabled beforehand. To enable the teach pendant, satisfy the following condition: ■
The teach pendant enable switch must be turned on.
To prevent the program from being started by mistake, prohibit starting a program with a teach pendant while teaching.(See Fig. 2.3.1 (f), ”Function menu”) - 277 -
5.PROGRAMMING
5.3.1
B-82594EN-4/01
Registering a Program Enter a program name and register the program. A program name consists of up to eight alphanumeric characters including symbols to discriminate program names from one another. For the program name, see Subsection 4.1.1. Register a program on the program registration screen.
CAUTION When a new program is made, the current program is halted.
Entering a program name There are three methods for entering a program name: • Words: Up to five words consisting of up to seven characters can be used as program names. Enter these reserved words, such as PRG, MAIN, SUB, and TEST, in $PGINP_WORD[1 TO 5] in advance (See Section 3.15, ”SYSTEM CONFIG MENU”) • Uppercase or lowercase alphabetic characters: Any letter of the alphabet can be specified for a program name. The alphabetic characters combined with any numeric characters and/or any symbols are used as the characters of a program name.
CAUTION Asterisks (*) and at marks (@) should not be used in a program name.
Options During optional settings, an overwrite or insert mode can be specified for character entry, or character string deletion. • In the overwrite mode, entered characters are written over existing characters. • In the insert mode, entered characters are inserted before the character pointed to by the cursor. In this case, all the characters to the right of the entered character(s) are shifted to the right. INSERT or OVRWPT is displayed on the screen. • All the characters in the field where the cursor is positioned are deleted.
NOTE The program name should not begin with a numeral.
Setting program information Set the following program information items on the program information screen. See Section 4.1. • Program name • Subtype
- 278 -
5.PROGRAMMING
B-82594EN-4/01
•
• • •
Procedure 5-2
Comments
: Comments can be written in a program. Up to 16 alphanumeric characters and symbols, which can be used for a program name. In some cases, comments may not be entered. Group mask : Specifies a motion group to be controlled in a program. Write protection : Prevents a program from being changed. Interruption disable : Causes the program having no motion no to be paused by an alarm with a severity of WARN, PAUSE, STOP and SERVO, the emergency stop, and HOLD. However, this setting is not applied to the alarm that is generated by the program. In this case the program is stopped.
Registering a program
Condition ■
The teach pendant must be enabled.
Step 1 Press the MENUS key to display the screen menu. 2 Select SELECT. Alternatively, the following program selection screen can also be displayed by pressing the SELECT key.
3
Press the F2 [CREATE] key. The program registration screen is displayed.
- 279 -
5.PROGRAMMING
B-82594EN-4/01
4
Select a method for entering a program name (words or alphabetic characters) using the cursor keys.
5
Enter a program name by pressing the function keys corresponding to the characters in the program name. The function key menu displayed depends on the method selected in step 4. With alphabetic character entry, for instance, press the function key corresponding to a desired character repeatedly until the character is displayed in the program name field; that is, if you want to enter P, press the F4 function key four times. Press the NEXT key to move the cursor to the right one character. Repeat this procedure until the program name is completely entered.
NOTE When creating a program using RSR or PNS for automatic operation, follow the rule below. Otherwise, the program does not run. • A RSR program must be written as RSRnnnn, where nnnn represents a four-digit number. An example is RSR0001. • A PNS program must be written as PNSnnnn, where nnnn represents a four-digit number. An example is PNS0001.
- 280 -
5.PROGRAMMING
B-82594EN-4/01
6
After entering a program name, press the ENTER key.
7
To edit the registered program, press the F3 (EDIT) or ENTER key. The program edit screen for the registered program is displayed.
8
To enter program information, press the F2 (DETAIL) key (or the ENTER key). The program information screen is displayed.
9 •
Specify the following program information items: To change a program name, move the cursor to the setting field, change the program name, then press the ENTER key. To change a subtype (see Subsection 4.1.3), press the F4 [CHOICE] key to display a subtype menu. Then, select None, Job, Process, or Macro. JOB or PROCESS can be selected only when system variable $JOBPROC_ENB is set to 1. To enter comments, move the cursor to the setting field, enter the comments, then press the ENTER key (see Subsection 4.1.2). To specify a group mask, move the cursor to the setting field and select 1, *. The specified motion group is controlled (see Subsection 4.1.4). For safety, specify (*, *, *, *, *) for programs which do not contain any motion instructions.
•
• •
CAUTION You cannot change the motion group of a program that contain operation instructions cannot be changed. - 281 -
5.PROGRAMMING
B-82594EN-4/01
NOTE If the system used does not have the multi-group setting, only either of the following settings is allowed: The first group is set as 1; An asterisk (*) indicating no group is set. • •
To specify write protection, move the cursor to the setting field and select ON or OFF (see Subsection 4.1.5). To specify interruption disable, move the cursor to the setting field and press the function key (ON or OFF) (see Subsection 4.1.6). Select ON for programs not to be halted when an alarm occurs such as macro instructions or automatic start programs.
NOTE To return to the list screen, press the PREV key repeatedly until the list screen is displayed.
10
After entering the program information items, press the F1 (END) key. The program edit screen for the registered program is displayed.
- 282 -
5.PROGRAMMING
B-82594EN-4/01
5.3.2
Changing a Standard Motion Instruction For specification of a move statement, many items including move type, move speed, and positioning type need to be set. For convenience, the user can register frequently used move instructions as standard move statements. To modify a standard operation statement, first press the F1 key. A list of standard operation statements appears. Press the F key again. The screen for editing the standard operation statements appears.
•
Procedure 5-3
Press F1 POINT to list the standard operation statements.
Changing a standard motion instruction
Condition ■ ■
The program edit screen must be selected. The teach pendant must be enabled.
1
Press the F1 POINT key. The standard motion instruction menu is displayed.
Step
NOTE If the instructions listed on the submenu are necessary, they need not be changed.
- 283 -
5.PROGRAMMING
B-82594EN-4/01
2
To change a standard motion instruction, press the F1 ED_DEF.
3
Move the cursor to the instruction item to be changed (motion type, feedrate, positioning type, or supplementary motion instruction) using the cursor keys.
4
Select numeric keys and function keys to correct the instruction item. To change the feedrate, for instance, move the cursor to feedrate. Enter a new value with numeric keys, then press the ENTER key.
- 284 -
5.PROGRAMMING
B-82594EN-4/01
5.3.3
5
When [CHOICE] is displayed in the F4 key name field, press the F4 key. Then, an option of another instruction item can be selected from the submenu.
6 7
Repeat steps 3 to 5 for each instruction to be changed. After teaching is completed, press the F5 (DONE) key.
Teaching a Motion Instruction A motion instruction moves the robot to the specified position in the work area at the specified feedrate using the specified movement method. When the motion instruction is taught, the instruction items of the motion instruction and position data are simultaneously taught. The instruction items of a motion instruction are as follows (see Section 4.3 for the motion instruction): • Motion type: Controls a path to the specified position. (joint, linear, circular) • Position variable: Stores data on positions to which the robot moves. • Feedrate: Specifies the speed of the robot when it moves. • Positioning type: Specifies whether positioning is performed at the specified position. • Supplementary motion instruction: Specifies the instruction which executes with the loader robot. - 285 -
5.PROGRAMMING
B-82594EN-4/01
Teaching a motion instruction is selected after a standard motion instruction is created. In this case, the current position (position data) is stored in the position variable. • Press the F1, F2, F3, or F4 key to list the stored standard statements. Choose a desired statement from the list, and then program that statement. • To program a single standard statement repeatedly, hold down the shift key and press the F1, F2, F3, or F4 key.
•
Procedure 5-4
Press F1 POINT to list the standard operation statements. Check whether the position to be programmed is one of the robot’s singular points (for singular points, see Position data in 4.3.2). The user can program the position by using the axial method, if so desired. (see Singular point check functions in 5.7)
Teaching a motion instruction
Step 1 2
3
Move the robot to the desired position in the work area by jog feed. Move the cursor to END.
Press the F1 [POINT] key to display the standard motion instruction menu.
- 286 -
5.PROGRAMMING
B-82594EN-4/01
4
Select the standard motion instruction to be taught, press the ENTER key, and specify the desired motion instruction. At the same time the position is taught.
5
Repeat steps 2 to 4 for each motion instruction to be specified in the program. To specify the same standard motion instruction repeatedly, press the F1 [POINT] key while pressing the SHIFT key. This adds the previously specified motion instruction to the currently selected standard motion instruction.
6
5.3.4
Teaching an Supplementary Motion Instruction The supplementary motion instruction makes the robot do special work while it is moving according to the motion instruction. Some of the following supplementary motion instructions are provided (see Subsection 4.3.5 for the supplementary motion instructions): • Wrist joint motion instruction • Acceleration/deceleration override instruction • Skip instruction • Position compensation instruction • Direct position compensation instruction • Tool offset instruction • Direct tool offset instruction • Incremental instruction • Path instruction • Soft float • Asynchronous additional speed • Synchronous additional speed • Pre-execution • Post-execution
- 287 -
5.PROGRAMMING
B-82594EN-4/01
To teach a supplementary motion instruction, place the cursor behind the motion instruction and press the F4 [CHOICE] key to display the supplementary motion instruction menu. Select a supplementary motion instruction from the menu. (See Appendix A.3 for the program instruction menu.)
NOTE The available supplementary motion instructions vary according to your software configuration. Procedure 5-5
Teaching the supplementary motion instruction
Step 1
Place the cursor immediately behind the motion instruction.
2
Press the F4 [CHOICE] key. The supplementary motion instruction menu is displayed.
- 288 -
5.PROGRAMMING
B-82594EN-4/01
3
Select a desired item. For example, the following screen teaches a acceleration override instruction.
For details of the instructions, see Chapter 4.
Procedure 5-6
Teaching the incremental instruction
Step 1
Move the cursor to the space at the end of the motion instruction. The teaching incremental instruction is shown as follow.
CAUTION Teaching the incremental instruction makes the position data have no position information. Enter the incremental amount to the position data manually.
- 289 -
5.PROGRAMMING
5.3.5
B-82594EN-4/01
2
Enter the incremental amount directly to the position data.
3
Enter the incremental amount directly.
4
When you are fished to enter the position data, press F4,DONE.
Teaching a Control Instruction A control instruction is a program instruction for the Robot controller that is not a motion instruction. The control instructions are as follows: • Palletizing instruction • Register instruction • Position register instruction • Soft float instruction • I/O (input/output) instruction • Branch instruction • Wait instruction • Macro instruction - 290 -
5.PROGRAMMING
B-82594EN-4/01
• Program end instruction • Comment instruction • Supplementary motion instruction • Other instructions To teach a control instruction, first press the F1 (INST) key to display the submenu. Then, select a desired control instruction item from the menu (see Appendix A.3 for the program instructions menu).
NOTE The program instructions vary according to you software configuration. Procedure 5-7
Teaching a register instruction
Condition ■ ■
The teach pendant must be enabled. The program edit screen must be selected.
1 2
Move the cursor to END. Press the F1 (INST) key. Then, the control instruction menu is displayed.
Step
- 291 -
5.PROGRAMMING
B-82594EN-4/01
3
To teach a register instruction, select REGISTERS. The following screens indicate that the value of register [1] is increased by one.
For the details of the register instruction, see Chapter 4.
- 292 -
5.PROGRAMMING
B-82594EN-4/01
Procedure 5-8
Teaching the position register instruction
Step 1 2
Move the cursor to END. Press the F1, [INST] key. Then, the control instruction menu is displayed.
3
Select REGISTERS.
4
Select PR[ ]. Teach the instruction assigning the Cartesian coordinates of the current position to the position register on the following screens.
For details of the instruction, see Chapter 4. - 293 -
5.PROGRAMMING Procedure 5-9
B-82594EN-4/01
Teaching an I/O instruction
Step 1 2
Move the cursor to END. Press the F1, [INST] key. Then, the control instruction menu is displayed.
3
Select I/O. Teach the instruction that turns on RO[1] on the following screens.
For details of the instruction, see Chapter 4.
- 294 -
5.PROGRAMMING
B-82594EN-4/01
Procedure 5-10
Teaching move group instructions
Step 1
Move the cursor to the line number of a desired move statement (other than for circular movement).
2
Press F1, [INST]. Then, a list of control instructions is displayed.
3
Select Independent GP or Simultaneous GP. The contents of group 1 are moved to another group. Note that in this case, position data remains unchanged.
4
For a move statement within the move group instructions, edit the move type, move speed, and positioning type in the same way as for an ordinary move statement. Note that the following operations cannot be performed: • Changing the move type to circular • Specification of position data type (R[], PR[]) • Position number change • Teaching of additional move instructions (Deletion is allowed.) • Deletion/creation of move groups • Position modification by SHIFT + TOUCHUP For details of instructions, see Chapter 4.
- 295 -
5.PROGRAMMING
5.3.6
B-82594EN-4/01
TP Start Prohibition The Robot controller can execute the program immediately while editing it. To prevent the program from being executed by mistake, you can prohibit starting the program while teaching with this function. When you select Disable FWD/BWD in the function menu, starting a program with a teach pendant is prohibited. At this time, ”FBD” is reversely displayed in the upper right hand corner of the teach pendant screen to inform that TP FWD/BWD key is disabled. This ”FBD” means ”Forward, Backward Disabled”. To release the prohibition mode, press Disable FWD/BWD in the function menu again. At this time, the indicator of ”FBD” disappears and the override is decreased to the setting value specified in the system variable, $SCR.$FWDENBLOVRD, if it is larger than the setting value. (Standard value : 10%) Though the indicator, ”FBD”, displayed in upper right hand corner of the screen disappears when the teach pendant is disabled, ”FBD” is displayed again when the teach pendant is enabled again. Press and hold the SHIFT key, and press FWD or BWD in prohibition mode. At this time, a warning message, ”Teach pendant is disabled”, is displayed at the first line of the screen.
Jog feed during TP start prohibition A system variable can be set to enable jog feed only in the TP start prohibition state. To make this setting, system variable $SCR.$TPMOTNENABL is used. To enable this function (to enable jog feed only in the TP start prohibition state), change the value of system variable $SCR.$TPMOTNENABL from 0 to 1 (or from 2 to 3) on the system variable screen. The table below indicates the relationship between the value of system variable $SCR.$TPMOTNENABL and whether TP start and jog feed are enabled. Table 5.3.6 Setting for Jog feed during TP start prohibition $SCR.$TPMOTNENABL TP start Jog feed 0 1 2 3
Enabled Enabled Disabled Disabled
Enabled Disabled Enabled Enabled
With the standard setting, this function is disabled (jog feed is enabled irrespective of whether the teach pendant can start a program).
- 296 -
5.PROGRAMMING
B-82594EN-4/01
Procedure 5-11
Prohibiting Starting with Teach Pendant
Step 1 2
Press the FCTN key. The function menu is displayed. Select 2 Disable FWD/BWD. ”FBD” is reversely displayed in the uppermost right hand line of the screen.
3
To release the prohibition mode, select ”2 Disable FWD/BWD” in the function menu again. ”FBD” disappears and the override is reduced to a setting of $SCR.$FWDENBLOVRD.
- 297 -
5.PROGRAMMING Procedure 5-12
B-82594EN-4/01
When effective/disable of teach pendant is switched
Condition ■ ■
TP is in prohibition mode. The teach pendant is disabled.
1
The following program edit screen is displayed. ”FBD” is not displayed in TP prohibition state because a teach pendant is disabled.
2
Enable the teach pendant. ”FBD” is displayed at uppermost right hand corner of the screen and the override is reduced to the setting of $SCR.$FWDENBLOVRD.
Step
- 298 -
5.PROGRAMMING
B-82594EN-4/01
5.4
CHANGING A PROGRAM The method of changing the contents of an existing program is described in this section. • Selecting a program • Modifying a standard motion instruction • Changing a motion instruction • Changing a control instruction • Editing a program instruction Inserting a blank line Deleting a program instruction Copying a program instruction Finding a program instruction item Replacing a program instruction item Renumbering program lines
Selecting a program Select a program from the menu of existing programs.
Changing a motion instruction Change a motion instruction item. An example is position data, which is an instruction item that must be frequently changed.
Changing other instructions Change other instructions.
5.4.1
Selecting a Program When selecting a program, call the registered program to display the program edit screen for editing, changing and executing a program. Once a program is selected, the program is effective until another program is selected. While another screen is displayed such as the current position screen, the currently selected program is started by the start switch. • When the teach pendant is enabled (The current or halted program is forcibly terminated when a program is selected.) • When the teach pendant is disabled Another program cannot be selected while a program is being executed or halted. Select a program on the program selection screen.
- 299 -
5.PROGRAMMING Procedure 5-13
B-82594EN-4/01
Selecting a program
Step 1 Press the MENUS key. 2 Select SELECT. Alternatively, press the SELECT key to enable a program to be selected. In this case, the program selection screen is displayed.
3
5.4.2
Move the cursor to the name of a program to be corrected using the cursor keys (↑ and ↓) press the ENTER key. The selected program edit screen is displayed.
Changing a Motion Instruction When changing a motion instruction, change the instruction items of the motion instruction or change taught position data. For the motion instructions, see Section 4.3.
Changing position data To change position data, assign new position data to the position variable by pressing the F5 (TOUCHUP) key while pressing the SHIFT key.
- 300 -
5.PROGRAMMING
B-82594EN-4/01
Position data information The coordinates and configuration for position data can be directly changed on the position data information screen.
• • • •
F2 (PAGE):
Toggles between the standard axes and the extended axes F3 (CONFIG): Edits the configuration value. F4 (DONE): Terminates changing the position data information. F5 (REPRE): Toggles between Cartesian coordinates and joint coordinates.
Changing an instruction item To change an instruction item, press the F4, [CHOICE] key to display the motion instruction item menu, then select an instruction item from the menu. • Motion type: Controls a path to the end position (joint, linear, circular). When the motion type is changed, the feedrate unit is also automatically changed. • Position variable: The variable storing position data and the variable number are changed. • Feedrate: The speed of the robot when it moves (robot motion speed) and the feedrate unit are changed. • Positioning type: Positioning at the specified position is changed. • Supplementary motion instruction: An additional instruction to be executed when the robot is moving is changed.
CAUTION If teaching is made by joint coordinates, changing the user coordinate system does not affect the position variables and position registers. If the position variable is taught according to rectangular type, and the user coordinate system input option is not used, the position variable is not affected by the user coordinate system. In other cases, both of the position variable and position register are affected by the user coordinate system. Procedure 5-14
Changing position data
Condition ■ ■
The program to be changed must be selected. The teach pendant must be enabled.
- 301 -
5.PROGRAMMING
B-82594EN-4/01
Step 1
Move the cursor to the line number at which the motion instruction to be changed is displayed.
2
Move the robot to a new position and press the F5 [TOUCHUP] while pressing the SHIFT key. The new position is recorded.
3
When the position data is taught to the motion instruction with a incremental option again, a incremental option is removed.
• •
YES : A incremental option is removed and position data is taught. NO : The position data is not taught.
- 302 -
5.PROGRAMMING
B-82594EN-4/01
4
Procedure 5-15
When position data is taught in the position register as a position variable, the position data in a register is changed by editing.
Changing position data information
Step 1
To display position data information, move the cursor to the desired position variable, then press the F5, [POSITION] key. The position data information screen is displayed.
2
To change the position, move the cursor to the coordinates for each axis and enter new coordinates.
- 303 -
5.PROGRAMMING
B-82594EN-4/01
3
To change the configuration value, press the F3 [CONFIG] key, move the cursor to the configuration field, then enter a new configuration value with the cursor keys (↑ and ↓).
4
To change a coordinate system, press the F5 [REPRE] key and select the coordinate system to be changed.
NOTE JOINT display is valid when the robot is adjusted to the zero-degree position or when non-kinematic operation such as table operation control is executed. 5
Procedure 5-16
After changing position data information, press the F4 [DONE] key.
Changing a motion instruction
Step 1
Move the cursor to the instruction item of a motion instruction to be changed.
- 304 -
5.PROGRAMMING
B-82594EN-4/01
2
Press the F4 [CHOICE] key to display the submenu of the instruction items, then select the instruction item to be changed from the submenu. The following screens show changing the motion type from linear motion to joint motion:
3
The following screens show changing from the position variable to the position register.
- 305 -
5.PROGRAMMING
B-82594EN-4/01
4
Change the feedrate.
5
Change the feedrate unit.
6
Change the positioning type.
- 306 -
5.PROGRAMMING
B-82594EN-4/01
Procedure 5-17
Changing a circular motion instruction
Step 1
Place the cursor at the motion type of the circular motion instruction to be changed. The following screens show changing the circular motion instruction to the linear motion instruction.
NOTE When a circular motion is changed to a joint or linear motion, two motion instructions are created as a result. One instruction moves the tool to the passing point of the circular motion, while the other moves the tool to the end point.
- 307 -
5.PROGRAMMING
B-82594EN-4/01
2
The following screens show changing the linear motion instruction to the circular motion instruction.
NOTE When a joint or linear motion instruction is changed to a circular motion instruction, the taught data for the end point of the arc is canceled.
- 308 -
5.PROGRAMMING
B-82594EN-4/01
Procedure 5-18
Adding and deleting an additional motion instruction
Step 1
Position the cursor to an additional motion instruction. To add an offset condition instruction, for example, follow the procedure below:
- 309 -
5.PROGRAMMING
B-82594EN-4/01
2
To delete an offset condition instruction, for example, follow the procedure below:
Procedure 5-19 Changing the move speed (between numeric specification and register specification)
Step 1
To switch from numeric specification to register specification for the move speed of a move instruction, move the cursor to the speed value. Then, press the function key F1, [REGISTER].
- 310 -
5.PROGRAMMING
B-82594EN-4/01
2
Enter a desired register number (2 for example). For indirect specification, press F3 [INDIRECT]. (To return to direct specification mode, press F2 [DIRECT].)
3
To switch from register specification to numeric specification for the move speed of a move instruction
4
Move the cursor to the speed value. Then, press the function key F1 (SPEED).
5
Enter a desired speed value (20 for example).
- 311 -
5.PROGRAMMING
5.4.3
B-82594EN-4/01
Changing a Control Instruction You can change the syntax, item, or variable of a control instruction.
Procedure 5-20
Changing a control instruction
Step 1
Move the cursor to the instruction item to be changed.
- 312 -
5.PROGRAMMING
B-82594EN-4/01
2
Press the F4 (CHOICE) key to display the instruction menu and select the instruction item to be changed. The following screens show changing the wait instruction.
- 313 -
5.PROGRAMMING
5.4.4
B-82594EN-4/01
Program Edit Instructions The program edit instructions are used to edit a program. Press the F5 (EDCMDT) key to display the program edit instruction menu and select a desired program edit instruction from the menu.
Insert Inserts blank lines, the number of which is specified, between the existing lines of a program. When blank lines are inserted, the program lines are renumbered.
Delete Deletes a series of instructions from a program. After the instructions are deleted, the program lines are renumbered.
Copy Copies a series of instructions and inserts the instruction range into another location in the program. When a series of instructions is copied, the instruction group is selected and recorded in memory. Once the series of instructions is copied, it can be inserted into other locations in the program repeatedly.
Find A specified element of a program instruction is found. A specified element of a long program can be found quickly.
Replace Replaces an item of the specified program instruction with another item. This program is used, for example, when setup data for the program is changed. (For example, when the I/O allocation is changed, and DO[1] is to be changed to DO[2] in the program)
Comment On the program editing screen, the user can choose whether to display or hide a comment for the instructions listed below. Note that no comment can be edited.
- 314 -
5.PROGRAMMING
B-82594EN-4/01
• • • • •
DI instruction, DO instruction, RI instruction, RO instruction, GI instruction, GO instruction, AI instruction, AO instruction, UI instruction, UO instruction, SI instruction, SO instruction Register instructions Position register instructions (including position registers in the position data format for move instructions) Palletizing instructions Move instruction register speed specifications
NOTE The AI and AO instructions are analog I/O soft options. The instructions listed below are always accompanied by a comment, and do not allow display switching but allow editing. • Move instruction position variable • Label instructions • Power control instructions
NOTE 1 The comment display area for an instruction item that is too long to be displayed on one line of the screen may be shortened. 2 No comment is displayed for a register indirect specification. Position register [register [1]] = ...
Renumber Renumbers the program lines by line number in ascending order. Whenever a motion instruction is taught, the line number is increased regardless of its location in the program. When insertions and deletions are repeated, the line numbers are not sequentially arranged in a program. Renumbering arranges them sequentially in the program. The progress of renumbering is displayed as it is being performed.
CAUTION Do not perform power down before the progress indication reaches 100%. Otherwise, the program will be incomplete.
- 315 -
5.PROGRAMMING
B-82594EN-4/01
Undo Program edit operations such as an instruction modification, line insertion, and line deletion can be cancelled to return to the state present before those edit operations are performed. If an undo operation is performed during editing of a program line, all operations performed for that line are undone. For example, if a line is inserted or deleted, the state before the insertion or deletion operation is restored. If an undo operation is immediately followed by another undo operation, the state present before the first undo operation is performed is restored.
NOTE If an undo operation is performed for a line during program editing, all operations performed for that line are undone. This means that if an instruction is taught in a blank line or the last line of a program, and an undo operation is performed for that line during editing, the taught instruction is deleted. Procedure 5-21
Inserting blank lines
Step 1
Press the NEXT, > to display F5, EDCMD.
2
Press the F5, [EDCMD] key. The edit instruction menu is displayed. Select Insert.
3
- 316 -
5.PROGRAMMING
B-82594EN-4/01
In the example below, two blank lines are inserted between the 3rd and 4th lines. 4 Move the cursor to the line where instructions are to be inserted. In this example, move the cursor to the 4th line. 5 Enter the number of blank lines to be inserted (two) and press the ENTER key.
The two blank lines are inserted into the program and all the lines in the program are renumbered.
Procedure 5-22
Deleting instructions
Step 1 2
3
Move the cursor to the top of the line in which the instruction to be deleted is positioned. (Specify the line to be deleted with the cursor.) Press the NEXT, > to display F5, EDCMD.
Press the F5, [EDCMD] key to display the editing instruction menu.
- 317 -
5.PROGRAMMING
B-82594EN-4/01
4
Select Delete
CAUTION Once an instruction is deleted, the instruction is not restored. Be sure to confirm whether an instruction to be deleted should be done before doing it, or important data may be lost. 5
Specify the range of instruction lines to be deleted with the cursor keys (↑ and ↓).
6
To cancel deleting the selected line, press the F5 (NO) key. To delete the selected lines, press the F4 (YES) key.
- 318 -
5.PROGRAMMING
B-82594EN-4/01
Procedure 5-23
Copying and pasting instructions
Step 1
Press the NEXT, > until F5, EDCMD.
2 3
Press the F5, [EDCMD] key. The editing instruction menu is displayed. Select 3 Copy. The following screens show copying 2th to 4th lines to 5th to 7th lines.
4
Select the range of lines to be copied.
As a result of above steps, the selected instructions (2nd to 4th lines in this example) were copied in memory.
- 319 -
5.PROGRAMMING
B-82594EN-4/01
5
Decide where you want to paste the sentences copied in the memory.
6
Select the copying and pasting method (copying from the original).
7
By repeating the above steps 5 to 6, the same instruction group can be pasted at any number of locations in the program. To terminate the pasting of instructions, press the PREV key
8
Pasting methods The following copying and pasting methods are provided:
• • •
F2 (LOGIC)
: Copies and pastes motion instructions with no position data specified. F3 (POS-ID) : Copies and pastes motion instructions with the position numbers unchanged. F4 (POSITION) : Copies and pastes motion instructions with the position numbers updated.
- 320 -
5.PROGRAMMING
B-82594EN-4/01
Pressing the next page key (NEXT) displays the following function key menu:
The selected instructions are copied in reverse order. F3 and F5 have the following functions: • F3 (RM-POS-ID) : Copies the move instructions at a copy source in reverse order without changing the position numbers of the move instructions. The move type, move speed, and so forth of each move instruction are changed so that a movement totally opposite to the movement of the copy source is made. • F5 (RM-POS) : Copies the move instructions at a copy source in reverse order. Then assigns new position numbers. The move type, move speed, and so forth of each move instruction are changed so that a movement totally opposite to the movement of the copy source is made.
NOTE The copy function for a reverse movement is not supported for the additional move instructions listed below. If the move instructions at a copy source include any of the move instructions below, RM-POS-ID or RM-POS generates a warning, and only a copy operation in reverse order is performed. • Application instruction • Skip and high-speed skip instructions • Incremental instruction • Continuous rotation instruction • Pre-execution/post-execution instruction • Multi-group operation Example When the F4 (R-POSITION) is pressed
- 321 -
5.PROGRAMMING Procedure 5-24
B-82594EN-4/01
Finding a program instruction item
Step 1
Press the NEXT, > until F5, EDCMD.
2
Press the F5, [EDCMD] key. The editing instruction menu is displayed. Select Find. Select a program instruction item to be found. The following screens show how to find instruction, WAIT.
3 4
- 322 -
5.PROGRAMMING
B-82594EN-4/01
5
When the item to be found is an index, enter the value. To find an item regardless of whether the item is an index, press the ENTER key without entering anything.
If the specified instruction is found in the program, the cursor stops at the instruction. 6 To find the same instruction again, press the F4 (NEXT) key.
7
To terminate finding an instruction, press the F5 (EXIT) key.
NOTE The position of a track/offset instruction or touch sensor instruction cannot be found using the search instruction.
- 323 -
5.PROGRAMMING Procedure 5-25
B-82594EN-4/01
Replacing a program instruction item
Step 1
Press the NEXT, > until F5, EDCMD.
2
Press the F5, [EDCMD] key. The changing instruction menu is displayed. Select Replace. Select a program instruction item to be replaced and press the ENTER key. In the screen below the feedrate specified in the motion instruction is changed to another value.
3 4
The following replacement items are displayed: • Replace speed: Changes the feedrate to another value. • Replace term: Changes the positioning type to another value. • Insert option: Inserts a supplementary motion instruction. • Remove option: Deletes a supplementary motion instruction.
- 324 -
5.PROGRAMMING
B-82594EN-4/01
5
Select Replace speed.
•
6
Unspecified type : Changes the feedrates in all motion instructions • J : Changes the feedrates only in motion instructions for joint control. • L : Changes the feedrates only in motion instructions for linear control. • C : Changes the feedrates only in motion instructions for circular control. Specify the target type of the operation instruction.
• •
7
ALL type : No speed type is specified. Speed value : Operation statements that specify a speed with a numeric value are specified. • R[ ] : Operation statements that specify a speed with a register are specified. • R[R[ ]] : Operation statements that indirectly specify a speed value with registers are specified. Specify a target speed format.
8
Specify a target speed unit.
- 325 -
5.PROGRAMMING
B-82594EN-4/01
•
9
Speed value : The selected statement is changed to an operation statement which specifies a speed with a numeric value. • R[ ] : The selected statement is changed to an operation statement which specifies a speed using a register. • R[R[ ]] : The selected statement is changed to an operation statement which indirectly specifies a speed by using registers. Specify the motion type of the motion instruction for which the feedrate is to be changed.
10
Specify the unit of the feedrate to be changed.
11
Enter a desired feedrate.
The kinds of replacing items are displayed. • F2 (ALL) : Replaces all the items in the current line and subsequent lines. • F3 (YES) : Replaces the item at the cursor and finds the next item. • F4 (NEXT) : Finds the next item.
- 326 -
5.PROGRAMMING
B-82594EN-4/01
12
Select a replacement method.
13
To terminate item replacement, press the F5 (EXIT) key.
CAUTION The replacement instruction allows no move instruction to be replaced with the track/offset instruction or touch sensor instruction. If an attempt for such replacement is made, a memory write alarm is issued. To replace a move instruction, first delete the move instruction, then insert the touch sensor instruction or track instruction. Procedure 5-26
Renumbering the position number
Step 1
Press the NEXT, >, then press the F5, EDCMD.
2
Press F5, EDCMD. The changing instruction menu is displayed. - 327 -
5.PROGRAMMING
Procedure 5-27
B-82594EN-4/01
3
Select Renumber.
4
To renumber the program lines, press the F4 (YES) key. To cancel renumbering the program lines, press the F5 (NO) key.
Comment display switching
Step 1
Press NEXT to display F5 (EDCMD).
- 328 -
5.PROGRAMMING
B-82594EN-4/01
Procedure 5-28
2
Press F5 (EDCMD) to display the edit instruction menu.
3
Select Item 7 Comment.
4
To disable comment display, select Comment of the function key F5 (EDCMD) again.
Undoing edit operations
Step 1
Press NEXT to display F5 (EDCMD).
- 329 -
5.PROGRAMMING
B-82594EN-4/01
2
Press F5 (EDCMD) to display the edit instruction menu.
3
Select Item 8 Undo.
4
To perform an undo operation, select F4, (YES). To cancel the undo operation, select F5, (NO). When F4, (YES) is selected, the edit operation is undone.
5
When an additional undo operation is performed in succession, the first undo operation performed can be cancelled; this means the state present before the first undo operation is performed is restored.
NOTE If an edit operation is performed after an undo operation, the undo operation cannot be cancelled. - 330 -
5.PROGRAMMING
B-82594EN-4/01
CAUTION An undo operation automatically rewrites the program, so that the results may not be those expected by the operator. Before executing a program after an undo operation, carefully check the program. •
• •
•
•
• •
•
This function can undo the following operations: a) Instruction modifications b) Line insertion c) Line deletion d) Copying of program statements (reading) e) Copying of program statements (insertion) f) Program instruction replacement g) Reassignment of position numbers An undo operation cancels all edit operations performed on the line where the cursor is currently placed, and restores the state present before those edit operations are performed. The undo function is disabled when any of the following operations is performed: a) Power-off b) Selection of another program Undo operation cannot be performed in any of the following states: a) The teach pendant is disabled. b) The program is write-protected. c) Program memory is insufficient. The following edit operations cannot be undone: a) Teaching and editing of palletizing instructions b) Deletion of lines including palletizing instructions c) Copying of lines including palletizing instructions (reading) d) Copying of lines including palletizing instructions (insertion) e) Replacement in a program including palletizing instructions f) Number reassignment in a program including palletizing instructions If the power is turned off while an undo operation is being performed, the undo operation is stopped. Note that in this case, the program may become unusable. If any of the following instructions is performed after an edit operation, the undo function cannot be performed: a) Laser instruction b) Palletizing instruction c) Spot welding instruction d) Line tracking instruction If any of the following function is executed after an edit operation, the undo function cannot be performed: a) Online position modification b) Fine adjustment of welding speed
- 331 -
5.PROGRAMMING
5.5
B-82594EN-4/01
PROGRAM OPERATION This section describes the following program operations: • Changing program information • Deleting a program • Copying a program • Reading a program • Storing a program • Printing a program • Displaying the attribute of a program
5.5.1
Changing Program Information The program header information is changed with a program detail screen(see Section 4.1 ). Setting without the motion group motion group can be done. The following items can be set: • Program name: Name of program to be changed. • Subtype: The subtype of a program to be changed. • Comments: The comments in the program to be changed. • Group mask: Specifies a motion group to be controlled in a program. You can also set so a program has no motion group. • Write protection: Prevents the modification of a program. • Interruption disable: Causes a program that has no motion group no to be paused by the alarm whose severity is SERVO or lower, the emergency stop, and the hold. Display the following items on the program information screen: • Creation Date: • Modification Date: • Name of the file to be copied • Positions: FALSE/TRUE • Memory area size of program
Deleting a program The unnecessary program can be deleted.
Copying a program The program with another name in the same content can be reproduced.
Display of a program attribute The following program header information can be displayed on the program selection screen: • Comment - The comment in a header information is displayed. • Protection - The settings of ”Write protect:” in a header information is displayed • Last Modified - The settings of ”Modification Date:” in a header information is displayed. • Size - The number of lines of program and memory size are displayed. - 332 -
5.PROGRAMMING
B-82594EN-4/01
•
Copy Source - The settings of ”Copy Source:” in a header information is displayed.
CAUTION All of the free memory size displayed on the directory screen may not be usable to store a program. Even if the size of free memory is not 0, for example, no program may be creatable. Procedure 5-29
Changing program information
Condition ■
The teach pendant must be enabled.
1 2
Press the MENUS key to display the screen menu. Select SELECT. The program selection screen is displayed. Alternatively, press the SELECT key to display the program selection screen.
3
Press NEXT, > to display the next page, then press the F2, (DETAIL) key. The program information screen is displayed.
4
Specify each item (see Section 4.1). If the motion instruction is taught in the program, you can not set the 3 ”Group Mask:” of this program.
Step
- 333 -
5.PROGRAMMING
B-82594EN-4/01
5
Procedure 5-30
After specifying program information, press the F1, (END) key.
Deleting a program
Step 1 Press the MENUS key to display the screen menu. 2 Select SELECT. The program selection screen is displayed. The program selection screen can also be displayed by pressing the SELECT key, instead of executing steps 1 and 2 above.
3
Move the cursor to the name of a program to be deleted, then press the F3 DELETE key.
4 5
Press the F4 (YES) key. The specified program is deleted.
- 334 -
5.PROGRAMMING
B-82594EN-4/01
CAUTION Once a program is deleted, the program cannot be restored. Make sure you delete only programs that you no longer want. Procedure 5-31
Copying a program
Step 1 2 3
Press the MENUS key to display the screen menu. Select SELECT. The program selection screen is displayed. Press F1 (copy) on the next page and then a program copy screen is displayed.
4
Enter the name of the program to be copied, then press the ENTER key.
5 6
Press the F4 (YES) key. The desired program is copied to the specified program, PROGRAM1.
- 335 -
5.PROGRAMMING Procedure 5-32
B-82594EN-4/01
Displaying the Attribute of the Program
Step 1 2
Press the MENUS key. The screen menu is displayed. Select ”0 ― next ―”. ”1 SELECT” in the next page is displayed. You can select a program selection screen by pressing the SELECT key instead of the above 1 to 2 procedure.
3 4 5
Press F5,[ATTR]. Select Size. The number of lines and size of a program is displayed at the place that the comments are displayed.
6
When you want to display the other item, select the desired item in the procedure 4.
- 336 -
5.PROGRAMMING
B-82594EN-4/01
5.6
BACKGROUND EDITING While the robot is being operated, the background editing function allows another program to be edited in the background. With this function, another program can be modified and checked without stopping robot operation, thus increasing productivity and maintenance efficiency.
WARNING This function allow editing when the teach pendant is disabled. However, when the teach pendant is disabled, any edit operations performed by an operator near the robot are very dangerous. To ensure operator safety, be sure to perform edit operation outside the robot movement range.
Outline of this function This function is outlined below. • Background editing is started by selecting a special program name for background editing when the teach pendant is disabled. The special program name is ”-BCKEDT-”. • During background editing, the following data is displayed on the top of the edit screen of the teach pendant: Program name selected in the background <> for indicating that background editing is in progress
• •
a: Execution status of the program selected (status line) b: Program name selected in the background c: Indication that background editing state is set No modifications to a program being edited in the background are reflected in the original program until the background editing is completed. To terminate background editing, press the F5 [EDCMD] key on the edit screen to display a menu, then select End_edit from the displayed menu. Here, the user can choose whether to reflect the results of background editing in the original program or discard the results of background editing.
- 337 -
5.PROGRAMMING
B-82594EN-4/01
•
No multiple programs can be edited in the background at a time. The background editing of a program must be terminated by End_edit operation before another program can be edited in the background. • If another program is selected without performing End_edit operation during background editing, the results of background editing are preserved. Background editing can be restarted by reselecting the special program name (”-BCKEDT-”) for background editing on the program directory screen. • When the teach pendant is disabled, and the edit screen is displayed, the user can switch between the display of the program selected in the foreground (not background) and the display of the preserved results of background editing. • When the teach pendant is enabled, the special program name for background editing can be selected from the program directory screen, and can be executed with the teach pendant. • When the teach pendant is disabled, the special program for background editing cannot be externally selected and executed. • When an external start signal is applied during background editing, the program selected in the foreground is started. • The program started during automatic operation or executed by subprogram calling is the original program selected in the background. • Even if a program is externally selected with the external program selection function (PNS) during background editing, the background editing can be continued without being interrupted. The operation flows of the following cases are explained using figures below: • When background editing is started with the teach pendant disabled • When background editing is started with the teach pendant enabled • When a program is externally selected during background editing • When a start signal is externally applied during background editing • When the teach pendant is enabled during background editing • When the teach pendant is disabled during background editing • When the screen is switched using the edit key on the teach pendant • When background editing is terminated with the teach pendant disabled • When background editing is terminated with the teach pendant enabled
- 338 -
5.PROGRAMMING
B-82594EN-4/01
When background editing is started with the teach pendant disabled When a program is selected in background editing, the program selected in the foreground is not modified. Even if no program is selected in the foreground, background editing is started.
- 339 -
5.PROGRAMMING
B-82594EN-4/01
When background editing is started with the teach pendant enabled If the special program for background editing is selected when the teach pendant is enabled, the program is selected in the foreground, and its test execution is enabled.
When a program is externally selected during background editing If a program is externally selected during background editing (with the teach pendant disabled), the status line displays the state of the selected program. The state of background editing remains unchanged.
- 340 -
5.PROGRAMMING
B-82594EN-4/01
When a start signal is externally applied during background editing If a start signal is externally applied during background editing (with the teach pendant disabled), the program selected in the foreground is started, and the status line displays RUNNING. The state of background editing remains unchanged.
When the teach pendant is enabled during background editing If a program is selected in the foreground, background editing and the program being executed are suspended, and the program selected in the foreground is displayed on the screen. If an alarm is issued from the program being executed, for example, the point of alarm generation can be immediately located and corrected by enabling the teach pendant according to this function. To return to background editing, disable the teach pendant, then press the edit key or reselect ”-BCKEDT-” from the program directory screen.
If no program is selected in the foreground, the special program (”-BCKEDT-”) is selected to allow the program being edited in the background to be executed. The status line displays the state of ”-BCKEDT-”.
- 341 -
5.PROGRAMMING
B-82594EN-4/01
When the teach pendant is disabled during background editing If ”-BCKEDT-” is selected in the foreground, the foreground enters the program nonselection state when the teach pendant is disabled. (The status line disappears.) So, the program being edited in the background cannot be executed externally. The background editing can be continued without modification.
When the screen is switched using the edit key on the teach pendant If the teach pendant is disabled, and the program edit screen is displayed, pressing the EDIT key switches screen display between the display of the program selected in the foreground and the display of suspended background editing. If there is a program in the foreground and background as well, the screen display switches between foreground display and background display each time the edit key is pressed, as shown below.
If no program is selected in the foreground, pressing the edit key does not switch screen display; the error Program is not selected occurs. If no program is selected for background editing, pressing the edit key does not switch screen display; the error Not editing background program occurs. This error occurs only when the background editing option is selected.
- 342 -
5.PROGRAMMING
B-82594EN-4/01
When background editing is terminated with the teach pendant disabled When background editing is terminated, the program directory screen appears. At this time, the user can specify whether to reflect the results of background editing in the original program.
- 343 -
5.PROGRAMMING
B-82594EN-4/01
When background editing is terminated with the teach pendant enabled When background editing is terminated, the program directory screen appears. The program edited in the background is selected in the foreground, and the status line displays the state of the program.
- 344 -
5.PROGRAMMING
B-82594EN-4/01
Operation flow The operation flow of this function is shown on the next page.
- 345 -
5.PROGRAMMING
B-82594EN-4/01
Notes When using this function, note the points below. • When a program is selected for background editing, the selected program is internally copied to the special program for background editing. So, memory larger than the size of a selected program needs to be allocated beforehand. • When the background editing of a program is terminated, the original program is backed up, and the background program is reflected in the original program. So, memory larger than the size [(original program) + (increment produced by background editing)] needs to be allocated beforehand. • If background editing cannot be terminated for a cause such as insufficient memory, the following error and its cause are displayed in the alarm display lines (line 2 and 3) on the teach pendant: TPIF-054 Could not end editing MEMO-126 No more available memory • When the power to the robot is turned off then back on while background editing is being terminated (while the original program is being updated) To prevent the updating of the original program from being stopped halfway, restore the original program from the backup program when the power is turned on. If the results of background editing need to be reflected, check the results of background editing, then perform another editing termination operation. If an attempt to restore the original program fails, the following error is displayed: TPIF-055 Could not recovery original program In this case, check the results of background editing, then perform another editing termination operation. If the power is turned off then back on when editing is terminated, check the state of the original program before starting continuous operation. • If the original program is executed when background editing is terminated, the robot may stop, depending on the timing of the execution. When terminating background editing, carefully check that the original program is not executed. Four cases can be considered for the timing relationship between background editing termination operation and program execution. Case 1: The program is being executed when background editing is terminated. In this case, the message “You could not implement the modification because the program was executing or pausing” is displayed in the central part of the teach pendant, and the results of background editing cannot be reflected. Case 2: The program is started exactly when the results of background editing have been reflected In this case, the program reflecting the results of background editing is executed.
- 346 -
5.PROGRAMMING
B-82594EN-4/01
-
•
• •
•
•
•
Case 3: An attempt is made to start the program while the results of background editing are being reflected One of the following errors occurs, and the robot stops: SYST-011 Failed to run task MEMO-004 Specified program is in use Case 4:When the original program is deleted, and a program is re-created to reflect the results of background editing, an attempt is made to start the program. One of the following error occurs, and the robot stops: SYST-011 Failed to run task MEMO-027 Specified line does not exist When the original program is write-protected (Write-protect is ON), editing cannot be terminated. In this case, one of the following error occurs: TPIF-054 Could not end editing TPIF-008 Memory protect violation Background editing can be terminated even when the special program for background editing is write-protected. The status line displays the execution state of a selected program. So, if a subprogram being executed is terminated forcibly, and the main program is selected in the foreground, the status line continues to display the subprogram name. If program start operation is initiated here, the execution of the selected main program is started, and the status line displays the execution state of the main program. If the disabled edit key or teach pendant is enabled on the background screen in the state above, the status line does not display the subprogram but the main program selected in the foreground. When the teach pendant is disabled, a program can be created/ deleted. However, when a program is created, the following error occurs; no selection is made in the foreground, and no direct transition to the edit screen is made: TPIF-104 Teach Pendant is disabled If the teach pendant is disabled after the special program for background editing is selected and executed with the teach pendant enabled, the end state is set. If the teach pendant is disabled when a subprogram is executed from the special program, the execution is terminated, and the program directory screen appears. When there is a suspended program in the background, the special program for background editing (”-BCKEDT-”) cannot be read from the floppy disk. In this case, the following message appears: This program is being edited Before reading the special program from the floppy disk, terminate background editing.
- 347 -
5.PROGRAMMING
5.7
B-82594EN-4/01
SINGULAR POINT CHECK FUNCTION If a move statement is taught, or a position modification is made based on rectangular coordinate position data when the robot is positioned near a singular point, the robot may move with an attitude different from the taught attitude when the move statement is executed. (See Subsection 4.3.2.) To prevent such trouble, the singular point check function checks to see if a taught position is a singular point when the position is taught. Then, the function teaches such a position according to axial type based on the user’s choice.
Function To enable this function, set the system variable $MNSING_CHK to TRUE. If a move statement is taught with SHIFT + POINT key or a position modification is made with SHIFT + TOUCH UP key when the robot is at a singular point, this function checks if the taught position is a singular point. This check is made when the following conditions are satisfied: • The additional instructions do no include incremental instructions, position compensation instructions, and tool compensation instructions. • The UF (user coordinate system number) of position data is 0. • The registered position type is rectangular type. If a check finds that the taught position is a singular point, the top two lines of the teach pendant display the following warning message: TPIF-060 Can’t record on cartesian (G:1) MOTN-023 In singularity i: Move group number at a singular point At the same time, the following prompt message is displayed at the lower part of the teach pendant: Record current position on joint At this time, the function keys YES and NO are displayed. Select one of the two keys. • YES: Deletes position data according to axial type. • NO: Does not perform position teaching/modification. The position data of a program that has multiple move groups is checked for singular points in ascending order of group numbers. If multiple groups are at singular points, a warning message and prompt message are displayed for each group.
Notes This function is not applicable to the teaching of typical palletizing loading points and passing points.
- 348 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
6
EXECUTING A PROGRAM This chapter describes testing a program and automatic operation. Contents of this chapter 6.1 6.2 6.3 6.4 6.5 6.6 6.7
PROGRAM HALT AND RECOVERY...................................350 EXECUTING A PROGRAM...................................................357 TESTING..................................................................................366 MANUAL I/O CONTROL.......................................................377 OPERATING THE HAND MANUALLY...............................382 AUTOMATIC OPERATION...................................................384 ONLINE POSITION MODIFICATION ..................................392
- 349 -
6.EXECUTING A PROGRAM
6.1
B-82594EN-4/01
PROGRAM HALT AND RECOVERY Program halt refers to stopping a running program. A program halt is caused by: • An alarm occurring accidentally while the program is running. • An intentional stop of a running program by the operator. The operating robot stops in one of the following ways: • Fast stop : The robot is quickly decelerated until it stops. • Slow stop : The robot is slowly decelerates until it stops. Program halt states are classified into two types: • Forced termination (end): Display the termination status of a program execution. ABORTED is displayed on the screen of the teach pendant. If the main program is terminated while a subprogram is being executed, information on return of control to the main program is lost.
•
Halt (temporary stop): The execution of a program is stopped temporarily. PAUSED is displayed on the screen of the teach pendant. The temporarily stopped program can be restarted. The subprogram called with a program call instruction returns control to the main program.
To start from another line in the same program or another program, abort a program to release the paused state. There are two methods to halt a program intentionally: • Press the emergency stop button on the teach pendant or the machine operator’s panel or release the deadman switch. Peripheral device I/O *IMSTP input • Press the HOLD button on the teach pendant or use the input signal *HOLD of the peripheral I/O: These inputs halt the execution of the program. • Select 1 ABORT(ALL) from the miscellaneous menu. Peripheral device I/O *CSTOPI input. This method aborts the program.
- 350 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
6.1.1
Halt by an Emergency Stop and Recovery To stop the robot immediately, press the emergency stop button on the machine operator’s panel/box or teach pendant. In this time an emergency stop alarm occurs. Pressing the emergency stop button causes the following: • The robot stops operating immediately and the program is halted. • An alarm occurs and the power to the servo system is turned off.
Procedure 6-1
Emergency stop and recovery
Emergency stop procedure - Step 1
Press the emergency stop button on the teach pendant or the machine operator’s panel. This halts the running program, PAUSED is displayed on the teach pendant. The emergency stop button is locked to keep it pressed (on state). The emergency stop alarm message is displayed on the screen of the teach pendant. The FAULT lamp lights.
Emergency stop button
Recovery procedure 2 3
Eliminate the cause of the emergency stop. For example, correct the program. Rotate the emergency stop button clockwise to unlock the button.
- 351 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
4
6.1.2
Press the RESET key on the teach pendant (or operator’s panel). The alarm message then disappears from the screen of the teach pendant, and the FAULT lamp goes off.
Halt by a Hold and Recovery To decelerate the robot slowly until it stops, press the HOLD key on the teach pendant or the operator’s panel. Pressing the HOLD key causes the following: • The robot decelerates slowly until it stops (the program is halted). • A setting can be made to cause an alarm to turn off the servo power. To make this setting, select SETUP General on the general item setting screen. (→ See Section 3.16, “SETTING THE GENERAL ITEMS”.)
Procedure 6-2
Hold and recovery
Hold procedure - Step 1
Press the HOLD key on the teach pendant. The running program is halted, and PAUSED is displayed on the teach pendant. The alarm message is only displayed when the halt alarm is enabled.
2
To release the halt state, restart the program.
Recovery procedure
- 352 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Procedure 6-3
Terminating (aborting) a program forcibly
Abort a program - Step 1 2
6.1.3
To release the paused state and make a program aborted, press the function key to display the function menu. Select ABORT(ALL). The program is aborted then the halt state is released.
Halt Caused by an Alarm An alarm is issued when a failure is detected or when the emergency stop signal or another alarm signal is input from a peripheral device while the operator teaches or plays back a program. When an alarm is generated, it is indicated on the teach pendant, and processing such as robot operation and program execution is stopped to ensure safety.
Displaying an alarm The operator can check whether an alarm has occurred by watching the FAULT lamps on the teach pendant and the first line and second line on the screen of the operator’s panel. The kind of a alarm is recognized by a alarm code. The cause and corrective action of a alarm can be known by a alarm code.(See APPENDIX C.1) Alarm
Fig. 6.1.3 (a) Display and Indication of an Alarm
- 353 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Alarm history To display the alarm history, select an alarm history screen [4 ALARM].(See APPENDIX C.1, ”ALARM CODES”)
NOTE The WARN alarm history is not recorded when system variable $ER_NOHIS = 1.
Alarm detail information Alarm has the detail information. To display the alarm detail information, press F5, HELP in the alarm history screen [4 ALARM].
• • • •
Alarm code: Identifies an alarm. Alarm detail code: Identifies an alarm detail. Generation date: The generation date of the alarm is indicated. (It is not supported currently.) Alarm severity: Indicates the severity of an alarm.
- 354 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Resetting an alarm After eliminating the cause of an alarm, press the RESET key to reset the alarm. The alarm indicated in the first and second lines of the teach pendant disappears. When the servo power is turned off, it is turned on. Resetting an alarm usually enables the robot.
Fig. 6.1.3 (b) RESET Key
Disabling the output of peripheral I/O alarm signals The output of alarm signals (FAULT output) can be disabled. • Set $ER_NO_ALM.$NOALMENBLE to 1 (enabled). • Specify the number of alarms for which output is to be disabled in $ER_NO_ALM.$NOALM_NUM. • Specify the codes of the alarms for which output is to be disabled in $ER_NO_ALM.$ER_CODE1 to $ER_NO_ALM.$ER_CODE10. (See Alarm code) (Meaning: SERVO-002 alarm) 11 002 Alarm ID Alarm No.
Halt alarm The halt alarm function issues an alarm and turns off the power to the servo system when the operator presses the HOLD key to halt the robot. Specify the fault alarm function in [6 SETUP General] on the general item setting screen (see Section 3.16, “SETTING THE GENERAL ITEMS”).
- 355 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Alarm severity The alarm severity indicates the severity of an alarm and the cause of the alarm. Whether program execution and robot operation are stopped, and whether the servo power is turned off depend on the alarm severity.
Program NONE WARN PAUSE.L PAUSE.G STOP.L STOP.G SERVO ABORT.L ABORT.G SERVO2 SYSTEM Range
Table 6.1.3 (a) Alarm Severity Robot operation Power to servo system
none
none
pause
decelerate the robot slowly until it stops
abort
stop the robot immediately decelerate the robot slowly until it stops stop the robot immediately
none
off none off
Range — — Local Global Local Global Global Local Global Global Global
Indicates the range in which an alarm is issued when more than one program is executed (multitasking function). Local An alarm is issued only to the program that caused the alarm. Global An alarm is issued to all programs.
NOTE Some alarms do not observe the above rules. Severity WARN
PAUSE STOP SERVO
ABORT SYSTEM
Table 6.1.3 (b) Description of Alarm Severity Description A WARN alarm warns the operator of a comparatively minor or unimportant failure. The WARN alarm does not affect the operation of the robot. When a WARN alarm occurs, no corresponding LED on the teach pendant or the machine operator’s panel lights. To prevent a possible failure in the future, action should be taken for this alarm. When a PAUSE alarm occurs, the execution of the program is halted, and the operation of the robot is stopped. Appropriate action must be taken for the alarm before the program is restarted. When a STOP alarm occurs, the execution of the program is halted, and the robot is decelerated until it is stopped. Appropriate action must be taken for the alarm before the program is restarted. When a SERVO alarm occurs, the execution of a program is paused(or aborted) and the power to the servo system is turned off to stop the robot immediately. The most common cause of a SERVO alarm is hardware failure. When an ABORT alarm occurs, the execution of the program is forcibly terminated, and the robot is decelerated until it is stopped. A SYSTEM alarm is issued when a major system failure occurs. When a SYSTEM alarm occurs, every robot in the system is disabled. Contact the FANUC Service Division. After taking appropriate action for the alarm, turn on the power again.
- 356 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
6.2
EXECUTING A PROGRAM To execute a program is to play back a taught program. A taught program is played back just like a recorded video tape is played back.
6.2.1
Starting a Program A program can be started by: • Using the teach pendant (SHIFT key and FWD or BWD key) • Setting the START button on the operator’s panel. : option panel only • Using the peripheral device (RSR 1 to 4 input, PROD_START input, and START input)
Fig. 6.2.1 (a) Starting a program
For safety’s sake, a program can be started only in a device having motion control. Motion control can be switched by using the teach pendant enable switch on the operator’s panel and the remote Local mode switch. (For the remote local mode switch, see Section 3.15, “SYSTEM CONFIG MENU”.)
Fig. 6.2.1 (b) How to Set the Right to Start a Program
- 357 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
CAUTION When the start right is switched by using the enable switch on the teach pendant or the remote/Local mode switch, any programs that are currently running are temporarily halted.
6.2.2
Robot Motion The robot moves just as it is instructed by the motion instructions in the program. See Section 4.3, ”MOTION INSTRUCTIONS”. The following factors determine the motion of the robot: • Feedrate override: Robot motion speed (operating speed) • Cartesian coordinate system: Work area where the robot moves
Feedrate override The feedrate override determines the operating speed. The feedrate override is specified as a percentage of the feedrate specified in the program (programmed speed). The current feedrate override is displayed in the upper right corner of the screen of the teach pendant, as shown in Fig. 6.2.2 (a). Pressing the feedrate override key displays a popup window in reverse video in the upper right corner of the screen to call the operator’s attention. The popup window in reverse video automatically disappears a few seconds later or after another key is pressed.
Fig. 6.2.2 (a) Screen Display for Feedrate Override
A feedrate override of 100% would cause the robot to operate at the maximum speed specified in the current setting. Table 6.2.2 shows the change in feedrate override when the override key is pressed. Table 6.2.2 Feedrate Override When the override key is pressed
When the override key is pressed while pressing the SHIFT key(*1)
VFINE → FINE → 1% → 5% → 50% → 100% In 1% In 5% increments increments VFINE → FINE → 5% → 50% → 100%
*1 Enabled only when $SHFTOV_ENB is 1
- 358 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
To change the feedrate override, press the override key. Whenever the negative override key is pressed while the SHIFT key is pressed, the feedrate is decreased in the order: VFINE, FINE, 5%, 50%,100%. However, the feedrate is changed in this way only when system variable $SHFT OV_ENB = 1. Note that FINE and VFINE are enabled only during a jog feed. When FINE or VFINE is specified, the robot moves at a feedrate override of 1%.
Fig. 6.2.2 (b) Override Keys
A feedrate override must be determined according to the condition of the machining cell, type of robot motion, and the skill of the operator. Therefore, an inexperienced robot operator should use a low feedrate override. The feedrate override can only be increased up to the maximum value specified in $SCR.$RUNOVLIM. When the safety speed signal (*SFSPD input) (→ see Section 3.3) is turned off, the speed override value falls to the $SCR.$FENCEOVRD value. In this case, the speed override can be increased only up to the upper limit specified in $SCR.$SFRUNOVLIM. The system provides a function for allowing the original speed override to be restored when the safety fence is closed. (→ See Section 3.16.)
Operating speed The operating speed is the speed at which the robot moves while the program is played back. The operating speed is obtained from the following expressions:
Fig. 6.2.2 (c) Operating Speed
- 359 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Checking a Cartesian coordinate system When position data is played back according to Cartesian coordinates, the coordinate system number of the Cartesian coordinate system to be used is checked. When one of the coordinate system numbers 0 to 9 is specified and the specified coordinate system number does not agree with the currently selected coordinate system number, the program is not executed. The coordinate system number is specified for position data when the position is taught. To change a written coordinate system number, use the tool change function/coordinate system change function [option].
- Tool coordinate system number (UT) The number of a mechanical interface coordinate system or tool coordinate system is specified as a tool coordinate system number (UT). This number determines the tool coordinate system. -0 : The mechanical interface coordinate system is used. - 1 to 9 : The tool coordinate system having the specified tool coordinate system is used. -F : The coordinate system having the currently selected tool coordinate system number is used.
- User coordinate system number (UF) The number of a world coordinate system or user coordinate system is specified as a user coordinate system number (UF). This number determines the coordinate system for the work area. -0 : The world coordinate system is used. - 1 to 9 : The user coordinate system having the specified user coordinate system is used. -F : The coordinate system having the currently selected user coordinate system number is used.
Position data information Pressing the F5, [DETAIL] key displays position data information.
- 360 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Fig. 6.2.2 (d) Selecting a Tool Coordinate System and User Coordinate System
6.2.3
Resuming a Program Resuming a program means to restart a halted program. Before a program is halted, the system records the program. As a result, the following is possible: • Control can be passed to the main program called with the program call instruction. • The path for a circular motion can be reproduced.
Path for circular motion In circular motion, the robot moves from the current position to the target point along the path that passes through the passing point. After the robot motion is interrupted by program halt, the robot is moved by jog feed, and the program is resumed. In this case, the robot moves along a path that is similar to the one that was specified before the program was halted. (The locus of an arc is recalculated on the assumption that the pass point is the current position after jogging, and that the start point is that used before the interruption.) When a step test halted at the end of a circular motion is resumed after jog feed, the tool is returned to the end point of the circular motion, by means of a linear motion. (For a step test, see Subsection 6.3.2.) The motion is executed at the travel speed specified in the circular motion instruction.
- 361 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Fig. 6.2.3 Path for a Circular Motion
Releasing the halt state The halt state of the program is released when: • 1 PROGRAM ABORT is selected from the miscellaneous menu. • Switching of the start right (→ See Subsection 6.2.1.) • Creating new program when the teach pendant is enabled. For program creation, see Section 5.3. • Selecting another program when the teach pendant is enabled. For program selection, see Subsection 5.4.1.
Moving the cursor in the halt state When the cursor is moved to a desired line in the halted program and the program is to be resumed, the system asks the operator whether the program is to be resumed at the line to which the cursor has been moved. When YES is selected in response to this message, the program is halted at the line to which the cursor has been moved. When NO is selected, the cursor is returned to the line it was at before it was moved (original line), then the program is halted at that line. For both YES and NO, when the program is resumed, program execution starts at the line to which the cursor has been moved.
Procedure 6-4
Releasing the halt state
Condition ■
The program must be halted. (PAUSED is displayed on the screen.)
1
Press the FCTN key to display the miscellaneous menu.
Step
- 362 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
2
Procedure 6-5
Select 1 PROGRAM ABORT. The program is terminated. (ABORTED is displayed on the screen.)
Moving the cursor in the halt state
Condition ■
The program must be halted. (PAUSED is displayed on the screen.)
1 2
Move the cursor to the line where the program is to be resumed. Restart the program. The system asks the operator whether the program is to be resumed at the line to which the cursor has been moved.
3
Select YES to resume the program at the line to which the cursor has been moved. This line is then specified as the current line.
Step
Select NO to resume the program at the line the cursor was at before it was moved (original line). The cursor is then returned to the original line.
- 363 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Restart position check function When a program is restarted in AUTO mode, this function compares the current robot position with the robot position present when the program was halted. If the comparison shows that the difference in position is beyond a set tolerance, the function issues a warning not to start the program. If a warning is issued, select the restart method from the choices listed below. Make a choice with the teach pendant. (1) Restart the program with no special action. (2) Change the mode and return the robot to the stop position, then restart the program. When restarting the program, on the restart position check screen of the setting menu, set the tolerable distance between the current robot position and the position at which the robot was halted.
1.
2. 3.
4.
Group For each group, you can enable or disable the restart position check function and set tolerances. Set a target group number for setting. When the restart position check function is enabled for more than one group, a warning is issued if a tolerance of one group is exceeded. Enabling/disabling tolerance check To enable the restart position check function, select YES. (The default setting is YES.) Tolerable distance (mm) At program restart, when the difference in distance between the current robot position and the position at which the robot was halted is greater than the value set here, a warning is issued, and the program is not started. Tolerable attitude (deg) At program restart, when the difference in joint angle between the current robot position and the position at which the robot was halted is greater than the value set here, a warning is issued, and the program is not started.
- 364 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
5.
Tolerance for axes: Rotation axis (deg) When the difference in angle between the current position of a rotation axis in the robot and the position at which the robot was halted is greater than the value set here at program restart, a warning is issued, and the program is not started. 6. Tolerance for axes: Linear axis (mm) When the difference between the current position of a linear axis in the robot and the position at which the robot was halted is greater than the value set here at program restart, a warning is issued, and the program is not started. When a program is restarted, this function compares the current robot position with the position at which the robot was halted. If the comparison shows that any of the distance, attitude, and axis position data exceeds a tolerance, a warning is issued, and the program is not started. In this case, the following message appears on the teach pendant:
(1) When STOP is selected When “STOP” is selected, this pop-up menu is disappeared, and the program is still paused. After select “STOP”, if start signal input, the tolerance check is executed and the pop-up menu is appeared again. To resume the program, please move the robot to the position within the tolerance by jog feed, then input start signal. (2) When CONTINUE is selected The popup menu disappears, and the program remains halted. When the start signal is input under these circumstances, the program is started. If jog feed is performed after CONTINUE is selected, checking is made again when the program is restarted next.
CAUTION This function cannot be used with the line tracking function and the constant joint path function at the same time. This function is associated with the restart sequence of a motion statement containing a spot instruction as a motion option.
- 365 -
6.EXECUTING A PROGRAM
6.3
B-82594EN-4/01
TESTING Testing refers to checking the operation of the robot alone before automatically operating the robot in the site line. Testing the program is very important. It must be done to ensure the safety of the workers and the peripheral devices. The following two methods can be used for testing: • Step test: Execute the program line by line using the teach pendant or operator’s panel. • Continuous test: Execute the program from the current program line to the end of the program (up to the end-of-program symbol or program end instruction) using the teach pendant or operator’s panel. The teach pendant must be enabled before testing is performed using the teach pendant. The teach pendant is enabled when. ■ The teach pendant enable switch is on. Before test operation can be started from the operator’s panel/box, the operator’s panel must be in the enabled state. The operator’s panel can be placed in this state provided the following conditions are satisfied: ■ The enable switch on the teach pendant is set to OFF. ■ The remote switch on the operator’s panel/box is set to the local position. ■ The peripheral device I/O *SFSPD input is on. Before starting a program containing motion instructions, the following operation conditions must be satisfied: ■ The input signal ENBL for the peripheral I/O must be on. ■ An alarm must not be occurring The typical test procedure is as follows: 1 Turn on the machine lock switch, perform step operation, and check program instructions and I/O. 2 Turn off the machine lock, and perform step operation from the teach pendant to check the robot operation, program instructions, I/O, and so forth. 3 Perform continuous operation at low speed. 4 Perform continuous operation at high speed and check the position of the robot and the operation timing.
- 366 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
6.3.1
Specifying Test Execution To specify test execution is to specify the requirements for test execution of a program.
Items Robot lock
Dry run Cart. dry run speed
Joint dry run speed Jog dry run speed
Digital/Analog I/O
Table 6.3.1 Setting of test execution Descriptions This function specifies whether the robot is disabled. - ON : The robot is disabled; it ignores all motion instructions. - OFF : The robot is enabled, it usually accepts motion instructions. When the robot lock function is ON, the power to the servo system is assumed to be on. Pressing the RESET key resets all the servo alarms. NOTE Even when the robot lock is ON, the robot can not be operated when the emergency stop button is pressed. When this function is enabled, the robot moves at the speed specified with “Cart. dry run speed.” This parameter specifies a robot feedrate during a dry run. When the motion of the robot is under path control (linear or circular motion control), the robot constantly moves at the specified speed (unit: mm/ s). This parameter specifies a robot feedrate during a dry run. When the motion of the robot is under joint control, the robot constantly moves at the specified speed. The dry run speed (jog) indicates the robot move speed used when operation is performed with the dry run setting. When a robot motion is linear or circular, the speed indicated in this item is used from the beginning to the end of the robot motion. Digital/Analog I/O specifies whether to communicate with a peripheral device via digital I/O and group I/O signal lines or not. When this is set to disable, the robot does not send or receive the digital I/O signal with a peripheral device. Internally, all the I/O signals are given the simulated flag(S) and the simulated flag can not be released until the setting is set to enable. (See Section 6.4,”MANUAL I/O CONTROL”) When you set the disable flag, the output to the peripheral device does not change. You can simulate the output without changing the state of the peripheral device. When you set the flag to enable, the output returns to the state it was in before the disable flag was set. Control of the peripheral device returns to the controller. When you set the disable flag, the input from the peripheral device to the controller is retained by the controller. When you set the flag to enable the input returns to the state it was in before the disable flag was set.
- 367 -
6.EXECUTING A PROGRAM Items Step statement type
Step path node
Procedure 6-6
B-82594EN-4/01
Descriptions Step statement type specifies how to execute a program in single step mode. - STATEMENT : The program execution is paused at each line. - MOTION : The program execution is paused at every motion instruction. - ROUTINE : Almost the same as STATEMENT, however, the pause is not done in a program that is called by a CALL instruction. - TP & MOTION : At all KAREL instruction except for motion instructions, a program does not pause. NOTE ”TP & MOTION” is not used currently. When ”Step path node” is set to be ON, the robot pauses at every node during execution of the KAREL instruction, ”MOVE ALONG”.
Specifying test execution
Step
6.3.2
1 2
Press the MENUS key to display the screen menu. Select 2 TEST CYCLE. The test cycle screen is displayed.
3 4
Specify requirements for test execution. To change the group number, press F2 GROUP.
Step Test To perform a step test (step operation) is to execute the program line by line. After one line of the program is executed, the program is halted. After executing a logic instruction, the next line becomes the current line and the cursor moves to the next line, but for the motion instruction, the cursor stays at the line that execution is completed.
- 368 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Specifying the step mode (single step) To specify the step mode, press the STEP key on the teach pendant. When the step mode is specified, the STEP LED on the teach pendant is lit. The STEP LED is off when continuous operation is specified.
Fig. 6.3.2 (a) STEP Key
Fig. 6.3.2 (b) Starting Step Operation
Step operation can be performed in two ways: Forward execution and backward execution.
Forward execution In forward execution, the program is executed in normal order. To perform forward execution of the program, press and hold down the SHIFT key, then press and release the FWD key on the teach pendant.
When a program is started, the program is executed for one line pointed to by the cursor, then the program is halted. When a motion instruction is executed, the cursor is held at the executed line. When a logic instruction is executed, the cursor is moved to the next line. Each time forward execution of the program is started, the next line of the program is executed. When executing the circular motion instruction in step mode, the robot pauses near the through position on an arc. Moreover, if the robot is paused just before the through position, the robot does not stop at the through position after resuming a program. - 369 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Backward execution In backward execution, the program is executed in reverse order. To perform backward execution of the program, press and hold down the SHIFT key, then press and release the BWD key on the teach pendant.
•
During backward execution, only the motion instructions can be executed. However, a skip instruction forward execution instruction, backward execution instruction, soft float instruction, and other optional move instructions are ignored while the program is executed. After one line of the program is executed, the cursor is moved to the previous line. • The instruction before the line where the following program instructions is taught can not be executed in backward execution. When you execute these instructions in backward execution, the cursor moves to the line following the line that contains taught these instructions: Halt instruction (PAUSE) Abort instruction (ABORT) Program end instruction (END) Jump instruction (JMP LBL[ ]) User alarm instruction (UALM[ ]) Execution instruction (RUN) • The following program instructions cannot be executed: Incremental instruction (INC) • A blank line does not affect the execution of the program (Both Forward and Backward execution) When the terminated program is restarted, the motion instruction in the line pointed to by the cursor is executed, then the program is halted. Each time backward execution of the program is started, the program is executed using the motion format and feedrate specified in the current line, and the position data and positioning path of the motion instruction in the previous line. • When the motion instruction in the current line specifies a circular motion, the robot moves to the target point along the path which passes through the passing point (Start point of an arc motion in normal program execution) specified in the current line. • When the motion instruction in the previous line specifies a circular motion, the robot moves to the destination position specified in the previous line using the motion format and feedrate specified in the current line. To disable backward execution of the program while the program is being executed, insert the halt instruction (PAUSE) into the desired location. After the halt instruction is executed, the cursor returns to the position it was at before the program was executed.
- 370 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
When the halt instruction is specified in the line before the line at the cursor is pointed at, backward execution of the program is disabled. To restart backward execution of the program, move the cursor to the line before the line that contains the halt instruction (two lines before the line at which the cursor is pointed).
Inter-program reverse program execution With the inter-program reverse operation function, control can be returned from a subprogram to the main program that called the subprogram by performing reverse operation (SHIFT + BWD).
NOTE 1 Even if a subprogram exists during reverse operation of a main program, the subprogram cannot be called. 2 When program termination occurs within a subprogram, control cannot be returned to the main program. When reverse execution is performed from a subprogram to the main program, the cursor stops at the line of the instruction that calls the subprogram taught in the main program. Sample program Example: When reverse operation is performed starting from the fourth line of a subprogram Main_Prg 1: 2:R[1]=R[1]+1 3:J P[1] 100% FINE 4:IF R[1]=100, JMP LBL[100] 5:CALL Sub_Prog 6: . . [End] Sub_Prog 1:DO[1]=ON 2:DO[2]=ON 3:L P[2] 1000mm/sec FINE 4:L P[3] 1000mm/sec FINE [End]
1 2 3 4
Start reverse operation with the cursor positioned to the fourth line of the subprogram. Reverse operation (SHIFT + BWS) from P[3] to P[2]. The cursor is positioned to the third line of the subprogram. Reverse operation (SHIFT + BWS) to the fifth line of the main program (CALL SUBPROGRAM). The cursor is positioned to the fifth line of the main program. Reverse operation (SHIFT + BWS) from P[2] to P[1]. The cursor moves from the fifth line to third line of the main program.
- 371 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Program end in backward execution If the system variable $BWD_ABORT is set to TRUE, when the first line of the program is finished to be executed during the backward execution, this program ends.
Procedure 6-7
Step test
Condition ■ ■ ■ ■
The teach pendant must be enabled. The single-step mode must be set. The system must be in the operation enable state. No one must be in the operating area. No obstacle must be placed in the operating area.
1 2
Press the SELECT key. The program selection screen is displayed. Select the program to be tested and press the ENTER key. The program edit screen is displayed. Press the STEP key to select the step mode. The STEP LED lights. (Check that the STEP LED lights when the STEP key is pressed.) Move the cursor to the program start line. Press and hold down the deadman switch, then turn on the teach pendant enable switch.
Step
3 4 5
WARNING The execution of the program instructions starts in the next step. The execution causes the robot to make a motion, which may produce unpredictable results. The operator should check that no persons and no unnecessary equipment is in the work area and that each part of the protective fence is sound. Otherwise, injury or property damage would occur. If the program needs to be stopped before it terminates, the operator should release the SHIFT key or deadman switch or press the HOLD or emergency stop button. 6
Start the program. • To perform forward execution of the program, press and hold down the SHIFT key, then press and release the FWD key. Do not release the SHIFT key until execution of the program is completed. • To perform backward execution of the program, press and hold down the SHIFT key, then press and release the BWD key. Do not release the SHIFT key until execution of the program is completed.
- 372 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
7
After one line of the program is executed, the program is halted. • When a motion instruction is executed, the cursor stops at the executed line. The next time forward execution of the program is performed, the next line of the program is executed. • When a control instruction is executed, the cursor moves to the next line. To release the step mode, press the STEP key. Turn off the teach pendant enable switch, then release the deadman switch.
8 9
6.3.3
Continuous Test To perform a continuous test is to execute the program in the normal order from the current program line to the end of the program (end-of-program symbol or the program end instruction). Backward execution of the program is disabled during a continuous test. A continuous test can be started using the teach pendant or operator’s panel. To perform a continuous test using the teach pendant, press and hold the SHIFT key, then press and release the FWD key. The program is then executed from the current line. To start continuous test operation (cycle operation) from the operator’s panel/box, momentarily press the start button on the operator’s panel. Program execution then starts from the current line.
NOTE The continuous text execution can be executed in the forward direction only. Procedure 6-8
Continuous test (using the teach pendant)
Condition ■ ■ ■ ■
The teach pendant must be enabled. The continuous mode must be set. (The STEP lamp must be off.) The system must be in the operation enable state. No one must be in the operating area. No obstacle must be placed in the operating area.
1 2
Press the SELECT key. The program selection screen is displayed. Select the program to be tested and press the ENTER key. The program edit screen is displayed. Set the continuous mode. Check that the STEP LED is off. (If the STEP lamp is on, press the STEP key to turn it off.) Move the cursor to the program start line. Press and hold down the deadman switch, then turn on the teach pendant enable switch.
Step
3 4 5
- 373 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
WARNING The execution of the program instructions starts in the next step. The execution causes the robot to make a motion, which may produce unpredictable results. The operator should check that no persons and no unnecessary equipment is in the work area and that each part of the protective fence is sound. Otherwise, injury or property damage would occur. If the program needs to be stopped before it terminates, the operator should release the SHIFT key or deadman switch or press the HOLD or emergency stop button. 6
Procedure 6-9
Press and hold down the SHIFT key, then press the FWD key. Hold down the SHIFT key until the execution of the program is completed. When the SHIFT key is released, the program is halted. The program is executed to the end, then forcibly terminated. The cursor is returned to the first line of the program.
Continuous test operation (started from the operator’s panel)
Condition ■ ■ ■ ■
The operator’s panel must be in the enabled state. Continuous operation mode must be set. (The step lamp must not be lit.) The system must be ready for operation. Nobody must be within the work area. There must be no obstacles.
Step 1 2 3 4 5
Press the select key. The program list screen is selected. Select a program to be tested, and press the enter key. The program edit screen appears. Set continuous operation mode. Check that the step lamp is not lit. (If the STEP lamp is on, press the STEP key to turn it off.) Position the cursor to the first line. Place the system in local mode. (For how to switch to local mode, see the description of Remote/Local setting in Section 3.16, ”SYSTEM CONFIG MENU.”
- 374 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
WARNING The execution of the program instructions starts in the next step. The execution causes the robot to make a motion, which may produce unpredictable results. The operator should check that no persons and no unnecessary equipment is in the work area and that each part of the protective fence is sound. Otherwise, injury or property damage would occur. If the program needs to be stopped before it terminates, the operator should release the SHIFT key or deadman switch or press the HOLD or emergency stop button. 6
6.3.4
Press the start button on the operator’s panel/box. Program execution is performed up to the end of the program then terminated forcibly. The cursor returns to the first line of the program.
Program Look/Monitor When the program is executed, the screen of the teach pendant becomes a monitor screen by which the execution of the program is displayed. In the monitor screen, the cursor moves to follow the line which is executed and you can not edit a program.
Press F2,LOOK, then the program looking screen is displayed and the cursor of the program which is being executed stops(Program is kept to be executing). You can look at the desired part except the line which is executed with the arrow keys.
- 375 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
The message ”Under the LOOK mode” is highlighted at the prompt line while looking at the program. To return to the monitor screen, press F2,MONITOR. When the monitor screen is displayed, the cursor specifies the line which is executed at that time. If the execution of the program is paused or ended, the program edit screen is displayed in place of the program looking screen.
- 376 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
6.4
MANUAL I/O CONTROL Under manual I/O control, signals are transmitted between the robot and peripherals before the program is executed. The manual I/O control refers to the following items: • Forced output • Simulated output and simulated input • Wait instruction
6.4.1
Forced Output Forced output is to manually turn digital output signals on or off. For the group output and the analog output, specify the value.
Procedure 6-10
Forced output
Condition ■
Assignment of the signals to be output must be completed.
1 2
Press the MENUS key to display the screen menu. Select 5, I/O. The I/O screen is displayed.
Step
Manual forced digital output 3 4
Press the F1, [TYPE] key to display the screen change menu. Select Digital. The digital output screen or digital input screen is displayed. If the input screen is displayed, press the F3, (IN/OUT) key to change the input screen to the output screen.
- 377 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
WARNING Forced output activates connected equipment. Before executing the forced output, the operator should check which equipment is connected to the digital output and what operation the forced output would cause. Otherwise, injury or property damage could occur. 5
Move the cursor to the status field for the signal number to be changed, then press the F4 (ON) or F5 (OFF) key to change the signal output setting.
Manual forced group output 6 7
Press F1, [TYPE]. The screen change menu is displayed. Select Group. The group output screen is displayed.
8
Move the cursor to the setting field of the signal number you want to change, enter the value. Pressing F4,FORMAT toggles between the decimal expression and the hexadecimal expression.
- 378 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
6.4.2
Simulated I/O The Simulated I/O function changes the state of signals internally without making digital, analog or group I/O communicate with peripherals. This function is used to execute the program or to test the I/O instruction when connection of I/O with peripherals is not completed. Simulated input/output can be used for digital, analog and group I/O. To enable simulated input/output, set the simulated flag, S.
Simulated output The simulated output function internally changes the signal state using the I/O instruction of the program or manual output, but does not change the state of output to peripherals. This function holds the state of output to peripherals when the simulated flag is set. When the simulated flag is reset, the output is restored to the original state.
Simulated input The simulated input function internally changes the signal state with the I/O instruction of the program or manual input. The state of input from peripherals is ignored, and the signal state is not changed internally. When the simulated flag is reset, the input enters the current state. Refer to 6.3.1,”Specifying test execution” to specify whether I/O signal is disable in the test execution.
Procedure 6-11
Simulated input / output
Condition ■
The input/output signal has been allocated.
1 2 3 4
Press the MENUS key. The screen menu is displayed. Select I/O. The I/O screen is displayed. Press F1, [TYPE]. The screen change menu is displayed. Select Digital. Digital I/O screen is displayed.
Step
- 379 -
6.EXECUTING A PROGRAM
6.4.3
B-82594EN-4/01
5
Move the cursor to the SIM field for the signal number to be changed and press the F4 (S) or F5 (U) key to change the simulated setting.
6
Move the cursor to the status field for the number of the signal to be simulated output and press the F4 (ON) or F5 (OFF) to change the simulated output setting.
Standby Release When a standby instruction in a program waits until the I/O conditions are satisfied, the standby release function skips this instruction, and halts program execution at the next line. Standby release is enabled only when a program is being executed. Standby release is performed by choosing from the miscellaneous function menu.
Procedure 6-12
Standby release
Condition ■
Program execution is currently in the I/O wait state.
- 380 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Step 1 2
Press the function key to display the miscellaneous function menu. Select 7 RELEASE WAIT. The I/O wait is skipped, and the cursor moves to the next line. The program is then halted. When program execution is restarted, the next instruction is executed.
- 381 -
6.EXECUTING A PROGRAM
6.5
B-82594EN-4/01
OPERATING THE HAND MANUALLY To operate the hand manually using the teach pendant, hand instruction must be assigned to the manual operation screen when macro instructions are set. When teaching the operation of the hand, check whether the hand can actually hold a workpiece at the target position by operating the hand. The macro instructions are optional functions.
Fig. 6.5 Operating the Hand Manually
Procedure 6-13
Operating the hand manually
Condition ■ ■ ■
The teach pendant must be enabled. No one must be in the operating area. All obstacles must be removed from the operating area. The hand instruction must be defined as a macro for manual operation (MF).
Step 1
Press and hold down the deadman switch, then turn on the teach pendant enable switch. • Press the TOOL1 (or TOOL2) key. The Tool 1 (or Tool 2) screen is displayed.
•
Otherwise, select MANUAL FCTNS from the screen menu to display the manual operation screen.
- 382 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
2
Move the cursor to the desired macro instruction. Press and hold down the SHIFT key, then press the F3 (EXEC) key.
- 383 -
6.EXECUTING A PROGRAM
6.6
B-82594EN-4/01
AUTOMATIC OPERATION Peripheral I/O can be used to automatically start a program and operate a production line. (See Section 3.8, ”SETTING AUTOMATIC OPERATION”.) • The robot start request signals (RSR1 to RSR4 inputs) select and start a program. When a program is being executed or halted, the selected program is placed in the wait state. It is started once the currently executed program terminates. • The program number selection signals (PNS1 to PNS8 inputs and PNSTROBE input) select a program. When a program is being halted or executed, these signals are ignored. • The automatic operation start signal (PROD_START input) starts execution of the currently selected program from the first line. When a program is being halted or executed, this signal is ignored. • Cycle stop signal (CSTOPI input) forcibly stops the currently executed program. Any programs enqueued by RSR are canceled. If CSTOPI for ABORT on the system setting menu is set to FALSE, the program currently being executed is executed up to the end of the program, then is terminated forcibly. Programs placed in the wait state by RSR are cleared. (Standard setting) If CSTOPI for ABORT on the system setting menu is set to TRUE, the program currently being executed is immediately terminated forcibly. Programs placed in the wait state by RSR are cleared. • The external start signal (START input) starts a currently halted program. If START for CONTINUE only on the system setting menu is set to FALSE, the currently selected program is started from the current line. A temporarily stopped program is also started. (Standard setting) If START for CONTINUE only on the system setting menu is set to TRUE, any temporarily stopped program is started. This signal is ignored when there is no temporarily stopped program. To start a program by peripheral I/O input, the robot must be in the remote mode. The remote mode is set when the following remote conditions are satisfied: ■ The teach pendant enable switch is turned off. ■ Place the system in remote mode. (For how to switch to remote mode, see the description of #139-3-1 in Section 3.16, ”SYSTEM CONFIG MENU.” ■ Peripheral device I/O *SFSPD input is on. ■ ENBL input of peripheral I/O is on. ■ System variable $RMT_MASTER is 0 (peripherals).
- 384 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
NOTE The value of $RMT_MASTER may be 0 (peripheral device), 1 (CRT/keyboard), 2 (host computer), or 3 (no remote device). To start a program containing motion instructions, the following ready conditions must be satisfied: ■ ENBL input of peripheral I/O must be on. ■ The servo power is turned on. (No alarm is being issued.) It is convenient to monitor the input acceptable signal (CMDENBL output) for starting a program using the peripheral I/O. The CMDENBL signal is output when the following conditions are satisfied: ■ Remote condition ■ Operation enable condition ■ Continuous mode (step mode is disabled)
Fig. 6.6 Automatic Operation of Robot System
6.6.1
Automatic Operation by Robot Start Request (RSR) The robot start request (RSR) function allows a remote device to select and start a program through the peripheral device I/O. This function uses eight robot start request signals (RSR1 to RSR8). 1 When a signal from RSR1 to RSR8 is input, the control unit determines whether the input RSR signal is valid. If the signal is invalid, it is ignored. When a program started by a non-RSR signal, such as a start signal from the teach pendant or the operator’s panel, or when a dedicated signal START is being executed or halted, an RSR signal input is ignored. Whether RSR is valid or invalid is set in system variables $RSR1 to $RSR8. These values can be changed on the RSR setting screen or by using a programmed RSR instruction.
- 385 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
2
Eight RSR registration numbers can be assigned to RSR. A base number is added to each RSR registration number to indicate an RSR program number (four-digit integer). For example, when the RSR2 signal is input, a program having the following name is selected: RSR + (RSR2 registration number + base number) (four digits)
NOTE The name of a program to be started must be of ”RSR + RSR program number” format. (Example: RSR0121) The base number is set in $SHELL_CFG.$JOB_BASE. It can be changed by using Base number on the RSR setting screen or by using a programmed parameter instruction. 3 The RSR acknowledge output signal (ACK1 to ACK8) corresponding to one of the RSR1 to RSR8 input signals is output as a pulse signal. Even when one of the ACK1 to ACK8 signals is being output, RSR input is accepted. 4 When programs are in the terminated state, a selected program is started. When another program is being executed or halted, the request (job) is placed in a queue. It is started when the program currently being executed terminates. Jobs (RSR programs) are executed in the order in which the programs were enqueued. 5 Programs in the queue are canceled (cleared) by the cycle stop signal (CSTOPI input) or forced program termination. The start of a program by RSR is enabled in the remote mode. (Normally, in remote mode, the CMDENBL input is on.)
Fig. 6.6.1 Robot Start Request
- 386 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Procedure 6-14
Automatic operation by robot start request (RSR)
Condition ■ ■ ■ ■
RSR settings are completed. (See Subsection 3.7.1.) Remote mode is set. The system is ready for operation. Nobody must be within the work area. There must be no obstacles.
WARNING Applying this procedure starts automatic operation which causes the robot to move. An unpredictable operation could occur. Check to ensure that nobody is in the work area, that there are no unnecessary objects in the work space, and that the safety fence is normal. Also, check that all the automatic operation conditions are set correctly. Otherwise, personal injury or damage to the facilities could occur.
Step 1 2 3 4 5 6
6.6.2
Set the enable switch on the teach pendant to OFF. Place the system in remote mode. (For how to switch to remote mode, see the description of #139-3-1 in Section 3.15, ”SYSTEM CONFIG MENU.” Send the robot start signal (RSR1 to RSR8 input) of a target RSR number to the control unit. The RSR program is placed in a queue. To stop the program currently being executed, use the emergency stop button or hold button, or the immediate stop (*IMSTP input), hold (*HOLD input), or cycle stop (CSTOPI input) signal. To cancel a job in the queue, use the cycle stop signal (CSTOPI input). To restart a halted program, use the external start signal (START input).
Automatic Operation with Program Number Selection (PNS) The program number selection (PNS) function enables selection or checking of a program, using the peripheral I/O, from the remote controller. Eight input signals, PNS1 to PNS8, specify a PNS program number. 1 When the PNSTROBE pulse signal is input, the control unit reads the PNS1 to PNS8 input signals. When a program is being executed or halted, the signals are ignored. While the PNSTROBE pulse input signal is on, no program can be selected from the teach pendant.
- 387 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
2
The received PNS1 to PNS8 inputs are converted into a decimal number to obtain a PNS number. A program number (four digits) can be obtained by adding a base number to the PNS number, as shown below: (Program number) = (PNS number) + (base number) The selected program has the following name: PNS + (program number) When zero is input through the PNS1 to PNS8 input signals, no program is selected on the teach pendant.
NOTE The name of a started program must be of (PNS + PNS program number) format. (Example: PNS0138) The base number is set in $SHELL_CFG.$JOB_BASE. It can be changed by using Base number on the PNS setting screen or a programmed parameter instruction.
Fig. 6.6.2 Program Number Selection
3
The selected program number output signals (SNO1 to SNO8) are output for PNS confirmation. The PNS acknowledge output (SNACK) signal is output as a pulse signal. This signal causes the external device to read SNO1 to SNO8 output signals. Even while the SNACK signal is being output, PNS and PROD_START input signals are accepted. 4 When confirming that the output values of SNO1 to SNO8 match the input values of PNS1 to PNS8, the remote control unit sends the automatic operation start input (PROD_START) signal. 5 The control unit receives the PROD_START input signal, then starts the program. Program start by PNS is enabled in remote mode. (Normally, in remote mode, the CMNDENBL input signal is on.) - 388 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Procedure 6-15
Automatic operation by program number selection
Condition ■ ■ ■ ■
PNS setting must be completed (See Subsection 3.7.2). The remote condition must be satisfied. The operation enable condition must be satisfied. No one must be within the work area. There must be no obstacles.
WARNING Start automatic operation as follows: When the robot starts operation, an unexpected situation may occur. To prevent any problem from occurring, be sure to check that no one is in the work area, that the work are a is free from unnecessary equipment, that the safety barrier is in place, and that all the automatic operation conditions are correctly specified. Otherwise, the robot may injure a person or damage the equipment in the work area.
Step 1 2 3
4 5 6
Turn off the teach pendant enable switch. Place the system in remote mode. (For how to switch to remote mode, see the description of #139-3-1 in Section 3.15, ”SYSTEM CONFIG MENU.” Send the program number selection signals (PNS1 to PNS8 inputs) indicating a target PNS number and the PNS strobe signal (PNSTROBE input) to the control unit. A PNS program is then selected. The control unit outputs the selected program number signals (SNO1 to SNO8 inputs) and PNS acknowledge signal (SNACK output) for confirmation. Send an external start signal (PROD_START input). The selected program is then started. To stop the program currently being executed, use the emergency stop button or hold button, or the immediate stop (*IMSTP input), hold (*HOLD input), or cycle stop (CSTOPI input) signal. To restart a halted program, use the external start signal (START input).
- 389 -
6.EXECUTING A PROGRAM
6.6.3
B-82594EN-4/01
External Override Selection Function The external override selection function changes feedrate override by turning on or off digital input (DI) signals. Two DI signals are defined. These two signals can be combined in four different ways. So four types of feedrate override can be selected.
When the function changes the feedrate override, the feedrate override is not displayed, namely, the popup menu is not displayed at the upper right corner of the screen. To enable the external override selection function, the following requirements must be satisfied: ■ The external override selection function must be enabled. (OVERRIDE SELECT on the setting screen) ■ The remote mode must be set. When the external override selection function is enabled, the following occurs: • The override key of the teach pendant is practically disabled.(The changed value is quickly returned to the setting value by the external override selection.) • The override instruction has no effect to the override value. • You can not change the settings of DI signal number and Override. Before these settings can be modified, Function Enable:DISABLE must be set. • When this function is effective at turning off the power of the controller, the override will get the value which had been set by this function when turning on it again. • It is possible to specify the same number as two DI signal numbers. In this case, only the combination of ON-ON or OFF-OFF has the meaning. Moreover, note the following: • After this function is disabled because the remote condition is not satisfied, the override keeps to remain the value specified by this function in effective until the value is changed by the teach pendant or override instruction. Set this function on the external override selection setting screen (6 OVERRIDE SELECT).
- 390 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Procedure 6-16
Selecting an external override
Step 1 2
3
Press the MENUS screen to display the screen menu, then select 6 SETUP. Select Ovrd Select from the screen change menu.
Set items. a Enable or disable the function. b Assign DI signals.
c
The states of DI signals are indicated. When *** is displayed, the setting of the function cannot be changed. Feedrate override to be changed by turning on or off the signals
- 391 -
6.EXECUTING A PROGRAM
6.7
B-82594EN-4/01
ONLINE POSITION MODIFICATION Online position modification (optional function) replaces all the position data and move speeds in the move instructions within a certain range in a program at one time, according to the position modification condition, during program execution. The following program information can be modified: • Position data (position compensation) • Move speed Position data is modified by adding a position compensation value. A movement speed is modified by rewriting it. Up to ten position modification conditions can be defined.
Position compensation value A position compensation value is the difference between the current position and the correct position. The position data coded in the move instructions within a specified range of a program is rewritten by adding a position compensation value to the data. If the position data resulting from modification falls outside the allowable axial movement range, an alarm is generated when the program is executed.
CAUTION If position compensation is performed during execution, it may take a while for the compensation to be reflected in actual operation. The specifiable ranges (+/-) for the position compensation values are set in system variables $PRGADJ.$X_LIMIT to $R_LIMIT. The standard value is +/-26 mm for (X, Y, Z) and +/-0.5 degrees for (W, P, R). Any position compensation value falling outside these ranges cannot be set.
Move speed Move speeds in the move instructions within a specified range of a program are replaced with specified speeds. The move speed for axial movement is replaced by the value specified in Joint speed, while the move speed for linear and circular movement is replaced by the value specified in Motion speed.
CAUTION Once a speed has been rewritten, the original speed cannot be restored.
- 392 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Position modification status The position modification statuses are classified into the following three types: • EDIT indicates that the current position modification condition is being edited. It is not reflected in the program. This state is indicated when no position modification condition is set or when a valid position modification condition is edited. • ENABLED indicates that the current position modification condition is reflected in the program. • DISABLED indicates that the position modification condition reflected in the program has been canceled. The result of ENABLED is reflected immediately if the program is being executed. When the position modification condition is modified after ENABLED, changes made to the program are determined, and state EDIT is indicated. Online position modification is set by using 1 UTILITIES Prog Adjust on the utility screen. Online position modification conditions include the following information:
Item Program Range
Offset relative to
Table 6.7 Online Position Modification Settings Description Specifies the name of the target program for position modification. Specifies the range (the start and end lines) of the program lines to which position modifications are to be applied. NOTE The end line number must be greater than or equal to the start line number specified in item 2. When only one line is to be modified, the end line number must equal the start line number. User Modification is performed in reference to the user coordinate system. Tool Modification is performed in reference to the tool coordinate system.
- 393 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Item
Description
X to R adjustment
The position modification status indicates whether a specified position modification condition is reflected in the program. • EDIT : The position modification condition is being edited. • ENABLED : The position modification condition is reflected in the program. • DISABLED : The position modification condition is not reflected in the program. Compensation values X to R indicate the position compensation amounts. Values (X, Y, Z) are in mm or inches, while values (W, P, R) are in degrees. The values specified here are included in the position data. These speed items replace the move speeds. Motion speed replaces the linear and circular movement speed with a specified speed. Joint speed replaces the axial movement speed with a specified speed.
Status
Motion speed Joint speed
CAUTION Once the move speed is rewritten, the original speed cannot be restored.
Motion group Adjust Y for
UNIT SCHED ENABLE
DISABLE
COPY CLR_ADJ
CLR_ALL
Procedure 6-17
Select an operation group to be subjected to modification. This item is displayed only when an additional built-in traveling axis is set up as the seventh axis in group 1. The direction of the additional built-in axis is indicated in motion group. Specify the compensation target for the indicated direction. Robot: Modify only the position of the robot. Additional axis: Modify the position of the additional axis. All: Modify both the positions of the robot and the additional axis. If offset relative to is set to “Tool,” only the robot can be selected. The position modification unit function changes the units of the position modification values (mm or inches). The schedule function is used to input the number of the position modification condition to be edited next. ENABLED reflects the current position modification condition in a target program. The position data and move speeds are rewritten according to the position modification condition. This function key can be specified only when EDIT or DISABLED is indicated. DISABLED cancels the current position modification condition reflected in a target program. The position data used before modification is restored. This function key can be specified only when ENABLED is indicated. The original move speed cannot be restored. The position modification condition copy function copies a selected position modification condition into another condition number. After copying, EDIT is indicated as the modification status. The position modification condition erase function erases all the position modification and speed values set in a selected position modification condition. The program name and range are not erased. When erase is performed, the modified program is not restored to its original state. This function key erases a selected position modification condition entirely including the program name and range. When erase is performed, the modified program is not restored to its original state.
Online position modification
Condition ■
There is a program to be modified. - 394 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
Step 1 2 3 4
Press the menus key to display the screen menu. Select 1 UTILITIES. Press F1, [TYPE] to display the screen selection menu. Select Prog Adjust. then, the position modification condition list screen appears.
5 6
Position the cursor to the line number of a program to be modified. If the program to be modified is not indicated, select ”***”. Press F2, DETAIL. Then, the position modification condition detail screen appears. When ”***” is selected, EDIT is indicated as the status.
7
Set each items as desired.
NOTE When only one program line is to be modified, enter the same value for both the start and end lines.
- 395 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
8
After completing the modification condition settings, press F4 ENABLE to reflect the position modifications in the target program. The result of ENABLE is reflected immediately if the program is being executed.
NOTE 1 To modify a position modification condition after making it valid, cancel the condition once, then modify it. 2 When move instructions include a position register or incremental instruction, modifications are not reflected. 9
To cancel a set modification condition, press F5 DISABLE. When DISABLE is used, the current position modification condition must be valid.
CAUTION Once a move speed has been changed, the original speed cannot be restored even by pressing DISABLE.
- 396 -
6.EXECUTING A PROGRAM
B-82594EN-4/01
10
To set the position modification condition of another condition number, press F3 SCHED.
11
Press PREV to redisplay the position modification list screen.
12
To copy the set modification condition to another modification condition number, position the cursor to the condition number of the copy source, and press F1, COPY on the next page. Enter the condition number of the copy destination. Immediately after a copy operation, EDIT is indicated as the status. Modify the items as necessary.
13
To erase the set modification condition, press F2 CLR_ADJ on the next page.
- 397 -
7.STATUS DISPLAY
7
B-82594EN-4/01
STATUS DISPLAY The user can check various statuses of the robot with status display. Several types of screens are used for status display. Contents of this chapter 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11
LEDS ON THE TEACH PENDANT.......................................399 USER SCREEN........................................................................400 REGISTERS.............................................................................401 POSITION REGISTERS..........................................................403 PALLETIZING REGISTERS ..................................................407 CURRENT POSITION ............................................................408 SYSTEM VARIABLES ...........................................................411 PROGRAM TIMER .................................................................413 SYSTEM TIMER .....................................................................415 EXECUTION HISTORY .........................................................416 MEMORY USE STATUS DISPLAY......................................418
- 398 -
7.STATUS DISPLAY
B-82594EN-4/01
7.1
LEDS ON THE TEACH PENDANT The LEDs on the teach pendant indicate the following statuses:
LED FAULT HOLD
STEP BUSY RUNNING JOINT XYZ
TOOL
Table 7.1 LEDs on the Teach Pendant Description This LED indicates that an alarm has been issued. When the alarm is released, this LED goes off. This LED goes on while the HOLD key on the teach pendant or operator’s panel is pressed or while the peripheral I/O signal, *HOLD, is applied. This LED goes on when the single step mode is set. This LED goes off when the continuous operation mode is set. This LED indicates that a program or other processing is being executed. This LED indicates that a program is being executed. This LED goes on when the manual-feed coordinate system is a joint jog coordinate system. This LED goes on when the manual-feed coordinate system is a Cartesian jog coordinate system (jog coordinate system or cartesion coordinate system or user coordinate system). This LED goes on when the manual-feed coordinate system is a tool jog coordinate system.
Fig. 7.1 LEDs on the Teach Pendant
- 399 -
7.STATUS DISPLAY
7.2
B-82594EN-4/01
USER SCREEN A message instruction for the program being executed is displayed on this screen. (See Subsection 4.14.6.) When a message instruction is executed, the screen display automatically switches to the user screen.
Procedure 7-1
User screen display
Step 1 2
Press the MENUS key. Select “9 USER.”
NOTE 1 When a message instruction is not executed, nothing is displayed on this screen. 2 Even after the program is forcibly terminated, the message remains on the screen.
- 400 -
7.STATUS DISPLAY
B-82594EN-4/01
7.3
REGISTERS A register is a variable for holding an integer or fraction. Two hundreds registers are provided. The register screen is used to display and set registers.
Procedure 7-2
Displaying register screen
Step 1 2 3 4
Press the MENUS key to display the screen menu. Press ”NEXT, ” then select “DATA.” Alternatively, instead of steps 1 and 2 above, the user can press the DATA key. Press F1 “TYPE.” Select “Registers.” The register screen appears.
WARNING Registers are used in a program. Never change the value of a register before checking how the register is used in the system. Otherwise, the program can be adversely affected. 5
6
To enter a comment, use the following procedure: a Move the cursor to a desired register number field, then press ENTER key. b Select a comment input method. c Press a desired function key, then enter a comment. d Upon completion of input, press the ENTER key. To change the value of a register, move the cursor to the register value field, then enter a desired value.
- 401 -
7.STATUS DISPLAY
B-82594EN-4/01
Programming example 7
Registers are used in programs when the following are specified: Register instruction (See Subsection 4.5.1) Indirect specification of arguments (See Section 4.2)
- 402 -
7.STATUS DISPLAY
B-82594EN-4/01
7.4
POSITION REGISTERS A program register is a variable for holding position data. One hundreds position registers are provided. The position register screen is used to display and set registers.
Procedure 7-3
Position register setting
Step 1 2 3 4
Press the MENUS key to display the screen menu. Press “0 NEXT,” then select “3 DATA.” Alternatively, instead of steps 1 and 2 above, the user can press the DATA key. Press F1, [TYPE] to display the screen change menu. Select “Position Reg.” The position register screen appears.
WARNING Position registers are used in a program. Never change the value of a position register before checking how the register is used in the system. Otherwise, the program can be adversely affected. 5
To enter a comment, use the following procedure: a Move the cursor to a desired position register number field, then press ENTER key. b Select a character input method. c Press a desired function key, then enter a comment. d Upon completion of input, press the ENTER key.
- 403 -
7.STATUS DISPLAY
B-82594EN-4/01
6
To change the value of a position register, move the cursor to the position register value field. Then, press F3 “RECORD” while holding down the SHIFT key.
-
“R” indicates that a position register already holds a taught value. An asterisk (*) indicates that it does not.
NOTE In a multi-motion group system, teaching a position register records the position data for all axes regardless of the current motion group. 7
To delete position data loaded into a position register, press F5 “CLEAR” while holding down the SHIFT key.
8
Select “YES.” The position data of the desired position register is cleared.
- 404 -
7.STATUS DISPLAY
B-82594EN-4/01
9
To find out the current values of position data, press F4 “POSITION.” The position detail data screen appears. To change a value, move the cursor to the desired field, then enter a new value.
10
To change the configuration, press F3 “CONFIG.” Move the cursor to a desired field, then change joint placement data using the ↓ and ↑ keys.
11
To change the storage form of the position data, press F5,[REPRE] and select the storage form.
NOTE JOINT display is valid when the robot is adjusted to the zero-degree position or when non-kinematic operation such as table operation control is executed.
- 405 -
7.STATUS DISPLAY
B-82594EN-4/01
12
To change the display to the additional axes (subgroup), press F2 PAGE.
13
Upon completion of setting, press F4 “DONE.”
14
The position register can be used in the program as the following case: Position data of motion instruction(See Subsection 4.3.2) Position register instruction and offset instruction, etc. (See Section 4.5 and Subsection 4.3.5)
- 406 -
7.STATUS DISPLAY
B-82594EN-4/01
7.5
PALLETIZING REGISTERS The palletizing register screen displays the current values of the palletizing registers.
Procedure 7-4
Displaying a palletizing register screen
Step 1 2 3 4
Press the MENUS key to display the screen menu. Press “0 NEXT,” then select “3 DATA.” Alternatively, instead of steps 1 and 2 above, the user can press the DATA key. Press F1 “TYPE” . Select “Pallet regis.” The pallet register screen is displayed.
WARNING Palletizing registers are used in a program. Never change the value of a palletizing register before checking how the register is used in the system. Otherwise, the program can be adversely affected. 5
6
To enter a comment, use the following procedure: a Place the cursor on the comment line, then press ENTER key. b Select the way of naming the comment. c Press a desired function key, then enter characters. d Upon completion of input, press the ENTER key. To change the value of a palletizing register, move the cursor to the palletizing register value field, then enter a new value.
- 407 -
7.STATUS DISPLAY
7.6
B-82594EN-4/01
CURRENT POSITION The current position of the robot shows the location and the orientation of the robot in the work space. The current position can be represented in the cartesian frame and the joint frame.
Joint coordinates Joint coordinates represent the current position by the angular displacement from the base side of each axis.
Fig. 7.6 (a) Joint Coordinate System
NOTE If the system has an additional axis, E1, E2 and E3 indicate the position data of the additional axis.
- 408 -
7.STATUS DISPLAY
B-82594EN-4/01
Displaying cartesian coordinates The current position represented in cartesian coordinates is defined by the tool frame which is defined on the wrist to specify the location and orientation of the tool ,and the cartesian frame which is fixed in the work space. Cartesian coordinates is represented by the world frame or the user frame.
Fig. 7.6 (b) Cartesian coordinate system
- 409 -
7.STATUS DISPLAY Procedure 7-5
B-82594EN-4/01
Displaying current position screen
Step 1 2
Press the MENUS key to display the screen menu. Select NEXT, then select POSITION from the next menu.
3
The current position screen can be also displayed by pressing the POSN key. To display joint coordinates, press F2 “JNT.” To display user coordinates, press F3 “USER.” To display world coordinates, press F4 “WORLD.”
- 410 -
7.STATUS DISPLAY
B-82594EN-4/01
7.7
SYSTEM VARIABLES All the system variables can be seen with the system variable screen. Settings of the system is stored in the system variables.
WARNING The operation of the robot and control unit is controlled with system variables. Only a person who knows details of the influence of changes in system variables should set system variables. If a person without detailed knowledge attempts to set the system variables, the robot and control unit would malfunction. Procedure 7-6
Displaying system variable screen
Step 1 2 3 4
Press the MENUS key. The screen select menu is displayed. Select NEXT, then select SYSTEM. Press F1,[TYPE]. Select Variables. The system variable screen is displayed.
5
To change the settings of the system variables, move the cursor to the desired field and press the ENTER key after entering the value, or select the desired item from the function labels
- 411 -
7.STATUS DISPLAY
B-82594EN-4/01
6
When one of the system variables has plural items which belong to this variable(hierarchical structure),move the cursor to the desired system variable and press the ENTER key. Then the list of items which belongs to this variable is displayed.
WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage would occur.
7
To return to the upstairs layer, press the PREV key.
- 412 -
7.STATUS DISPLAY
B-82594EN-4/01
7.8
PROGRAM TIMER A program timer is a timer for measuring the execution time from one line to another in a program. Ten program timers can be used as standard. A program timer can be started and stopped by using a timer instruction (see Subsection 4.14.3). It also stops at forced termination and upon a halt. The program timer detail screen displays the following information: • Program name and line number for which a timer was started most recently • Program name and line number for which a timer was stopped most recently
Fig. 7.8 Program Timer Measurement
Program timers are indicated by using 4 STATUS/Prg Timer on the program timer screen.
- 413 -
7.STATUS DISPLAY Procedure 7-7
B-82594EN-4/01
Displaying program timers
Step 1 2 3 4
Press the menus key to display the screen menu. Press 0 NEXT, and select 4, STATUS. Press F1, [TYPE] to display the screen selection menu. Select Prg Timer. Then, the program timer screen appears.
5
To display detail information, press F2, DETAIL. Then, the program timer detail screen appears.
6
To enter a comment, position the cursor to the comment field, and press the enter key. Select the input method, and enter characters using function keys. As the start program, a program for which the timer was started most recently is indicated. As the stop program, a program for which the timer was stopped most recently is indicated.
7
- 414 -
7.STATUS DISPLAY
B-82594EN-4/01
7.9
SYSTEM TIMER A system timer is a timer for indicating the system operation time. The times for four items are indicated. Four types of timers are provided for each operation group.
Item Power-on time Servo-on time Operation time Standby time
Table 7.9 System Timer Display Description Time during which the power to the control unit is on Time during which the system is ready for operation (servo on) after the release of an alarm. Program execution time. The halt period is not included. Time required to execute a standby instruction
To display the system timers, use 4, STATUS Sys Timer on the system timer screen.
Procedure 7-8
Displaying the system timer screen
Step 1 2 3 4
Press the menus key to display the screen menu. Select 4, STATUS on the next page. Press F1, [TYPE]. Select Sys Timer. Then, the system timer screen appears.
5
To switch between operation groups, press F2, GROUP#, and enter a group number. To enable or disable lap time measurement, position the cursor to a desired item, and press F3, ON/OFF to switch the setting. To reset the lap time, position the cursor to a desired item, and press F4, RESET.
6 7
- 415 -
7.STATUS DISPLAY
7.10
B-82594EN-4/01
EXECUTION HISTORY The function of the program execution history records the execution history of the program which has been executed or which is being executed at the end, and enables you to see the execution history after the program is finished or paused. For example,this function enables you to recognize the execution status of the program at power failure after the cold start is done in case that power supply is turned off for any causes while the program is executed.
NOTE You can not see the execution history of the program which is been executed. The following information can be referred with the execution history screen. • Executed program name and line number(The status of the latest executed program is displayed at the first line.) • Direction of execution FWD : The line was executed by the forward execution. BWD : The line was executed by the backward execution. • Status of execution Not exec : The line was read but the line has not been executed. Paused : (The program was paused while executing the line) Done : The execution of the line has been completed. Aborted : The program has finished to be executed. The maximum number of the execution history which can be recorded is 200. The number of record lines can be changed using the maximum number setting screen, selectable from the control start menu. When the maximum number of lines that can be recorded has been reached, subsequent history data recording is performed by automatically erasing the recorded data, starting from the oldest. Note the following when you use this function: • When a macro is executed by using the manual function, user key, etc except the program, the execution history of it is not be recorded. When the program assigned to be a macro is executed in the program edit screen, the assigned program name in place of the macro name is recorded as the execution history. • When the KAREL program is executed, its execution history is not recorded. • The execution history of the program automatically started at power on is not recorded.
- 416 -
7.STATUS DISPLAY
B-82594EN-4/01
Procedure 7-9
Displaying program execution history
Step 1 2 3 4
Press the MENUS key. The screen select menu is displayed. Select STATUS from the next page. Press F1,[TYPE]. Select Exec-hist. The execution history screen is displayed.
NOTE If a single program has been executed, F2, NEXT TASK and F4, ALL CLEAR are not displayed on the execution history screen. 5 6 7
Only when the displayed status of a program is ”Aborted”, the execution history can be cleared by pressing SHIFT + F5,CLEAR. When multitasking is used, pressing SHIFT + F5 CLEAR displays the history of another task. When multitasking is used, the execution history of all the tasks can be cleared by SHIFT + F5 CLEAR provided Abort is indicated for all the tasks.
- 417 -
7.STATUS DISPLAY
7.11
B-82594EN-4/01
MEMORY USE STATUS DISPLAY This screen displays the use status and hardware configuration of the control unit memory. The display includes the following information:
Items TPP PERM SYSTEM TEMP
Table 7.11 (a) Memory Use Status Display( Pools ) Descriptions Displays the use of area to hold programs. Displays the use of area to hold system variables and registers. Displays the use status for a part of the system software. Displays the use status of work area used by system software.
Table 7.11 (b) Memory Use Status Display( Hardware ) Items Descriptions F-ROM Storage capacity of the F-ROM module used in control unit D-RAM Storage capacity of the D-RAM (RAM) module used in control unit C-MOS Storage capacity of the C-MOS (RAM) module used in control unit
When the [STATUS memory] screen is selected, the following screen appears on the teach pendant. This screen indicates the information collected immediately before it appears. A list screen displays the use status of program area, permanent area and temporary area.
- 418 -
7.STATUS DISPLAY
B-82594EN-4/01
A detailed screen displays use status of all the area mentioned above and displays the hardware information.
To move from a list screen to a detailed screen, press F2, DETAIL. To move from a detailed screen to a list screen, press F2, BASIC. Explanation of each area is displayed by pressing F5, HELP on both screens. To display the previous screen, press PREV key.
NOTE This function indicates the use status of the memory. It does not change the use status.
- 419 -
8.FILE INPUT/OUTPUT
8
B-82594EN-4/01
FILE INPUT/OUTPUT This chapter describes file transfer to and from a communication device. Contents of this chapter 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8
FILE INPUT/OUTPUT UNITS ...............................................421 SETTING A COMMUNICATION PORT...............................430 FILES .......................................................................................435 SAVING FILES .......................................................................438 LOADING FILES ....................................................................449 PRINTING FILES ....................................................................457 AUTOMATIC BACKUP .........................................................461 IMAGE BACKUP FUNCTION...............................................467
- 420 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
8.1
FILE INPUT/OUTPUT UNITS With the robot control unit, the various file I/O devices can be used. The standard setting specifies the use of memory cards. If using another file I/O device, perform the operation below to change the file I/O device setting.
Procedure 8-1
Changing file I/O devices
Step 1 2
Press MUNES to display the screen menu. Select 7 FILE. The file screen appears.
3
Press F5 UTIL, and select Set Device. Then, the following screen appears:
- 421 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
4
Select a file I/O device to be used. An abbreviation for the currently selected file I/O device appears in the upper left part of the screen.
File input/output units The robot controller allows the use of the following types of storage units to save programs and files. •
•
•
•
•
•
•
•
Memory card (MC:) Flash ATA memory card or SRAM memory card. It is possible to use a Compact Flash card by attaching a PCMCIA adapter to it. The memory card slot is on the main board. Backup (FRA:) Area to which files are saved with auto backup. It can retain information when the power is interrupted, with no backup battery. FROM disk (FR:) Capable of storing program and other backups and any files. It can retain information when the power is interrupted, with no backup battery. RAM disk (RD:) Capable of storing program and other backups and any files. As standard, it is placed on DRAM, and all files are erased when the power is interrupted. It can be placed on SRAM with appropriate settings, in which case, it can retain information with its backup battery when the power is interrupted. It cannot be used with a spot tool. MF disk (MF:) The MF disk is a device in which a FROM disk and a RAM disk are synthesized together. The file list on the MF disk displays the files on both the FROM disk and the RAM disk, so that the files on both disks can be read. When a backup is to be made to the MF disk, a confirmation message appears asking which of FR: and RD: to use for storage. FTP (C1: to C8:) Writes and reads files to and from a FTP server such as a PC connected via Ethernet. It is displayed only if FTP client settings have been made on the host communication screen. Memory device (MD:) The memory device is capable of handling data on the memory of a control unit, such as robot programs and KAREL programs, as files. Console (CONS:) Device for maintenance only. It can reference the log file containing internal information. - 422 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
•
USB memory (UD1:) USB memory mounted to the USB port on the operator panel.
As standard, the settings are such that a memory card is used.
CAUTION In the R-30iA, the floppy disk (FLPY:) units below cannot be used. • Floppy cassette adapter (A16B-0150-B001) • Handy file (A16B-0159-B002) (It cannot be used regardless of whether it is in FANUC or MS-DOS format.) In the R-30iA, the printer unit FANUC PRINTER (A86L-0001-0103) cannot be used. To print the content of a program, use the ASCII save function to output the content of the program in ASCII format to a file input/output unit, load it into a personal computer, etc., and print it.
Setting up a communication port The R-30iA provides the communication ports below. • Port 1 RS-232-C Operator panel • Port 2 RS-232-C JD17 connector on the main CPU printed circuit board • Port 3 RS-422 JD17 connector on the main CPU printed circuit board With the standard settings, the port list screen displays ports 1 and 2 only. To enable port 3 (RS-422), perform a control start and change the system variable ＄RS232_NPORT to 4 on the system variable setup screen. Port 3 is added to the port list screen so that a communication unit can be set up for port 3. In the R-30iA, the "Handy File", "FANUC Floppy", "Handy F MS-DOS", "Printer" items are not displayed as communication unit settings on the port setup screen.
- 423 -
8.FILE INPUT/OUTPUT
8.1.1
B-82594EN-4/01
Memory Card A flash ATA memory card and SRAM memory card can be used.
CAUTION Flash ATA memory card 1 It is recommended that files on a flash ATA memory card be backed up to storage device to protect the flash ATA memory card contents against accidental loss. SRAM memory card 1 The SRAM memory card requires a backup battery. When an SRAM memory card is purchased, the battery is not installed. Always install the battery in the card before attempting to use it. 2 Once the battery in the SRAM memory card reaches the end of its service life, the data on the card will be lost. Therefore, always make a backup of the card contents.
Memory card insertion
Fig. 8.1.1 Memory Card Insertion
When a memory card is to be used, select the memory card according to the description of changing the file I/O devices (see Section 8.1).
- 424 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
8.1.2
USB Memory
Overview The robot controller provides a USB port on its operation panel, so that files can be loaded and saved using USB memory.
CAUTION USB units other than USB memory units are not supported. Do not connect a USB unit other than a USB memory unit to the robot controller.
- 425 -
8.FILE INPUT/OUTPUT Procedure 8-2
B-82594EN-4/01
Attaching a USB memory unit
Step 1 2
Insert a USB memory unit into the USB port on the operation panel. If the USB memory unit is recognized correctly, the message below appears on the alarm line on the teach pendant.
FILE-066
UD1 Ins BUFFALO ClipDrive
"UD1 Ins" and subsequent text in the message above differ depending on the USB memory product. For example, if SanDisk Inc. Cruzer Micro is attached, the message below appears. FILE-066 UD1 Ins SanDisk Corporation Cruzer Micro
CAUTION 1 If the FILE-066 message does not appear even after a USB memory unit is attached, remove the memory unit and insert it again gently. 2 It is not possible to use two or more USB memory units at the same time. Procedure 8-3
Removing the USB memory unit
Step 1 2
Remove the USB memory unit from the USB port on the operation panel. The message below appears on the alarm line.
FILE-067
UD1 Removed
CAUTION While a file is being loaded or saved, do not remove the USB memory unit. Otherwise, the files in the USB memory unit may be damaged. If the USB memory unit is provided with an access lamp, make sure that the access lamp is not flashing before removing the unit.
- 426 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
Procedure 8-4 Switching to the USB memory unit The abbreviation of a USB memory unit as a file input/output unit is UD1:.
Step 1 2 3
Press the [MENUS] key. Select the [FILE] item to enter the file screen. Press F5 [UTIL]. The menu below appears.
1 Set Device 2 Format 3 make DIR Select [Set Device]. 4
The menu below appears.
1 FROM Disk (FR:) 2 Backup (FRA:) 3 MF Disk (MF:) 4 Mem Card (MC:) 5 Mem Device (MD:) 6 Console (CONS:) 7 USB Disk (UD1:) Select [USB Disk (UD1:)]. 5
Check that the upper left file input/output unit currently selected is UD1:.
FILE 30% UD1:\*.*
JOINT
- 427 -
8.FILE INPUT/OUTPUT Procedure 8-5
B-82594EN-4/01
Operating the USB memory unit The file operations below can be performed in the same way as those on the memory card (MC:). • • •
Load and save files on the program list screen Save files, display a file list, delete files, and load files on the file screen Save programs on the auxiliary menu
CAUTION If the USB memory unit is not attached to the USB port or if the USB memory unit is not recognized correctly, performing a file operation on the USB memory unit causes the alarm below to appear on the teach pendant (where the numeric value xx denotes internal information). FILE-064
Internal DOS system error : xx
The operation may be performed normally if the above alarm is canceled with the [RESET] key and the file operation is attempted again or by removing the USB memory unit from the USB port and attaching it again.
Available products Some USB memory products cannot be recognized correctly by the R-30iA or accept file operations correctly. Those USB memory units that provide secure functions and require password authentication before access to the drive cannot be used. As of February 2006, those USB memory units that have been confirmed for operation are as follows: Clip Drive RUF-CL/U2 128/256 MB of BUFFALO INC. ToteBag TB-B 128 MB of I-O DATA DEVICE INC. Easy Disk Platinum 256 MB of I-O DATA DEVICE INC. (Caution: SecureEasyDisk of I-O DATA DEVICE INC. cannot be used.) CRUZER Mini, Micro 128/256 MB of SanDisk Inc.
- 428 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
CAUTION 1 USB units other than USB memory units are not supported. Do not connect a USB unit other than a USB memory unit to the R-30iA. 2 In the R-30iA, the floppy disk (FLPY:) units below cannot be used. • Floppy cassette adapter (A16B-0150-B001) • Handy file (A16B-0159-B002) (It cannot be used regardless of whether it is in FANUC or MS-DOS format.) In the R-30iA, the printer unit FANUC PRINTER (A86L-0001-0103) cannot be used. To print the content of a program, use the ASCII save function to output the content of the program in ASCII format to a file input/output unit, load it into a personal computer, etc., and print it.
- 429 -
8.FILE INPUT/OUTPUT
8.2
B-82594EN-4/01
SETTING A COMMUNICATION PORT The control unit performs data transfer to and from external devices through communication ports by performing serial communication via the RS-232C or RS-422 interface. The following communication ports are used. (Operator’s panel/box; see Subsection 2.3.2.) • Port 1: RS-232-C On the operator’s box • Port 2: RS-232-C JD17 connector on the main CPU printed circuit board • Port 3: RS-422 JD17 connector on the main CPU printed circuit board Main CPU printed circuit board
JRS16
RS-232-C (port 1)
JD17
RS-232-C / RS-422 (port 2/port 3) Operator's panel printed circuit board
JRS15
Teach pendant
Fig. 8.2 Communication Ports
RS-422 The use of the RS-422 interface has the following advantage: • While the RS-232-C standard supports a cable length of only about 10 to 20 m, the RS-422 standard allows a cable to be extended to about 50 m. • RS-422 is less susceptible to noise than RS-232-C. Application example • When the communication cable must be routed over a long distance, use the RS-422 interface.
NOTE The RS-422 interface uses electrical signals that are completely different from those of the RS-232-C interface. When the robot control unit and a personal computer are connected via the RS-422 interface, a commercially available RS-422-to-RS-232-C converter may be required since personal computers do not generally have a RS-422 interface.
- 430 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
Communication ports are set by using [6 Setting; port setting] on the port setting screen. Table 8.2 (a) Standard Communication Devices for Communication Ports Communication port Communication device Port 1 Port 2 Port 3
Items Device
Speed (Baud rate) Parity bit
Stop bit
Time-out value (sec)
Debug Console KCL/CRT Not used
Table 8.2 (b) Setting a Communication Port Descriptions This item specifies a communication device to communicate with the robot controller. The standard communication devices that can communicate with the robot controller are listed below: • PS-100/200 Disk • Sensor Fanuc Eye V120 • Host Comm Used when the R-30iA is connected to the host computer to use the data transfer function. • NO Use • KCL/CRT • Debug Console • Factory Terminal • TP Demo Derice • Current position • Development • CIMPLI CITY NOTE When the communication device is changed, other settings such as a baud rate are changed to the corresponding standard values. Later on, the user can change each setting as desired. Baud rate is the transmission rate and it is the number of codes which can be transmitted per second. Enter the transmission rate specified for the peripheral unit being used. To detect an error in data transfer, this item sets a mode of vertical parity check, which adds one extra bit to each transferred character. - Odd : The number of 1’s in each transferred character must be an odd number. - Even : The number of 1’s in each transferred character must be an even number. - None : No parity check is made. Enter the parity check mode specified for the peripheral unit being used. This item specifies the number of stop bits to be added at the end of the transferred characters, for data transfer synchronization. - 1 bit : One stop bit is added. - 1.5 bits : One and a half stop bits are added. - 2 bits : Two stop bits are added. Enter the number of stop bits specified for the peripheral unit being used. This item sets a maximum time during which control over transfer with a communication device must be exercised. If no data transfer occurs for a specified period of time, the communication line is disconnected. Table 8.2 (c) Standard Settings for Communication Devices Device Speed Parity bit Stop bit Time-out value Sensor Host Comm Factory Terminal KCL/CRT TP Demo Device
- 431 -
4800 4800 9600 9600 9600
Odd parity Odd parity None None None
1 bit 1 bit 1 bit 1 bit 1 bit
None None None None None
8.FILE INPUT/OUTPUT Procedure 8-6
B-82594EN-4/01
Setting a communication port
Step 1 2 3 4
Press the MENUS key to display the screen menu. Select “6, SETUP.” Press F1, [TYPE] to display the screen change menu, Select “Port Init.” The port selection screen appears.
Debug Console KCL/CRT
5
Move the cursor to a desired connecter port field, then press F3 “DETAIL.” The port setting screen appears.
Debug Console
6
To set a communication device, move the cursor to the “Device” field, then press F4, [CHOICE]. Select a desired communication device from the menu.
Sensor Host Comm No Use KCL/CRT
- 432 -
Debug Console Factory Terminal TP Demo Device
8.FILE INPUT/OUTPUT
B-82594EN-4/01
7
Select a communication device whose settings need to be changed. When the communication device is entered, the standard values are entered in the other setting fields.
Sensor Host Comm No Use KCL/CRT
Debug Console
The other setting fields can be changed field by field. When the “Device” field is changed to another communication device, the standard values for that device are entered in the other setting fields.
NOTE To indicate that a port is not used, set ”No Use” in the corresponding field of communication equipment. 8
Upon completion of setting, press F3 “LIST.” The port selection screen appears.
Debug Console KCL/CRT
NOTE When setting the communications device, the error message, ”The port was not initialized.”, may be displayed and the settings of the port is returned to the previous settings. In this case, confirm the following. •
• •
Has the communication device to be set already been set for another port? → The same communication device cannot be set for more than one port. To set ”Host Comm” to the field of device, software option, data transfer, is needed. For setting a sensor, the sensor interface option is required. - 433 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
•
With the standard settings, the port list screen does not display RS-422 port 3. To enable RS-422 port 3, make a control start (see Appendix B.1.3, "Controlled Start".) and on the system variable screen, change the system variable $RS232-NPORT from 3 to 4. This causes RS-422 port 3 to be added to the port list screen, allowing the user to set up the communication unit.
- 434 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
8.3
FILES A file is a unit of data storage in the memory of the robot controller. The following types of file are used mainly: • Program file (*.TP) • Default Logic File (*.DF ) • System file (*.SV) Used to store the settings of the system. • I/O Config Data File (*.IO ) Used to store the settings of Input/ Output configuration. • Date file (*.VR) Used to store data such as register data
8.3.1
Program File A program file ( *.MN) contains a sequence of instructions for the robot. These instructions are called program instructions. Program instructions control robot operations, peripheral devices, and each application. A program file is automatically stored in the C-MOS RAM of the controller. A directory of program files is displayed on the program selection screen (“SELECT”).
NOTE The directory of program files is not displayed on the file screen. The file screen enables you to select the external memory device which includes the desired files and manipulate the files. On the program selection screen, operations such as copy, delete, and rename can be performed. (For program operations, see Section 5.5.) • Registering a program (See Subsection 5.3.1.) • Deleting a program (See Section 5.5.) • Copying a program (See Section 5.5.) • Changing program detail information (including the renaming of a program) (See Section 5.5.) A program file also includes the information items listed below. These information items can be checked on the program selection screen by pressing F5 [ATTR]. • Comment : The function of a program is summarized. • Write protection : This prevents the program from being modified and deleted. • Modification Date : Indicates the latest date when the program was modified. • Program size : The size of the program is indicated in bytes. • Copy source : The name of the source program from which the program was copied is indicated. When the program is an original program, this information item is blank.
- 435 -
8.FILE INPUT/OUTPUT
8.3.2
B-82594EN-4/01
Default Logic File The default logic file (*.DF) includes the settings of the default logic instruction assigned to each function key (F1 to F4 key) in the program edit screen. The default logic file is divided to the following kinds: • DEF_MOTN0.DF Stores the settings of the default motion instructions.F1 key The following three files stores the settings of the default logic instruction assigned to each function keys which is displayed in the next page. • DF_LOGI1.DF F2 key • DF_LOGI2.DF F3 key • DF_LOGI3.DF F4 key
8.3.3
System File/Application File A system file/application file ( *.SV ) contains a system control program for operating the application tool software, or contains data used with the system. The following types of system file are used: • SYSVARS.SV: Used to store the settings of the system variables relative to the frames, reference points, joint operating area and brake control. • SYSSERVO.SV : Used to store servo parameter data • SYSMAST.SV : Used to store mastering data • SYSMACRO.SV : Used to store the settings of the macro command. • FRAMEVAR.SV : Used to store the settings of the reference position which is used at setting the frame, comments, etc. • SYSFRAME.SV : User frame and tool frame
8.3.4
Data File Date file (*.VR,*.IO,*.DT) is the file which stores the data used by the system. The following kinds are in the data file: • Data file (*.VR) NUMREG.VR : Used to store the data of the register. POSREG.VR : Used to store the data of the position register. (Only when position register software option is used.) • I/O configuration data file (*.IO) DIOCFGSV. IO : Used to store the settings of the I/O assignment. • Robot setting data file (*.DT) This file is used to store those settings that are made on the robot setting screen. The file name varies depending on the model.
- 436 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
8.3.5
ASCII File An ASCII file (*.LS) is a file of ASCII format. ASCII files cannot be read. The contents of an ASCII file can, however, be displayed and printed using a personal computer.
- 437 -
8.FILE INPUT/OUTPUT
8.4
B-82594EN-4/01
SAVING FILES The function of saving files stores the data which exists in the RAM memory in the controller to the external storage device. The following screens on the teach pendant can be used to save the files. • Program selection screen: A specified program is saved to a storage device as program files. • File screen: The specified program file, system file, etc can be saved to a storage device. The following files can be saved: When a batched save operation is executed, program files, system files, and application files can all be saved at the same time. Program file System file Default logic file Standard command file • “5 SAVE” in the function menu: It is possible to preserve it on the storage device as program file and a system file, etc. of the program and the data, etc. displayed on the screen. The following files can be preserved: Program file System file Data file Default logic file Standard command file
8.4.1
Saving with Program Selection Screen Program selection screen enables you to save the specified program as the program file.
Procedure 8-7
Requirements for saving program files
Condition ■
The file input/output device is set correctly. (See Section 8.1.)
- 438 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
Step 1 2
Press the MENUS key to display the screen menu. Select NEXT and then select “1 SELECT” on the next page. The program selection screen appears.
3
Press NEXT,>, and press F4,SAVE on the next page. The program save screen appears.
4
Enter the name of a program to be saved, then press the ENTER key. The specified program is saved to the device.
NOTE Do not include a file extension in the program name. 5
When a program having a same name as you want to save exists in the device, the file can not be saved.
- 439 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
CAUTION If the current device already has a file having the specified name, the save function cannot overwrite that file. Before a new file is saved, the current file should be deleted from the device. 6
8.4.2
When the device is filled, change the device and press F4,CONTINUE.
Saving all the Program Files Using the File Screen File screen enables you to save the program file or system file which is saved in the RAM memory in the device. The following files can be saved by pressing F4, BACKUP: • Program file (*.TP): Used to store all the programs file which has contents of programs. • Default logic file (*.DF): Used to store the settings of default logic instructions. • System file (*.SV ): Used to store the following files: System variable file ( SYSVARS.SV ) Servo parameter file ( SYSSERVO.SV ) Mastering data file ( SYSMAST.SV ) Macro data file ( SYSMACRO.SV ) Frame setup file (FRAMEVAR.SV) Frame data file (SYSFRAME.SV) • Application file -Used to save the settings of an application. (Example: SYSSPT.SV)） • I/O configuration data file (DIOCFGSV.IO) • Register data file (NUMREG.VR) • Robot setting data file To interrupt the saving, press the PREV key while saving.
NOTE At control start time, F4 is set to RESTOR instead of BACKUP. When RESTORE/BACKUP is selected from the auxiliary menu, BACKUP is displayed.
- 440 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
Procedure 8-8
Saving files using the file screen
Condition ■
The file input/output device is set correctly. (See Section 8.1.)
1 2
Press the MENUS key to display the screen menu. Select “7 FILE.” The file screen appears.
1
Press F4 “BACKUP”, then select “TPE programs.”
Step
Saving program files
-
2
F2, EXIT Ends saving program files F3,ALL Saves all the program file and default logic instruction file. F4 YES Saves the specified file (program, default logic instruction). F5,NO Does not save the specified file (program, default logic instruction). After the file has been saved, the system asks whether the next program file is to be saved. Select the desired function key. In this case, program file (*.MN) is saved in the device.
- 441 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
3
When the file which has the same name as you specified already exists in the device, the following message is displayed.
-
F3,OVERWRITE The specified file is overwritten and saved. F4,SKIP Does not save the specified file. F5,CANCEL Ends saving files.
Saving the system file. 1
Press F4,SAVE and select System files. The following file is displayed.
MC
2
To save all the system files, press F4,YES. System files (DIOCFGSV.IO, FRAMEVAR.SV, NUMREG.VR, SYSVARS.SV, SYSSERVO.SV, SYSMAST.SV, SYSMACRO.SV, SYSFRAME.SV) are saved in the device.
3
When the file having the same name as you want to save exists in the device, the following message is displayed.
-
F3,OVERWRITE The specified file is saved by overwriting. F4,SKIP The specified file is not saved. F5,CANCEL Saving files is ended.
- 442 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
4
When the device is filled with files, exchange the device and press F4,CONTINUE.
1
Press F4 BACKUP, then select ALL of above.
Batched save
NOTE Since F4, BACKUP does not appear in the control start, batched save operation cannot be used. 2
When F4, YES is selected, all the files in the external memory unit are erased, then all the data is saved. Processing is interrupted using the backward key. An interrupt occurs once the current file has been processed.
CAUTION Before a batched save operation, all files in the external memory unit are erased. Before executing a batched save operation, check the files in the external memory unit.
- 443 -
8.FILE INPUT/OUTPUT
8.4.3
B-82594EN-4/01
Saving with a Function Menu By selecting SAVE from a function menu, the data of a screen currently displayed can be saved into the device. The data of the following screens can be saved: • Program edit screen Program file (*.TP) • System variable screen System variable file (SYSVARS.SV) • Positioning screen Mastering data file ( SYSMAST.SV ) • Macro instruction setting screen Macro data file (SYSMACRO.SV) • Frame setup screen Frame setup data file (FRAMEVAR.SV) • Register screen Register data file (NUMREG.VR) • Position register screen Position register data file (POSREG.VR) • Pallet register screen Pallet register data file (PALREG.VR) • I/O screen I/O configuration data screen (DIOCFGSV.IP) • Edit screen for each default logic instruction. Each default logic instruction. (*.DF)
Procedure 8-9
Saving with a function menu
Condition ■
The file input/output device is set correctly. (See Section 8.1.)
1
Display the program edit screen or the program selection screen.
2 3
To display a function menu, press the FCTN key. Select ”2 SAVE.” A selected program file is saved.
Saving program files. - Step
- 444 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
4
When the program having the same name as you want to save exists in the device, the file can not be saved.
5
When the device is filled with the files, exchange the device and press F4,CONTINUE. All the data being saved at exchanging device is saved into the exchanged device.
1
Display the screen you want to save.
2 3
Display the function menu by pressing the FCTN key. Select ”2 SAVE.” The contents of the screen being displayed is saved.
4
When the file having a same name exists in the device, the file is overwrite. When the device is filled with the files, exchange the device and press F4,CONTINUE. All the data being saved at exchanging devices is saved into the exchanged device.
Saving other files. - Step
5
- 445 -
8.FILE INPUT/OUTPUT
8.4.4
B-82594EN-4/01
File Manipulation On the file screen, files saved on a device can be listed and a file can be copied or deleted.
Procedure 8-10
File manipulation
Condition ■
The file input/output device is set correctly. (See Section 8.1.)
1 2
Press the MENUS key. The screen menu is displayed. Select 7 FILE. The file screen is displayed.
3
Press F2,[DIR].
4
Select ”*.*”(all files).The list of the files being saved into the device is displayed.
Step
Displaying the list of files.
- 446 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
WARNING Before a program set as a macro instruction is copied from a control unit onto another control unit, the macro setting screens of the two control units should be compared. Be sure that the lists of the two control units match. The program should be copied only when the lists match. Otherwise, an unpredictable result would occur that could injure personnel or damage equipment.
Deleting files 5
Select the file you want to delete and press F1,DELETE.
NOTE Deleting a program from memory of the control unit does not automatically delete the identical program from a device. CAUTION The operator should check that the current device has the file to be deleted. Otherwise, a wrong file can be deleted. 6
Press F4,YES. The file will be deleted.
- 447 -
8.FILE INPUT/OUTPUT Procedure 8-11
B-82594EN-4/01
Execution of ASCII save function
Condition ■
The file input/output device is set correctly. (See Section 8.1.)
1 2
Press the MENU key to display the screen menu. Select SELECT on the next page. The program directory screen appears.
3
Press PRINT on the next page. The program print screen appears.
4
Enter the name of the program to be saved with the ASCII save function, then press ENTER.
5
The specified program is saved with the ASCII save function. A file is saved with extension LS. In the same way, print data can be output as a file of ASCII format by print operation based on the auxiliary menu (Subsection 8.6.2).
Step
- 448 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
8.5
LOADING FILES Loading files is to load the files being saved in the file input/output device to the memory in the controller. The files can be loaded with the following screens on the teach pendant: • Program selection screen -The specified program file is loaded from the device as the program. • File screen -The specified program files and system files can be loaded. The following files can be loaded. Program file (*.TP or *.MN) Default logic instruction (*.DF) System file (*.SV) Data file (*.VR,*.IO )
NOTE Selecting F4, RESTOR on the file screen in the control start (not control start 2) enables batched read. Files stored in an external memory unit are read in the following order: 1 Files having the same names as those saved when System files is selected 2 Files having the same names as those saved when Application is selected 3 *.TP, *.DF, and *.MN files in the external memory unit *.SV and *.VR files are automatically read by selecting Convert=YES. CAUTION If a program having the same name exists during a program read operation, the existing program is overwritten automatically.
8.5.1
Loading Using the Program Selection Screen In the program selection screen, the specified program file can be loaded from a device.
Procedure 8-12
Loading a program file using the program selection screen
Condition ■
The file input/output device is set correctly. (See Section 8.1.)
- 449 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
Step 1 2
Press MENUS key to display the screen menu. Select ”0 -- NEXT --” and select ”1 SELECT” from the next page. Program selection screen is displayed.
3
Press ”NEXT”,>, and press F3,LOAD, on the next page. Program load screen is displayed.
4
Enter the name of a program to be loaded, then press the ENTER key.
NOTE Do not include a file extension in the program name. A specified program is loaded from a device. 5 When the program having the same name as you want to load exists in the memory, the following message is displayed.
-
OVERWRITE Loads the new file and overwrites it. - 450 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
8.5.2
Loading a Specified Program File Using the File Screen In the file screen, the specified file is loaded from the device to the memory. The following files can be read: • Program file (*.TP or *.MN) -Program file having contents of the program can be loaded. • Default logic file (*.DF) -Default logic file having the settings of the default logic instruction can be loaded. The method of loading is the same as the program file. • Data file (*.VR,*.IO ) -The following data file can be loaded. Register data file ( NUMREG.VR ) Position register data file ( POSREG.VR ) I/O config data file (DIOCFGSV.IO) • System file (*.SV ) -The following system files can be loaded. However, system files can be loaded only at the controlled start.(See Subsection B.1.3, ”Controlled start”) System variable file ( SYSVARS.SV ) Servo parameter file ( SYSSERVO.SV ) Mastering data file ( SYSMAST.SV ) Macro data file ( SYSMACRO.SV ) Frame setup data file ( FRAMEVAR.SV ) Frame data file ( SYSFRAME.SV )
Procedure 8-13
Loading a program file using the file screen
Condition ■
The file input/output device is set correctly. (See Section 8.1.)
1 2
Press the MENUS key to display the screen menu. Select ”7 FILE” to display the file screen.
Step
- 451 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
Loading a program file 3
Press F2 “DIR.”
4
Select “*.TP” (program file). The directory of program files stored on the device is displayed.
5
Move the cursor to the program file you want to load and press F3,LOAD.
Selected program is loaded from the device.
- 452 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
6
If a program with the same name already exists in the RAM, the following indication is provided:
-
OVERWRITE Loads the new file and overwrites it. SKIP Skips to the next file.
7
If you want to load all program files, select ”*.TP” and press F3,LOAD. When the PREV key is pressed, the operation is interrupted after the current a file is loaded.
8
Press F2, DIR. Sub-menu is displayed.
Loading a data file
9
Select “*.VR” (variable data file). The directory of variable data files stored on the device is displayed. Select a program to be loaded. The selected program is loaded from the device.
- 453 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
10
Select a program file you want to load and press F3, LOAD.
The specified program is loaded from the device. Loaded data is set as the current data.
11
If you want to load all the file which has the same extension, Select ”*.VR”, ”*.IO”, etc and press F3,LOAD.
Loading system variable files Condition ■
Turn on the power by controlled start (See Subsection B.1.3, ”Controlled start”) The following simplified system starts.
- 454 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
12
Press the MENUS key, then select “2 File.” The file screen appears.
13
Press F2 “DIR” to display the submenu.
14
Select “*.SV” (system variable data file). The list of the system files which are saved in the device is displayed.
15
Select the file you want to load and press F3,LOAD. When you press the PREV key while the system files are loaded by selecting ”*.SV”, loading is kept on until the file being loaded at pressing the PREV key is finished to be loaded.
- 455 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
16
When a system file is read, it is necessary to specify whether conversion is to be performed to maintain compatibility with the old system. Normally, select YES.
17
Turn off the power again. Then, select “1 START (COLD)” from the function menu. The system is cold started.
1 2 3
Select a file screen in the control start (not control start 2). Select F4 RESTOR. A message asking the user for confirmation appears on the prompt line.
Batched read Step
Restore from MF: (OVRWRT)
4
Select F4 YES. Then, the read operation starts. Processing is interrupted using the backward key. An interrupt occurs once the current file has been processed.
- 456 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
8.6
PRINTING FILES Printing files is outputting the contents of a program, a data file, the contents of system variables, and so on to a file I/O device selected as described in the file I/O device selection section (→ 8.1), as ASCII format files. The image being displayed on the teach pendant screen can also be output (print screen). Printing files can be executed by the following screens. • Program selection screen: Can print the program files. • ”4 PRINT” on the second page of the FCTN menu: Can print the contents of the following screens: Program edit screen: Program detail information and contents of program. System variable screen: System variable data
Procedure 8-14
Printing files using program selection screen
Condition ■
The file I/O device is in an output enabled status.
Printing out a program file using the program selection screen Step 1 2
Press the MENUS key to display the screen menu. Select “1 SELECT” on the next page. The program selection screen appears.
- 457 -
8.FILE INPUT/OUTPUT
Procedure 8-15
B-82594EN-4/01
3
Press F5 “PRINT” on the next page. The program print screen appears.
4
Enter the name of a program file to be printed out, then press the ENTER key.
5
The specified program file is printed out. To stop printing, press the PREV key.
Printing using the miscellaneous function menu
Program printing Condition ■
The program edit screen is displayed.
- 458 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
Step 1 2
Press the function key to display the miscellaneous function menu. Press 0 NEXT, and select 4 PRINT.
3
The currently displayed program is printed. To interrupt printing, press PREV key.
■
The system variable screen is displayed.
1 2
Press the function key to display the miscellaneous function menu. Press 0 -- NEXT --, then select 4 PRINT.
3
A list of system variables is printed.
System variable printing Condition
Step
NOTE It takes at least three hours to print all the system variables. To interrupt system variable printing, press the backward key.
- 459 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
4
Procedure 8-16
To print only lower level system variables, for example, to print the system variables in $PARAM_GROUP, open the screen of the target level, and perform steps 1 and 2 above.
Printing the displayed screen ( print screen )
Condition ■
The desired screen to be printed out is displayed.
1 2
Press the FCTN key to display the auxiliary menu. Press 0 --NEXT--, then select 3 PRINT SCREEN.
3
The displayed screen is printed out. ”¥” is printed as the part of the reversed display on the teach pendant. To stop printing, press the PREV key.
Step
- 460 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
8.7
AUTOMATIC BACKUP
8.7.1
Overview of Automatic Backup •
• •
•
•
Automatic Backup function performs the transaction of “all backup” in File menu automatically at the following timing. The specified time (Up to 5 settings) The specified DI is turned on. Start up of the controller. (Interval can be specified.) The memory card (MC:) and the automatic backup area (FRA:) of F-ROM in the control unit can be specified as a backup copy destination. The FRA: is specified by default. Automatic Backup function can manage many versions of backup in one device. Even if you backup the wrong programs or settings, you can load the previous version of backup. The number of versions to keep can be set from 1 up to 99. (Default is 2.) A storage device to be used for automatic backup need be previously initialized for automatic backup. Automatic backup will not be performed for any external storage device that has not been initialized for automatic backup. Therefore, if an attempt is made to cause a backup copy to be automatically created on a memory card that has not be initialized for automatic backup, its content will not be lost. The FRA: need not be initialized, since it is previously initialized. If the control unit is turned off during automatic backup, or automatic backup is stopped immaturely, the latest backup copy is automatically restored into the system. No incomplete backup file is left in the storage unit, and the latest backup file can be read at any time.
NOTE This function automatically saves all files. If the storage device used for automatic backup becomes faulty, the data saved in it may not be read. In case such an unforeseen accident takes place, it is necessary to save backups to another storage device such as a memory card as well.
8.7.2
Usable Memory Cards The following table lists memory cards usable for automatic backup. Type
Recommended product
Flash ATA memory card Compact flash memory card + PC card adapter
PCMCIA Flash ATA Card manufactured by SanDisk and sold by I-O Data Device, Inc. CompactFlash MEMORY CARD manufactured by SanDiskCompactFlash PC CARD ADAPTER manufactured by SanDisk
- 461 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
Type SRAM memory card
Recommended product Available from FANUC. A87L-0001-0150#256K (with a capacity of 256 Kbytes) A87L-0001-0150#512K (with a capacity of 512 Kbytes) A87L-0001-0150#1M (with a capacity of 1 Mbyte) A87L-0001-0150#2M (with a capacity of 2 Mbytes)
NOTE 1 The SRAM card will lose its contents when the life of its built-in battery expires. Neither the Flash ATA memory card nor the Compact Flash memory card need batteries. It is recommended to use the Flash ATA or Compact Flash memory card for this function. 2 The required storage capacity is “(program size + 200 Kbytes) Í (number of backup copies + 1).” If the size of a program is 500 Kbytes, 13 backup copy versions of it can be made on a 10-Mbyte memory card. 3 If a memory card other then those recommended is used, a normal operation is not guaranteed, and a bad influence may occur on the control unit.
8.7.3
Setting of Automatic Backup MENU → “7 FILE” → F1([TYPE]) → “Auto Backup”. The following menu is displayed.
- 462 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
Power-on time backup If “Backup at Power up” is enabled, a backup copy is made when the power is turned on. If the date of the latest backup copy in the storage device is within a period range (specified in “Interval”) from the current date, no backup copy is made at power-on time. The period range is 7 days by default. If the default value is left unchanged, a backup copy is made at power-on time once every 7 days provided that “Backup at Power up” is enabled. The unit of interval can be selected from “Day,” “Time,” and “Minute.” If the “Interval” is reset to 0, a back-up copy is made every time the power is turned on. Initializing of the storage device * To use Memory Card for Automatic Backup, the Memory Card must be initialized for Automatic Backup. It is to protect to write to the other Memory Card. The status of device is displayed in ”Status” line. The FRA: need not be initialized, since it is previously initialized. Ready for auto backup Device is not ready!
Device is initialized for automatic backup Device is not ready or device is not initialized for automatic backup
Device is initialized by the following operation. (1) If the device is not formatted, please format the device in file menu. (2) Press F2 (INIT_DEV) (3) Message “Initialize the device for auto backup?” is displayed. Press F4 (YES). (4) Message “Enter number of versions to keep:” is displayed. Please enter the number (1 to 99) of versions to keep. Pressing only the enter key sets the number of backup copy versions to 2. INIT_DEV deletes all files in the device, and create the special files and directories.
CAUTION INIT_DEV does not format the device. Please format the device in file menu ( F5 (UTIL) → “Format”)
- 463 -
8.FILE INPUT/OUTPUT
8.7.4
B-82594EN-4/01
Perform Automatic Backup When the specified condition is satisfied, automatic backup is performed.
• • • • •
• • • •
While automatic backup is performed, the menu is displayed. When automatic backup is completed, the previous menu is displayed. If you press PREV key, backup is cancelled and the previous menu is displayed. Any key except PREV is not accepted while automatic backup is performed. Even if you are using Teach Pendant, when automatic backup is performed, this menu is displayed and any key except PREV is not accepted. Please wait for Automatic backup is completed. If an attempt is made to perform automatic backup during program execution, it is performed while the program is running. It is also possible to start a program from the outside during backup. If the backup-in-progress signal is set, the specified signal becomes on while this menu is displayed.
This menu appears if backup is impossible, for example, because no memory card has been inserted. In this case, the robot will not enter an alarm state. If a program is already running, it continues running. Also in this case, it is possible to start a program from the outside. By pressing F5(RETRY), backup is performed again. Pressing the PREV key resumes the previous menu.
- 464 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
•
8.7.5
If a backup error signal is set, the specified signal becomes on while this menu is displayed.
Version Management Automatic Backup function can keep many backups in one device. The number of versions to keep is set at initializing the device. And you can change the number of versions to keep by the item “Maximum number of versions” anytime. The number of versions exceeds the specified number, the oldest version is deleted automatically. If the device is FRA: If the size of a free storage area in F-ROM in the control unit becomes smaller than 1 Mbyte, the oldest backup version is deleted automatically. In this case, the number of back versions actually held becomes smaller than “Maximum number of versions.” If the size of a free storage area in F-ROM is too small to hold an additional backup version, an error is detected during automatic backup execution. If it is impossible to hold a specified number of backup versions on a memory card because of an insufficient storage capacity, an error is detected during automatic backup execution. Specify an appropriate number of backup versions by assuming the storage capacity required to hold one backup version is “program size + 200 Kbytes.” If an error is detected because of an insufficient storage area during automatic backup, decrease the value specified in “Maximum number of versions.” This will causes an old backup version to be deleted, thus increasing a free area in the storage device. Once a backup version is deleted by decreasing the value specified in “Maximum number of versions,” it cannot be restored by increasing the value. Backup is stored in individual sub directories. When automatic backup is performed, backup files are saved to the root directory, then these files are copied to the appropriate directory. File menu can access the files only in root directory, so the latest version of backup can be loaded by file menu. You can also load the older versions. (→ 8.7.6 Restore the backup) When “all backup” is performed in file menu to the device that is initialized for Automatic Backup, the files are copied to the appropriate sub directory as same as automatic backup. If the control unit is turned off during backup, or backup is stopped prematurely, all backup files created during the current backup session are deleted, and the last backup version selected is restored to the root directory.
- 465 -
8.FILE INPUT/OUTPUT
8.7.6
B-82594EN-4/01
Restore the Backup Backup files saved by Automatic Backup can be loaded by file menu. Pressing all of above on the file menu of the controlled start menu enables all files to be read simultaneously. Usually the latest version of backup is in root directory and the version can be loaded by file menu. You can load the previous version by the following operation. (1) Press F4 (CHOICE) on the “Loadable version” item. The menu that contains the backup time of all versions in the device is displayed.
(2) Please select the version to load, then the item “ Loadable version ” shows the time of the selected version. At this time, the files of the selected version of backup are copied to root directory. (3) You can load the files of the selected version in file menu. When controlled start is performed, pressing all of above on the file menu of the controlled start menu enables all backup files to be read simultaneously.
- 466 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
8.8
IMAGE BACKUP FUNCTION
Overview By using the image backup function, it is possible to create images of the F-ROM and S-RAM memories of the controller. These images are saved as several files to a selected storage unit. The image backup function can be used from the [FILE] menu when the system is in cold start mode. After [Image backup] is selected from the menu, actual backups are made the next time the controller is turned on. To restore backups, press and hold down the [F1] and [F2] keys and turn on the controller. A menu appears from which previously saved images can be restored. Storage units are a memory card (MC:) and a PC server (TFTP:) connected via Ethernet. To use a PC server as a storage unit, it is necessary to set up the Ethernet function of the controller correctly start up the TFTP server function on the PC server.
Executing image backup Procedure 8-17
Executing image backup CAUTION Image backup can be used only when the system is in cold start mode. It cannot be used during a control start.
Step 1 2 3 1 2 3 4 5 6 7 8 4
Press the [MENUS] key. Select the [FILE] item. Press the F4 [BACKUP] key. The menu below appears. System files TP programs Application Applic.-TP Error log Diagnostic All of above Image backup If the teach pendant is disabled when Image backup is selected, the prompt below appears.
Enable TP for image backup Otherwise, the storage unit selection menu below appears. - 467 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
1 Memory card 2 Ethernet (TFTP:) 5
(MC:
)
Image backup files are saved to the root directory of a selected unit. If the unit is MC: and it already contains *.IMG files, the confirmation message below appears.
Remove existing IMG files ? YES NO
CAUTION If the storage unit is TFTP:, *.IMG files are always overwritten. 6
Select [YES], and a prompt appears, requesting that the power be turned off and back on.
Cycle power ? OK Cancel
7 8
Select [OK], and the power is automatically turned off and back on, so that the system restarts. As soon as the power is turned on, image backup is automatically started. A screen such as that shown below appears.
WRITING MC:\FROM00.IMG WRITING MC:\FROM01.IMG …… WRITING MC:\SRAM02.IMG DONE!
WARNING 1 During image backup, do not turn off the power. 2 If the storage unit is MC:, do not remove the memory card during image backup. 9
After image backup is completed or if an error occurs, the controller completes an ordinary start sequence. When the start is completed, either of the screens below appears.
Image backup completed successfully. OK Image backup failed. OK
- 468 -
8.FILE INPUT/OUTPUT
B-82594EN-4/01
10. Press [OK], and the file screen automatically appears. 11. If backup fails, alarm SYST-223 "Image backup failed(0x%x)" is posted to the alarm log. (0x%x) indicates the cause of the failure.
Restoring image backups Procedure 8-18 Restoring image backups Step 1.
Press and hold down both [F1] and [F2] keys and turn on the robot. The [Image restore] screen appears.
***** RESTORE Controller Images ***** ** Device selection menu **** 1. Memory card(MC:) 2. Ethernet(TFTP:) Others. Cancel Select : 2.
If an item other than 1 and 2 is selected, the controller starts an ordinary start sequence. If item 1 or 2 is selected, the confirmation screen below appears.
***** RESTORE Controller Images ***** Current module size: FROM: 32Mb SRAM: 3Mb CAUTION: You SHOULD have image files from the same size of FROM/SRAM. If you don't, this operation causes fatal damage to this controller. Are you ready ? [Y=1/N=else] : 3.
If 1 is entered, restoration starts. After completion, the controller starts an ordinary start sequence, using the restored images. If 2 is entered, image restoration is canceled.
- 469 -
9.UTILITY
9
B-82594EN-4/01
UTILITY This chapter explains a macro instruction, which is a special function of the Robot controller. Contents of this chapter 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9.16 9.17 9.18 9.19 9.20 9.21 9.22 9.23 9.24 9.25
MACRO INSTRUCTION ........................................................471 SHIFT FUNCTIONS................................................................484 COORDINATE SYSTEM CHANGE SHIFT FUNCTIONS...502 SOFT FLOAT FUNCTION .....................................................508 CONTINUOUS ROTATION FUNCTION..............................515 POSITION REGISTER LOOK-AHEAD EXECUTION FUNCTION ..............................................................................521 OPERATION GROUP DO OUTPUT FUNCTION.................524 TIME BEFORE FUNCTION ...................................................526 DISTANCE BEFORE FUNCTION .........................................532 STATE MONITORING FUNCTION ......................................549 AUTOMATIC ERROR RECOVERY FUNCTION ................558 REMOTE TCP FUNCTION ....................................................580 HIGH-SENSITIVITY COLLISION DETECTION .................586 LOAD SETTING .....................................................................588 LOAD ESTIMATION..............................................................592 COLLISION DETECTION FOR AUXILIARY AXIS............602 GRAVITY COMPENSATION ................................................605 PASSWORD FUNCTION .......................................................607 SOFT PANEL...........................................................................630 MIXED LOGIC INSTRUCTION ............................................633 PMC MONITOR FUNCTION .................................................653 PMC EDIT FUNCTION...........................................................656 OPERATION LOG BOOK (OPTION)....................................659 ORIGINAL PATH RESUME ..................................................674 PROGRAM TOOLBOX ..........................................................680
- 470 -
9.UTILITY
B-82594EN-4/01
9.1
MACRO INSTRUCTION A macro instruction is a function for registering a program consisting of a sequence of instructions as one instruction, and calling such a set of instructions for execution as required.
Fig. 9.1 Macro Instructions
A macro instruction has the following capabilities: • A macro instruction, when taught in a program, can be started as a program instruction. • A macro instruction can be started using the manual operation screen on the teach pendant. • A macro instruction can be started using a user key on the teach pendant. • A macro instruction can be started using the user button on the operator’s panel. (The operation box can not be used because it does not have a user key.) • You can start the macro command using DI, RI or UI. Existing programs can be registered as macro instructions. Up to 20 macro instructions can be registered. A macro instruction can be used according to the following procedure: 1 Create a program to be executed as a macro instruction. 2 Register the created macro program as a macro instruction and determine from which device the macro instruction is to be called. 3 Execute the macro instruction. The macro instruction setting screen [6 SETUP. Macro] is used for setting a macro instruction.
- 471 -
9.UTILITY
9.1.1
B-82594EN-4/01
Setting Macro Instructions The setting of a macro instruction involves the following items: • Macro program • Name of a macro instruction • Assignment of a device used to start the macro instruction
Macro program A macro program is a program started by a macro instruction. A macro program can be taught and played back (when played back as a program) in the same way as an ordinary program, except for the following restrictions: • The subtype of a program, when registered as a macro program, is changed to MR (macro). When the registration of the macro program is canceled, the subtype returns to the original one. (For information about the subtype s, see Subsection 4.1.3.) • A macro program registered as a macro instruction cannot be deleted. • A program not including a motion (group) can be started even when the motion enabled state is not set (even when an alarm is issued). For group mask setting, the program information screen is used. (See Subsection 5.3.1.) • The macro command not having the motion instruction should be made as the program which does not contain the motion group.
Name of a macro instruction The name of a macro instruction is used to call the macro program from within a program. A macro instruction name must consist of an alphanumeric character string not longer than 16 characters. The macro command can be started while robot is moving.
Assignment of a device A macro instruction must be assigned to a key, screen item, etc. so it can be called. The item to which a macro instruction is assigned is called a device. The following devices are available: • Items on the manual operation screen on the teach pendant (MF) • User keys on the teach pendant (UK and SU) • User buttons and other buttons on the operator’s panel (not provided on the operator’s box) • DI, RI, UI
NOTE If a macro instruction is allocated to a key switch on the teach pendant, the function previously allocated to the key becomes unavailable.
- 472 -
9.UTILITY
B-82594EN-4/01
CAUTION The operator should check that no macro instructions are allocated to user keys of the teach pendant. If some instructions are allocated, a trouble would occur during execution. Macro instructions can be assigned to the following devices: • MF[1] to MF[99] : Items on the manual operation screen • UK[1] to UK[7] : User keys 1 to 7 on the teach pendant • SU[1] to SU[7] : User keys 1 to 7 + SHIFT key on the teach pendant • SP[4] to SP[5] : User button 1 to 2 on the teach pendant • DI[1] to DI[99] : DI 1 to 99 • RI[1] to RI[24] : RI 1 to 24 • UI[7] HOME signal
NOTE 1 MF numbers from 1 to 99 can be used, but no more than 20 macro instructions can be assigned to MF items. 2 The total number of the assign to the DI and RI is up to 5. 3 The allocation of macros to UI signals other than the HOME signal can be enabled with system variable $MACRUOPENBL. 4 The number which can be actually used is only logical number allocated to the input signal line. The macro instruction setting screen [6 SETUP. Macro] is used for setting a macro instruction.
WARNING Before a program set as a macro instruction is copied from a control unit onto another control unit, the macro setting screens of the two control units should be compared. It should be ensured that the lists of the two control units match. The program should be copied only when the lists match. Otherwise, an unpredictable result would be produced.
- 473 -
9.UTILITY Procedure 9-1
B-82594EN-4/01
Setting macro instructions
Condition ■
A macro program is created.
■
Macro program detail information is set.
Condition NOTE 1 For greater convenience, a group mask can be set for a program not including motion instructions. 2 If the program to be modified contains a motion instruction, the group mask cannot be set.
Changing the motion group (setting a group mask) Step 1 2 3 4
The program information screen is used to change the group mask. Press the MENUS key to display the screen menu. Select “1 SELECT” on the next page. The program selection screen appears. Press F2 “DETAIL” on the next page. The program information screen appears.
- 474 -
9.UTILITY
B-82594EN-4/01
5
Move the cursor to group 1 of “Group Mask.” Press F5 “*” to set (*,*,*,*,*).
NOTE If a motion instruction is already taught in a program to be modified, no group mask can be set.
Setting a macro instruction Step 1 2 3 4
Press the MENUS key to display the screen menu. Select “6 SETUP.” Press F1 “TYPE” to display the screen change menu. Select “Macro.” The macro instruction setting screen appears.
5
For macro instruction input, press the ENTER key to display the character string input screen, then enter characters using an F key.
- 475 -
9.UTILITY
B-82594EN-4/01
Upon completion of input, press the ENTER key.
NOTE No duplicate macro instruction definition is allowed. 6
For macro program input, press F4 [CHOICE] to display a directory of programs, then choose a program from the directory. When the macro program name is entered without the macro name, the program name will be used as the macro name.
- 476 -
9.UTILITY
B-82594EN-4/01
7
For device assignment, press F4 “[CHOICE]” to display a directory of programs, then choose a program from the directory.
8
Enter a desired device number.
CAUTION After all macro instructions are set, the setting information should be saved in external storage in case the information needs to be re-loaded. Otherwise, the current setting information would be lost when it is changed. 9
For macro instruction deletion, move the cursor to a desired field, then press F2“CLEAR” while holding down the SHIFT key.
- 477 -
9.UTILITY
B-82594EN-4/01
10
9.1.2
”Clear OK?” appears. To delete the macro instruction, press F4 ”YES.” To cancel deletion of the macro instruction, press F5 ”NO.”
Executing Macro Instructions A macro instruction can be executed by: ● Selecting an item on the manual operation screen on the teach pendant (with the SHIFT key held down) ● Pressing user keys on the teach pendant (without pressing the SHIFT key) ● Pressing user keys on the teach pendant (with the SHIFT key held down) ● DI, RI, UI ● Calling the macro instruction from the program When a macro instruction is started, the macro program is executed in the same way as an ordinary program is executed, except for the following restrictions: ● The single step mode is disabled. The continuous operation mode is always used. ● The macro program is always aborted without the pausing status. ● The macro program is always executed starting from the first line. When a macro program includes a motion instruction (uses a motion group), the motion enabled state must be set to execute the macro instruction. When no motion group is used, the motion enabled state need not be set. The motion enabled state is set when: ■ ENBL is on. ■ SYSRDY output is on. (Servo power supply is on) Table 9.1.2 Macro Instruction Execution Conditions Without a motion group
MF [ 1 to 99 ] SU [ 1 to 7 ] UK [ 1 to 7 ] SP [ 4 to 5 ] DI [ 1 to 999 ] RI [ 1 to 5 ] UI [ 1 to 8 ]
TP enabled
TP disenabled
With a motion group
Executable(*1)
Executable
Executable
-
Executable
Executable
NOTE (*1) Even when the teach pendant is disabled, a macro instruction that does not possess a motion group can be executed from an MF or SU by setting system variable $MACRTPDSBEXE = TRUE. - 478 -
9.UTILITY
B-82594EN-4/01
*)
It is possible to supply an argument in a macro instruction call in a program and use it in a macro program. For details, see Subsection 4.7.5, ”Arguments.”
Procedure 9-2 Executing a macro instruction using the teach pendant (manual operation screen)
Condition ■
The teach pendant is enabled.
NOTE Even when the teach pendant is disabled, a macro instruction that does not possess a motion group can be executed from an MF or SU by setting system variable $MACRTPDSBEXE = TRUE. ■
A device from MF[1] to MF[99] is set using the macro instruction setting screen.
1 2 3 4
Press the MENUS key to display the screen menu. Select “3 MANUAL FCTNS.” Press F1, [TYPE] to display the screen change menu. Select “Macros.” The manual operation screen appears.
Step
WARNING The macro program is started in the next step, causing the robot to make a motion. Before executing the operation, the operator should check that no persons and no unnecessary equipment are in the work area. Otherwise, injury or property damage could occur.
- 479 -
9.UTILITY
B-82594EN-4/01
5
To start a desired macro instruction, press F3 “EXEC” while holding down the SHIFT key. The macro program is started.
Hold down the SHIFT key until the execution of the macro program is completed.
NOTE When the macro program contains a motion group, hold down the shift key until execution of the macro program terminates. If the shift key is released while the macro is being executed, the macro program is stopped. When the macro program does not contain a motion group, program execution continues even if the shift key is released. CAUTION If the SHIFT key is released during execution, the macro program is terminated forcibly. Note that when execution is interrupted and F3 “EXEC” is pressed again, the macro program is executed from the first line again. Procedure 9-3
Executing a macro instruction using the teach pendant (using a user key)
Condition ■
The teach pendant is enabled.
NOTE Even when the teach pendant is disabled, a macro instruction that does not possess a motion group can be executed from an MF or SU by setting system variable $MACRTPDSBEXE = TRUE.
- 480 -
9.UTILITY
B-82594EN-4/01
■
A device from UK[1] to UK[7] or SU[1] TO SU[7] is set on the macro instruction setting screen.
1
To start a macro instruction on the teach pendant, use the assigned user key on the teach pendant.
Step
WARNING The macro program is started in the next step, causing the robot to make a motion. Before executing the operation, the operator should check that no persons and no unnecessary equipment is in the work area. Otherwise, injury or property damage would occur. 2
When a user key from UK[1] to UK[7] is assigned to the macro instruction, press the assigned user key to start the macro instruction.
NOTE A macro instruction that possesses a motion group cannot be executed using a device from UK[1] to UK[7]. A device from SU[1] to SU[7] must be assigned to such a macro instruction. 3
When a device from SU[1] to SU[7] is assigned to the macro instruction, press the user key while holding down the SHIFT key.
NOTE When the macro program contains a motion group, hold down the shift key until execution of the macro program terminates. If the shift key is released while the macro is being executed, the macro program is stopped. When the macro program does not contain a motion group, program execution continues even if the shift key is released.
- 481 -
9.UTILITY
B-82594EN-4/01
CAUTION If the SHIFT key is released during execution, the macro program is terminated forcibly. Note that when execution is interrupted and F3 “EXEC” is pressed again, the macro program is executed from the first line again.
Fig. 9.1.2 User Keys on Teach Pendant
CAUTION When a key on the teach pendant is assigned to a macro instruction, it becomes that macro instructions device, and the key can no longer be used for its original function.
- 482 -
9.UTILITY
B-82594EN-4/01
Procedure 9-4
Condition
Execution of macro command using DI,RI and UI
■ ■
The teach pendant must be disabled. DI[1 to 99], RI[1 to 24] or UI[7] is specified as the device in the macro instruction setting screen.
1
To start the macro command using DI, RI or UI, input the digital signal from the external device or directly input these signals in the I/O screen on the teach pendant. When DI or RI or UI which is set in the macro instruction setting screen is input, the macro command which is assigned to the signal will be started.
Step
2
NOTE Moreover, $MACROUOPENBL can be changed in the system variable screen displayed at controlled start.
- 483 -
9.UTILITY
9.2
B-82594EN-4/01
SHIFT FUNCTIONS The shift functions shift the specified positions for the operation instructions within a certain range of a previously taught program to other locations. The shift functions perform the following: ● Shift the position data for the operation instructions within the entire range or within a certain range of an existing program. ● Insert the shift results into a new or existing program. ● Repeat the same shift on another program.
Fig. 9.2 Shift
The following rules apply to converted position data: Rules governing position data: ● Position data having Cartesian coordinates is converted to Cartesian coordinates. Position data with joint coordinates is converted to joint coordinates. ● If converted joint coordinate position data falls outside the variable axis area, it is stored as unspecified. Converted Cartesian coordinate position data is stored as is even if it falls outside the variable axis area. ● Position data in the position registers is not converted. ● The position data with joint coordinates for operation instructions involving incremental instructions is stored as unspecified. Rules governing the Cartesian coordinate system number (UT, UF) in position data having Cartesian coordinates: ● The Cartesian coordinate system number is not changed due to conversion. ● During conversion (on the shift information input screen), a user coordinate system number (UF) of 0 is used. Position data is converted to data in the Cartesian coordinate system with a UF of 0 (world coordinate system) and displayed. - 484 -
9.UTILITY
B-82594EN-4/01
Rules governing the configuration (joint placement and turn number) of position data having Cartesian coordinates: ● The configuration is not changed as a result of the conversion. ● For the turn number, if the conversion causes rotation about the wrist axis by 180° or greater, the turn number for the axis is optimized, and a message appears so that the user can determine whether to accept it. The following shift functions are available: ● Program shift : Performs a 3-dimensional linear shift or linear rotation shift. ● Mirror shift : Performs a 3-dimensional symmetrical shift about a specified mirror plane. ● Angle-input shift : Performs a rotation shift about a specified rotation axis.
9.2.1
Program Shift Function The program shift function performs a linear shift or linear rotation shift on the specified positions for the operation instructions within a certain range of a previously taught program.
Fig. 9.2.1 (a) Linear Rotation Shift
The program shift function requires the following setup:
Program name setting Program name setting specifies the name of the source program, the range of lines on which the shift is to be performed, as well as the name of the program into which the shift results are to be inserted and the line at which they are to be inserted.
- 485 -
9.UTILITY
B-82594EN-4/01
Shift information input Shift information input specifies the direction and amount of the program shift function. Two types of shift are supported: linear shift and linear rotation shift. The shift direction and amount can be specified in either of two ways: representative point specification and direct specification. ● In representative point specification, the user indicates (specifies) representative source and destination points to determine the shift direction and amount. For a linear shift, one source point (P1) and one destination point (Q1) must be indicated (specified).
Fig. 9.2.1 (b) Specifying a Linear Shift
For a linear rotation shift, three source points (P1, P2, and P3) and three destination points (Q1, Q2, and Q3) must be indicated (specified).
Fig. 9.2.1 (c) Specifying a Linear Rotation Shift
●
In direct specification, the user directly specifies the direction and amount (X, Y, Z) of linear shift. In direct specification, linear rotation shift cannot be specified. To execute the program shift function, use the program shift screen PROGRAM SHIFT. The figure below shows how to navigate through the program shift screen.
- 486 -
9.UTILITY
B-82594EN-4/01
Fig. 9.2.1 (d) Program Shift Screen
The program name input screen contains the following items: Table 9.2.1 (a) Contents of the Program Name Input Screen Item Description Original Program RANGE
Start line
End line
New Program
Insert line
Specifies the name of the source program. Specifies the type of the desired range of the source program. ● WHOLE = Performs shift on the entire program. ● PART = Performs shift on part of the program. Specifies the start line of the desired range of the source program. If WHOLE is set to all, this item cannot be specified. Specifies the end line of the desired range of the source program. If WHOLE is set to all, this item cannot be specified. Specifies the program into which the shift results are to be inserted. If a new program name is specified, a new program is created with that name. If the name of an existing program is specified, the results are inserted into that program. Specifies the line at which the shift results are to be inserted, if insertion of the results are to be into an existing program is specified. If the program is a new one, this item cannot be specified.
The representative point specification screen contains the following items: Table 9.2.1 (b) Contents of the Representative Point Specification Screen Item Description Position data
Rotation Source position Destination position REFER
Indicates the position of the point where the cursor is currently located. The position is always represented by coordinates in the world coordinate system. Specifies whether rotation is to be performed. Specifies the position of a representative source point. Specifies the position of a representative destination point. F4 REFER allows the use of a position variable or position register in the source program as the position of a representative point.
- 487 -
9.UTILITY
Procedure 9-5
Condition
Step
B-82594EN-4/01
Executing the program shift function
■
The program on which the shift is to be performed exists.
1 2 3 4
Press the screen selection key. The screen menu appears. Select 1, UTILITIES. Press F1, [TYPE]. The screen switching menu appears. Select Program shift. The program name input screen appears.
5
Specify the necessary items.
- 488 -
9.UTILITY
B-82594EN-4/01
6
After specifying the items, go to the next screen with SHIFT + ↓. The representative point specification screen appears. To return to the previous screen, use SHIFT + ↑.
7
For a shift with rotation, set ”Rotation” to ON.
8
Specify representative source and destination points.
- 489 -
9.UTILITY
B-82594EN-4/01
9
For reference point input, press F4 REFER. Select F4 P[] or F5 PR[] to enter arguments.
10
After setting shift information, press F2, EXECUTE and then F4, YES. The conversion results are written into the program.
11 The direct input screen appears with F2, DIRECT on the next page. Specify the shift amount directly.
NOTE Set the shift amount using coordinates in the world coordinate system. 12
After setting the shift amount, press F2, EXECUTE to execute the shift.
- 490 -
9.UTILITY
B-82594EN-4/01
13
If the turn number is changed due to the shift, the user is notified and asked which to select.
14
F1 indicates the axial angle associated with the changed turn number. F2 indicates the axial angle associated with the original turn number. F3 uninit causes the data to become unspecified data. F5 QUIT interrupts the conversion. To erase all the shift information, press F1, CLEAR on the next page. Then, the currently selected program is specified as the source program.
15
9.2.2
Mirror Shift Function The mirror shift function shifts the specified positions for the operation instructions in a certain range of an already taught program symmetrically about a plane.
Fig. 9.2.2 (a) Mirror Shift Function
- 491 -
9.UTILITY
B-82594EN-4/01
Theoretically, the mirror shift function converts the attitude of the tool from right-handed coordinates to left-handed coordinates. In reality, however, the attitude is returned to the right-handed coordinate system by inverting the Y-axis because no left-handed coordinates exist. The mirror shift function, therefore, performs conversion most naturally when the plane of symmetry is parallel to the XZ plane of the tool coordinate system.
Fig. 9.2.2 (b) Conversion from One Tool Coordinate System to Another with the Mirror Shift Function
CAUTION 1 The tool coordinate system must be established accurately. The mirror shift function requires that the Z-axis match the tool direction. 2 The tool center point (TCP) must be set accurately to ensure correct operation with the points resulting from a symmetrical shift. Otherwise, the points resulting from the shift will contain offset values. The mirror shift function requires the following setup:
Program name setting Program name setting specifies the name of the source program, the range of lines on which the shift is to be performed, as well as the name of the program into which the shift results are to be inserted and the line at which they are to be inserted.
Shift information input Shift information input specifies the direction and amount of the mirror shift. Two types of shift are supported: symmetrical shift and symmetrical rotation shift. ● In representative point specification, the user indicates (specifies) representative source and destination points to determine the shift direction and amount. For a symmetrical shift, one source point (P1) and one destination points (Q1), two points in total, must be indicated (specified). For a symmetrical rotation shift, three source points (P1, P2, and P3) and three destination points (Q1, Q2, and Q3), six points in total, must be indicated (specified).
- 492 -
9.UTILITY
B-82594EN-4/01
Fig. 9.2.2 (c) Specifying the Mirror Shift Function
To execute the mirror shift function, use the mirror screen MIRROR IMAGE SHIFT. The explanation of the program shift screen also applies to the mirror screen.
Procedure 9-6
Executing the mirror shift function
Condition ■
The program on which the shift is to be performed exists.
1 2 3 4
Press the screen selection key. The screen menu appears. Select 1, UTILITIES. Press F1, [TYPE]. The screen switching menu appears. Select Mirror Image. The program name input screen appears.
Step
- 493 -
9.UTILITY
B-82594EN-4/01
NOTE The program selected last with the list screen is automatically selected as the source program. 5 6
Specify the necessary items. After specifying the items, go to the next screen with SHIFT + ↓. The representative point specification screen appears. To return to the previous screen, use SHIFT +↑.
7
For shift with rotation, set ”Rotation” to Yes.
8
Specify representative source and destination points. For details, see the explanation of the program shift function.
- 494 -
9.UTILITY
B-82594EN-4/01
9
After setting the shift amount, press F2 EXECUTE to execute the shift.
WARNING Avoid moving the robot to a position that is not correctly shifted. Check the shift results before moving the robot. Otherwise, serious problems can occur. 10
9.2.3
To erase all shift information, press F1 CLEAR on the next page.
Angle-input Shift Function The angle-input shift function allows the user to perform a program shift by directly entering three or four representative points and an angular displacement. It also allows the user to perform multiple shifts at equal intervals on the same circumference at one time by specifying the iteration. If many locations on the same circumference are subject to the same machining, such as the holes on a car wheel, this function allows the user to create position data for all the locations to be machined by specifying only a single location. The angle-input shift function requires the following setup:
Program name setting Program name setting specifies the name of the source program, the range of lines on which the shift is to be performed, as well as the name of the program into which the shift results are to be inserted and the line at which they are to be inserted.
- 495 -
9.UTILITY
B-82594EN-4/01
Shift information input Shift information input specifies the representative points for determining the rotation axis for the angle-input shift function and sets the angular displacement and shift iteration. The representative points can be specified in either of two ways: one in which the rotation axis is specified and one in which it is not specified. ● If the rotation axis is not specified, three representative points (P1, P2, and P3) on the same circumference must be specified. With these three points, the rotation plane and axis are automatically calculated. The intersection of the rotation plane and axis (rotation center) is set as representative point P0. Rotation center P0, which is set automatically, can be changed directly later. From the second conversion on, the position of the rotation center can be compensated for by enabling the rotation axis. ● If the rotation axis is specified, a point on the rotation axis must be specified for representative point P0 and any three points on the rotation plane must be specified for representative points P1, P2, and P3. (P1, P2, and P3 need not be on the same circumference.) The rotation plane is determined with representative points P1, P2, and P3. The axis that is vertical to the rotation plane and which passes through representative point P0 is determined as the rotation axis. In either way, the more distant the representative points P1, P2, and P3, the more precise the conversion. The direction of rotation is regarded as being positive when the rotation is from representative point P1 to P2.
Fig. 9.2.3 (a) Specifying the Angle-Input Shift Function
To execute the angle-input shift function, use the angle-input shift screen ANGLE ENTRY SHIFT. The figure below shows how to navigate through the angle-input shift screen.
- 496 -
9.UTILITY
B-82594EN-4/01
Fig. 9.2.3 (b) Angle-Input Shift Screen
The items on the program name setting screen are the same as those on corresponding screen for the program shift function. The shift amount setting screen contains the following items:
Item Rotation plane
Rotation axis enable Rotation axis
Angle
Table 9.2.3 Contents of the Shift Amount Setting Screen Description Specifies the positions of the representative points for determining the rotation plane. If the rotation axis is not specified, these points must be on the same circumference so that the rotation center can be calculated. If the rotation axis is specified, the representative points need not necessarily be on the same circumference. The positions must be specified with coordinates in the world coordinate system. Specifies how the rotation axis is to be determined from the representative points. The representative points must be specified differently depending on the setting made for this item. Specifies the position of representative point P0 for determining the rotation axis. This item is available only when Rotation axis enable is set to TRUE. Only representative point P0 can be specified directly with position data (numeric values) in any coordinate system. To specify P0 directly, position the cursor to this item and press the Enter key. The rotation axis direct specification screen appears. Specifies the angular displacement (in degrees) by which the shift is to be performed with the rotation axis and plane determined with the representative points. Enter an unsigned real number directly. (The plus sign need not be entered.) The direction of rotation is regarded as being positive when the rotation is from representative point P1 to P2.
- 497 -
9.UTILITY
B-82594EN-4/01
Item Repeating times
REFER
Procedure 9-7
Description Specifies the conversion iteration. If the locations to be machined are arranged at equal intervals on the same circumference, specifying the iteration allows the user to machine all the locations by specifying a single location. If the iteration is 2 or greater, a comment line is automatically inserted at the beginning of the program resulting from the shift. Consider the following example: Source program: Program A 1:J P[1] 100% FINE 2:L P[2] 1500mm/sec FINE If conversion is performed with the ”angular displacement” set to 20o, ”iteration” set to 3, and ”destination program” set to program B, program B will be as follows: Destination program: Program B 1:!Angle entry shift 1 (deg 20.00) 2:J P[1] 100% FINE 3:L P[2] 1500mm/sec FINE 4:!Angle entry shift 2 (deg 40.00) 5:J P[3] 100% FINE 6:L P[4] 1500mm/sec FINE 7:!Angle entry shift 3 (deg 60.00) 8:J P[5] 100% FINE 9:L P[6] 1500mm/sec FINE The position data in program B is as follows: P[1]: Position resulting from rotating P[1] in program A by 20° P[2]: Position resulting from rotating P[2] in program A by 20° P[3]: Position resulting from rotating P[1] in program A by 40° P[4]: Position resulting from rotating P[2] in program A by 40° P[5]: Position resulting from rotating P[1] in program A by 60° P[6]: Position resulting from rotating P[2] in program A by 60° F4, REFER allows the use of a position variable or position register in the source program as the position of a representative point.
Executing the angle-input shift function
Condition ■
The program on which the shift is to be performed exists.
1 2 3
Press MENUS. The screen menu appears. Select 1, UTILITIES. Press F1, [TYPE]. The screen switching menu appears.
Step
- 498 -
9.UTILITY
B-82594EN-4/01
4
Select Angle entry. The program name input screen appears.
5 6
Specify the necessary items. After specifying the items, go to the next screen with SHIFT + ↓. The shift amount setting screen appears. To return to the previous screen, use SHIFT + ↑.
7
For shift with the rotation axis specified, set ”Rotation axis specification” to TRUE. If required, specify ”Iteration.” Specify the representative points.
8
- 499 -
9.UTILITY
B-82594EN-4/01
9
For reference point input, press F4, REFER. Select F4 [P] or F5 [PR] to enter arguments.
10 11
Enter the angular displacement. After setting the shift information, press F2 EXECUTE to execute the shift.
12
If the turn number is changed due to the conversion, the user is notified and prompted to make a selection.
13
F1 indicates the axial angle associated with the changed (optimized) turn number. F2 indicates the axial angle associated with the original turn number. F3 uninit causes the data to become unspecified data. F5 QUIT interrupts the conversion. Select one of the above keys.
- 500 -
9.UTILITY
B-82594EN-4/01
14
To directly enter the position data for representative point P0, position the cursor to the P0 line and press the Enter key. The rotation axis direct specification screen appears.
15
To specify the position of representative point P0 with numeric values in any coordinate system, position the cursor to line Frame and press F4, [CHOICE]. From the menu that appears, select the desired coordinate system.
16
Provide the other necessary shift information has been set, press F2, EXECUTE to execute the shift.
17
To erase all the shift information, press F1, CLEAR on the next page.
- 501 -
9.UTILITY
9.3
B-82594EN-4/01
COORDINATE SYSTEM CHANGE SHIFT FUNCTIONS The coordinate system change shift functions change the tool coordinate system (tool) or user coordinate system for the operation instructions within a certain range of an already taught program, and convert the position data so that the TCP is located at the same position, considering the shift amount resulting from the change from the old to the new coordinate system.
NOTE The coordinate system change shift functions allow the user to specify that the position data not be converted.
Coordinate system change shift functions The coordinate system change shift functions perform the following: ● Change the tool coordinate system or user coordinate system number in the position data (Cartesian coordinates) for the operation instructions within the entire range or within a certain range of an existing program. ● If the position data is joint coordinates, convert the coordinates considering the shift amount resulting from the tool change or user coordinate system change. ● Insert the shift results into a new or existing program. ● Execute the same shift on another program.
Position data conversion The following rules apply to converted position data: Rules for positions and attitudes: ● Position data with Cartesian coordinates is converted to Cartesian coordinates. Position data with joint coordinates is converted to joint coordinates. ● If converted joint coordinate position data falls outside the variable axis area, it is stored as unspecified. Converted Cartesian coordinate position data is stored as is even if it falls outside the variable axis area. ● Position data in the position registers is not converted. ● Position data with joint coordinates for operation instructions involving incremental instructions is stored as unspecified. Rules for the configuration (joint placement and turn number) of position data with Cartesian coordinates: ● The configuration is not changed due to conversion. ● For the turn number, if the conversion causes rotation about the wrist axis by 180° or more, the turn number for the axis is optimized, and a message appears so that the user can decide whether to accept it.
- 502 -
9.UTILITY
B-82594EN-4/01
For the tool change shift functions, select the desired position data conversion method from the following: ● TCP fixed: The original position of the tool end point is preserved in the converted data.
●
For example, TCP fixed is useful if the previously used hand was damaged and replaced by a new one. By setting the tool coordinate system number of the old hand for Old UTOOL number and the tool coordinate system number of the new hand for New UTOOL number and using a tool change shift function with TCP fixed, the TCP of the new tool is moved to the original specified point correctly. Robot fixed: The original attitude of the robot (joint positions) is preserved in the converted data.
For example, Robot fixed is useful if the program was taught in a tool coordinate system different from that used by the actually mounted hand and the correct tool coordinates are set later. By setting the tool number used when the program was taught for Old UTOOL number and the correct tool coordinate system number for New UTOOL number, and using a tool change shift function with Robot fixed, the program can operate in the correct tool coordinate system, with the same positions as the originals. The coordinate change shift functions allow the user to specify whether to convert position data. ● Perform conversion: Position data is converted so that the TCP is located at the same position. ● Do not perform conversion: Position data is not converted even if the coordinate system number is changed.
Types of coordinate system change shift functions The following coordinate system change shift functions are supported: ● Tool change shift function: Changes the tool coordinate system number in the position data. ● Coordinate change shift function: Changes the user coordinate system number in the position data. To execute the coordinate system change shift functions, use the change shift screen TOOL OFFSET (UFRAME OFFSET). The figure below shows how to navigate through the change shift screen.
Fig. 9.3 Coordinate System Shift Screen
- 503 -
9.UTILITY
Procedure 9-8
B-82594EN-4/01
Executing the tool change shift function
Condition ■
The program on which the shift is to be performed exists.
1 2 3 4
Press MENUS. The screen menu appears. Select 1 UTILITIES. Press F1 TYPE. The screen switching menu appears. Select Tool offset. The program name input screen appears.
5 6
Specify the necessary items. After specifying the items, go to the next screen with SHIFT + ↓. The coordinate system number setting screen appears. To return to the previous screen, use SHIFT + ↑.
Step
- 504 -
9.UTILITY
B-82594EN-4/01
7 8
Enter the current and new tool coordinate system numbers. To set F as the new tool coordinate system number, enter 15. Press F2 EXECUTE to execute the shift.
9
If the turn number is changed as a result of the conversion, the user is notified and prompted to make a selection.
10
F1 indicates the axial angle associated with the optimized turn number. F2 indicates the axial angle associated with the original turn number. F3 uninit causes the data to become unspecified data. F5 QUIT interrupts the conversion. To erase all the shift information, press F->”>” and press F1 1 CLEAR on the next page.
11
CAUTION When the tool change shift function is performed, the tool coordinate system number selected by the system is changed to the new tool number.
- 505 -
9.UTILITY Procedure 9-9
B-82594EN-4/01
Executing the coordinate change shift function
Condition ■
The program on which the shift is to be performed exists.
1 2 3 4
Press MENUS. The screen menu appears. Select 1, UTILITIES. Press F1, [TYPE]. The screen switching menu appears. Select Frame offset. The program name input screen appears.
5 6
Specify the necessary items. After specifying the items, go to the next screen with SHIFT + ↓. The coordinate system number setting screen appears. To return to the previous screen, use SHIFT + ↑.
Step
- 506 -
9.UTILITY
B-82594EN-4/01
7 8
Enter the current and new user coordinate system numbers. To set F as the new user coordinate system number, enter 15. Press F2, EXECUTE to execute the shift.
9
If the turn number is changed as a result of the conversion, the user is notified and prompted to make a selection.
10
F1 indicates the axial angle associated with the optimized turn number. F2 indicates the axial angle associated with the original turn number. F3 uninit causes the data to become unspecified data. F5 QUIT interrupts the conversion. To erase all the shift information, press F->”>” and then press F1 CLEAR on the next page.
11
CAUTION When the coordinate change shift function is executed, the user coordinate system number selected by the system is changed to the specified new user coordinate system number.
- 507 -
9.UTILITY
9.4
B-82594EN-4/01
SOFT FLOAT FUNCTION Usually, the robot moves accurately toward the goal specified using the teach pendant (taught point). When the robot is used to mount workpieces on a machine tool, variances in workpiece precision may result in a shift in the workpiece position relative to the tool, thus possibly causing interference between the workpiece and tool. A soft float function has been added which is effective in mounting workpieces with variances in precision onto a machine tool. The soft float function is also very effective if the synchronization speed is unstable as in the extraction of workpieces in sync with hydraulic extrusion, and if workpieces that the robot cannot grip accurately, such as rough-machined workpieces, are to be handled.
Function The soft float function works as follows: ● Two types of soft float are supported: joint soft float for specifying the softness related to the direction of rotation of each arm of the robot, and Cartesian soft float for specifying the softness on the Cartesian axes. ● The function is enabled/disabled using an instruction in the program. Its conditions are also specified using the instruction. ● ”Servo flexibility” can be specified for each axis. The term servo flexibility indicates how strongly the axis resists external forces. It is specified between 0% and 100%. A servo flexibility of 100% corresponds to being the most flexible. The servo flexibility is specified using a condition table that contains a set of data for one group (for nine axes). ● If an external force above a certain level (so high as to overcome a static frictional force) is applied to a robot, the axis of the robot is pressed and moved. ● An external force applied to a robot may prevent it from reaching the taught point. The distance between the taught point and the point the robot can reach is nearly proportional to the magnitude of the external force. ● If static load is applied to a robot, the robot controls force to maintain its attitude even if the soft float function is enabled. The detailed descriptions of the soft float function follow.
Program instruction The following three program instructions related to the soft float function are supported.
- SOFTFLOAT[n] The soft float function is enabled using condition n. * The setting of soft float condition is explained in ”Condition setting menu”.
- SOFTFLOAT END The soft float function is disabled. - 508 -
9.UTILITY
B-82594EN-4/01
- FOLLOW UP When an external force is removed from a robot, it usually tries to go back to the taught point. However, this instruction causes the robot to assume that the current position is the taught point, and prevents it from going back to the taught point.
Soft float function effective range The SOFTFLOAT[n] instruction can be used in two modes; in one mode it is used solely in a program and in the other mode it is used as an auxiliary motion instruction after a motion statement. The range in which the soft float function is effective for robot operation is determined according in to which mode this instruction is used.
- Sole instruction The soft float function is enabled after the end of the motion specified on the line preceding the solely specified SOFTFLOAT[n] instruction. In the following example, the soft float function is enabled after the motion specified on line 1 ends, and disabled by SOFTFLOAT END on line 5. 1: J P[1] 100% FINE 2: SOFTFLOAT[1] 3: L P[2] 100mm/sec FINE 4: L P[3] 100mm/sec FINE 5: SOFTFLOAT END
- Auxiliary motion instruction The soft float function becomes enabled during execution of a motion statement attached with a SOFTFLOAT [n] instruction. The point at which the soft float function becomes enabled is determined by a soft float condition ”Exec Start Ratio.” Auxiliary motion instruction is specified as the ratio (from 0% to 100% in 1% steps) of a distance to be traveled before the robot reaches the taught point corresponding to a motion statement attached with a SOFTFLOAT[n]. In the following example, the soft float function is effective between P[1] taught using a motion statement on line 1 and P[2] taught using a motion statement on line 2 attached with the SOFTFLOAT[n] instruction.
- 509 -
9.UTILITY
B-82594EN-4/01
1: 2: 3: 4:
J P[1] 100% FINE L P[2] 100mm/sec FINE SOFTFLOAT[1] L P[3] 100mm/sec FINE SOFTFLOAT END
NOTE The auxiliary motion instruction is not supported by Cartesian soft float.
- 510 -
9.UTILITY
B-82594EN-4/01
- Condition setting menu The soft float conditions are specified on the [SETUP.Softfloat] menu, which consists of the following two menus. ● List menu ● Detail menu A function key is used to select either menu. Pressing the F3 (DETAIL) key on the list menu selects the detail menu. Pressing the F3 (LIST) key on the detail menu selects the list menu. Up to 10 conditions can usually be specified for the soft float function.
- 511 -
9.UTILITY
B-82594EN-4/01
The following data can be specified on the detail menu.
Items Comment
Soft float start ratio
Servo flexibility
Enable/Disable Coordinate X direction
Table 9.4 Setting items of Soft float detail menu Descriptions Soft float condition number. By default, ten numbers can be set. Pressing the input key with the cursor on line 1 enables entering a comment. The comment text can be specified in the same way as on other menus. Line 2 specifies the point where the soft float function is enabled if the SOFTFLOAT [n] is used as an auxiliary motion instruction. See ”Soft float function effective range” for the soft float start ratio. Servo flexibility for each axis can be specified on line 3 and the subsequent lines. The servo flexibility indicates how strongly the axis resist external forces. It is specified between 0% and 100%. A flexibility of 100% corresponds to being the most flexible. Whether the soft float function is enabled/disabled can be specified for each axis on line 3 and the subsequent lines. Setting the cursor at the rightmost end (enabled/disabled setting position) of each line causes the F4 (ENABLE) and F5 (DISABLE) keys to appear. Use these keys to specify whether to enable/disable the soft float function. NOTE Pressing the F2 (NUMBER) key selects another page of the detail menu for other conditions.
When this item is set to DISABLE, soft float cannot be executed. Select one of WORLD, USER, and TOOL. NOTE If the remote TP is used, USER indicates the coordinate system on the remote TCP. Set the softness on or around the X-, Y-, and Z-axes. If Soft Rat increases, the spring constant decreases, allowing the robot to move with less force. If Soft Tol increases, the maximum force and moment applied by the robot in that direction decreases, allowing the robot to move with less force. The difference between Soft Rat and Soft Tol is illustrated below.
- 512 -
9.UTILITY
B-82594EN-4/01
Cautions/restrictions When using the soft float function, observe the following cautions/ restrictions. ● Restrictions imposed when the soft float function is enabled It is not guaranteed that the robot always follows the taught path. The taught route changes according to override. The required operation time may be prolonged compared with normal operation. ● The soft float function is disabled automatically when: Program execution starts. Program execution ends. The program stops due to an alarm that turns off the servo. Jog feed is performed with the program at pause The program is restarted after the cursor is moved manually with the program at pause. Backward execution is performed. Power is applied ● If the program is caused to pause, then restarted, the states of the soft float function (such as enabled/disabled and the soft float start ratio) are set to the conditions which exist before the program is caused to pause, except for the cases in the above operation, where the soft float function is disabled. ● The soft float function cannot be enabled by any method other than the SOFTFLOAT instruction. ● When the soft float function is enabled, the robot moves in the CNT 0 mode (no position check is made) even if FINE has been specified as motion statement positioning mode. ● When the soft float function is enabled, if an external force causes the robot to move beyond a certain distance, the following servo alarms occur. If the robot is at rest : [SRVO-023 Stop error excess(G:i A:j)] If the robot is operating : [SRVO-024 Move error excess(G:i A:j)] ● If an attempt is made to enable the soft float function with a brake applied, the brake is released automatically before the function is enabled. ● When the soft float function is enabled, brake control is ineffective. ● If the motion group mask in a program is [*,*,*,*,*] (there is no motion group), when the program issues instructions with the soft float function, the following alarm occurs: [INTP-216 (program name, line number) Invalid value for group number] ● The range of motion with the soft float function enabled should be minimized. A weight balance may vary depending on the soft float ratio and travel distance, thus shifting the vertical axis upward or downward. The range of motion with an auxiliary motion instruction issued should also be minimized for the same reason. In addition, the speed of motion should be kept low. - 513 -
9.UTILITY
B-82594EN-4/01
●
When the soft float function is enabled, if follow-up processing requires more time than specified in system variable $SFLT_FUPTIM, the servo alarm or program pause alarm occurs. System variable $SFLT_ERRTP specifies which alarm to occur. $SFLT_FUPTIM Default value: 1000 (ms) This value varies from one system to another. The large value that does not cause an alarm during normal operation should be used.
●
● ●
$SFLT_ERRTYP Default value: 0 If 0, servo alarm ”SRVO-111 Softfloat time out” occurs. If 1, Program pause alarm ”SRVO-112 Softfloat time out” occurs. (The alarm number is different between the alarms.) The default value should be used unless turning the servo off invites as an alarm any inconvenience in the system. When the soft float function is enabled, follow-up processing is normally performed for individual motion instructions. This processing is enabled or disabled according to system variable $SFLT_DISFUP. $SFLT_DISFUP Default value: FALSE If FALSE, follow-up is performed at the start of each motion instruction in the program. If TRUE, follow-up is not performed for individual motion instructions in the program. This function cannot be used with arc tools. Please don’t apply an external force to the mechanical unit of the robot when the soft float function is disabled.
NOTE Follow-up With the soft float function, external forces are applied to the robot so that it operates at positions slightly different from those specified. When the external force is removed after the completion of the operation, the robot usually attempts to move back to a specified point abruptly. Follow-up prevents this abrupt movement.
- 514 -
9.UTILITY
B-82594EN-4/01
9.5
CONTINUOUS ROTATION FUNCTION The continuous rotation function allows continuous and limitless rotation about the final axis or an additional rotation axis of the robot in one direction.
NOTE For example, the ”final axis” refers to the J6 axis of a robot having six axes. For example, this function is useful for rotating those devices that require continuous rotation, such as conveyers, pumps, and grinders, about a robot axis or additional rotation axis. To specify the items for this function, such as disable/enable, use the SETUP Continuous T screen (new). The start and stop of continuous rotation are directed from a program. Before this function can be used, the setup necessary for continuous rotation must be performed. Only a single continuous rotation axis can be allocated for each operation group. The axis must satisfy the following conditions: ● Final axis of the robot ● Final axis of the built-in additional rotation axes ● Any of the normal additional rotation axes ● Final axis of the independent additional axes The continuous rotation axis must satisfy the following mechanical conditions: ● The mechanism must allow continuous operation (must be free of obstacles such as stoppers). ● The gear reduction ratio (value of Numerator of Gear Ratio/Denominator of Gear Ratio on the setting screen, the speed of the motor required for one rotation about the axis) must be 4000 or less. To use this function, an option (continuous rotation function) is required.
Function When this function is enabled, the axis allocated as a continuous rotation axis allows limitless rotation. The angle on the axis is, therefore, represented by a relative degree within +180°, not by an absolute one. For example, the figure below shows rotation from 0° to 200° in the positive direction. The angle on the axis after the rotation is -160°, not 200°.
- 515 -
9.UTILITY
B-82594EN-4/01
Fig. 9.5 (a) Angle on the Continuous Rotation Axis
When this function is enabled but continuous rotation is not performed (see the next page for an explanation of how to use continuous rotation), rotation is performed about the continuous rotation axis from the current angle to the target angle in whichever direction incurs the least amount of motion. (Usually, the direction of rotation about the axis is determined with the relationship between the current and target angles.) This ”shorter-way operation” is effective in reducing the cycle time.
Fig. 9.5 (b) Shorter-Way Operation
Setup To use the function, ● Perform setup on the SETUP Continuous T screen and ● Specify the start/stop of continuous rotation with the operation add instruction, ”continuous rotation speed instruction.”
Procedure 9-10
Setting up the continuous rotation function
Step 1 2 3
Press MENUS. The screen menu appears. Select SETUP. Press F1, [TYPE]. The screen switching menu appears.
- 516 -
9.UTILITY
B-82594EN-4/01
4
Select Cont Turn. The continuous rotation setup screen appears.
5
Specify the necessary items using the numeric and other keys. ● To disable the continuous rotation function, set ”0” for Continuous Turn Axis Num. ● The maximum value for Numerator of Gear Ratio and Denominator of Gear Ratio is 32766. ● Set the operation group number for Group. If a different number (number of the operation group to be viewed) is entered in this field, the other settings are changed to those of the operation group. After specifying the items, press F4 DONE. The following message appears.
6
7
Item
Turn off the power, then turn it back on with a cold start. The items on the continuous rotation setup screen are described below.
Table 9.5 Contents of the Continuous Rotation Setup Screen Description
Group Continuous Turn Axis Num Numerator of Gear Ratio Denominator of Gear Ratio
Set the operation group number. Set the number of the continuous rotation axis. If ”0” is set, this function is disabled for the operation group. Set the gear reduction ratio for the continuous rotation axis set for the above item. A value from 0 to 32766 can be set for each item. The items must, however, satisfy the following: Numerator of Gear Ratio ÷ Denominator of Gear Ratio ≤ 4000
- 517 -
9.UTILITY
B-82594EN-4/01
Using the function After setting up the continuous rotation axis, specify the start point of continuous rotation using the operation add instruction, ”continuous rotation speed instruction.” The following ”continuous rotation speed instruction” is supported. The ”continuous rotation speed instruction” must be specified as an operation add instruction. * The specification method is the same as that for other operation add instructions, and is therefore omitted. (→ Subsection 5.3.4, ”Teaching an Supplementary Motion Instruction”.) ● Continuous rotation speed instruction CTV * where i = –100 to 100, which is the ratio of the rotation axis speed to the maximum axis speed (%)
Starting continuous rotation Continuous rotation is started as soon as an operation statement with a continuous rotation speed instruction added is started.
Stopping continuous rotation Continuous rotation is stopped when the first operation statement with no continuous rotation speed instruction added is started since a continuous rotation speed instruction was started. When continuous rotation is stopped, the operation on the other axes for the same operation group also terminates. The robot, therefore, decelerates even if the positioning format for the previous operation is CNT. The robot starts decelerating to stop on the continuous rotation axis after it has completely stopped on the other axes. At this time, the robot is not necessarily at the specified position on the continuous operation axis. Thus, the synchronization of the operation on the continuous rotation axis with the operation on the other axes (including those for other operation groups) is lost. If an operation statement is specified next, the robot rotates in the same direction as the previous continuous rotation direction to move to the specified position.
Notes ● ● ● ●
Continuous rotation continues even if logic instructions (instructions other than those in operation statements) are executed. During program playback, the turn number for the continuous rotation axis is ignored, and is always assumed to be ”0.” The turn number for the continuous rotation axis at a point specified when this function is enabled is always stored as ”0.” If the rotation axis speed for a continuous rotation speed instruction is specified as ”0,” continuous operation is not performed. If an operation statement is specified next, shorter-way operation is performed on the continuous rotation axis. This feature is useful if continuous rotation about the continuous rotation axis is to be stopped temporarily but temporary stop of the - 518 -
9.UTILITY
B-82594EN-4/01
● ●
●
robot due to the end of the continuous rotation is to be avoided. (See the next section, ”Example of use.”) In single-step execution (both forward and backward), continuous rotation is not performed even if a continuous rotation speed instruction is added; shorter-way operation is performed. Continuous rotation stops due to a hold. If program execution is subsequently restarted, if the target position has already been reached on axes other than the continuous rotation axis, continuous rotation is not performed. If the target position has not been reached on axes other than the continuous rotation axis, continuous rotation is restarted. Continuous rotation about the continuous rotation axis is possible from jog feed.
Example of use The following shows an example of using the continuous rotation speed instruction. 1:J P[1] 100% 2:J P[2] 100% 3:J P[3] 100% 4:J P[4] 100% 5:J P[5] 100% 6:J P[6] 100% 7:J P[7] 100% 8:WAIT 100.0sec 9:J P[8] 100%
●
●
●
FINE CNT100 CTV100 FINE CNT100 CTV100 FINE CTV100 FINE FINE CTV100 FINE
Description of lines 1 to 3: During operation from P[1] to P[2], continuous operation is performed. Although the positioning format specified on line 2 is ”Smooth,” the robot decelerates (stops temporarily on all axes at the start of the operation on line 3) because a continuous rotation speed instruction is not added to the next line, line 3. Description of lines 4 to 6: Continuous rotation starts as soon as the execution of line 4 starts. Because the rotation axis speed specified with the continuous rotation speed instruction on line 5 is 0, continuous rotation stops temporarily at the start of the execution of line 5. Because continuous rotation continues, the positioning format CNT100 on line 4 is valid and the robot does not decelerate. When line 6 is executed, shorter-way operation is performed on the continuous rotation axis. Description of lines 7 to 9: Continuous rotation starts at the start of operation on line 7. Continuous rotation continues during the execution of the wait instruction (logic instruction) on line 8. The robot stops temporarily on all axes at the start of operation on line 9, and continuous rotation stops.
- 519 -
9.UTILITY
B-82594EN-4/01
Notes/restrictions Note the following when using this function: ● When continuous rotation is to be performed on a robot axis or built-in additional axis, The X and Y components of the tool coordinate system must both be 0. (Only the Z-axis component can have a value other than 0.) If this condition is not satisfied, the path of linear or arc operation cannot be guaranteed in normal operation other than continuous rotation. ● This function cannot be used together with the following functions: Asynchronous addition axis speed instruction. (The synchronous additional axis speed instruction can be used.) Arc sensor Weaving TCP speed estimation function (sealing flow rate control) ● This function automatically updates the mastering data (for the continuous rotation axis only) according to the amount of rotation about the continuous rotation axis. Thus, previously recorded mastering data may not match the current mastering data. After this function is disabled, it is not necessary to perform mastering. ● When this function is disabled, the current position on the continuous rotation axis may fall outside the stroke limits. If this occurs, move the position on continuous rotation axis within the stroke limits using jog feed or a program. ● If, on a multigroup system, the settings on the SETUP Continuous T screen are changed and the F4 DONE key is pressed, it is necessary to set system variable $PARAM_GROUP[group].$SV_OFF_ENBL[i] (where i is an axis number) to FALSE to disable break control for all the axes for all operation groups before turning the power back on with a cold start. ● On a multigroup system, even if there are multiple continuous rotation axes, separate continuous rotation speeds cannot be specified for them. ● At the end of continuous rotation, one or more rotations about the continuous rotation may be performed to ensure smooth deceleration and stop. (The amount of rotation differs depending on the acceleration/deceleration constant.) ● Even during backward execution (single-step execution), shorter-way operation is performed on the continuous rotation axis. If, therefore, forward step execution and backward execution are performed sequentially in an operation statement with the movement angle being very close to 180o, rotation may be performed about the continuous rotation axis in the same direction during the forward and backward executions.
- 520 -
9.UTILITY
B-82594EN-4/01
9.6
POSITION REGISTER LOOK-AHEAD EXECUTION FUNCTION While the robot is executing a program, it reads the lines ahead of the line currently being executed (look-ahead execution). Conventionally, look-ahead execution was performed for motion statements having normal position data (not using position registers). Look-ahead execution could not be performed for motion statements that used position registers for their position data. Motion statements using position registers could not be read in advance because the values in the position registers could be changed by the program, data transfer function, and so forth. * If the robot reads a motion statement using a position register prior to its execution, the value of the position register may yet be changed by a program or another function (such as data transfer). Such a change is not reflected in the motion statement that has already been read by the robot. Consequently, the robot’s operation may be unpredictable. Motion statements that use position registers can be classified into two types: ● Motion statements with the target position specified by a position register ● Motion statements with an offset instruction where an offset is given by a position register Even when a target position or offset is calculated during program execution, and a position register holding this calculation result is used with a motion statement, look-ahead execution was not performed for the statement, for the reason explained above. The position register look-ahead execution function enables look-ahead execution for position registers. For this purpose, an instruction to lock position registers and an instruction to unlock the registers are newly provided. By means of these instructions, the user can explicitly specify a program portion. Then, for the specified program portion, even when it contains motion statements that use position registers, look-ahead execution can be performed.
Function The position registers can be locked to prevent their contents from being changed after they are read. When an attempt is made to execute an instruction to change a locked position register (for example, an assign instruction for the position register, or an application instruction to set data in the position register), the following alarm message is issued: [INTP-128 Pos reg is locked] When a function (such as the data transfer function) other than the program attempts to change the value of a locked position register, the following alarm message is issued, and the attempt fails: [VARS-053 Pos reg is locked] Position registers are generally locked and unlocked with instructions taught in a program. When a program that has locked the position registers terminates, the position registers are unlocked automatically. - 521 -
9.UTILITY
B-82594EN-4/01
All position registers are locked simultaneously. While the position registers are locked, access to any position register is disabled, even in a different motion group.
NOTE Before using position register instructions, lock position registers. When position register instructions are used with the position registers unlocked, operation may become tight.
Operation The following program instructions have been added:
- LOCK PREG Locks all position registers. This instruction prevents any change being made to any position register.
- UNLOCK PREG Unlocks the position registers. These are control instructions (not motion instructions). They can be taught in the same way as other control instructions (See Subsection 5.3.5, ”Teaching a Control Instruction”).
Example The following shows how to use the LOCK PREG and UNLOCK PREG instructions in a program: 1: 2: 3: 4: 5: 6: 7: 8: 9: 10:
J P[1] 100% FINE PR[1]=PR[2] PR[2]=PR[3] LOCK PREG L P[2] 100mm/sec Cnt100 L P[3] 100mm/sec Cnt100 L PR[1] 100mm/sec Cnt100 L P[4] 100mm/sec Cnt100 offset, PR[2] L P[5] 100mm/sec FINE UNLOCK PREG
When line 4 of this sample program has been executed, the position registers are locked. They are unlocked when line 10 has been executed. Therefore, the motion statements with position registers in lines 7 and 8, which are executed with the position registers locked, are subject to look-ahead execution. If the program is terminated between lines 4 and 10, the locked position registers are unlocked automatically. If the program is paused between lines 4 and 10, the cursor is moved manually, then the program is restarted, the locked position registers are unlocked. In this case, look-ahead execution is not performed for the statements in lines 7 and 8.
- 522 -
9.UTILITY
B-82594EN-4/01
NOTE When back execution is performed, then normal execution is restarted, the position registers are unlocked. For example, suppose that program execution is paused during the execution of line 6, back program execution is performed up to line 5, then forward program execution is restarted. In this case, the position registers are unlocked. So, look-ahead execution is not performed for lines 7 and 8. When program execution is started from a line located after line 4, the position registers are not locked. So, look-ahead execution is not performed for lines 7 and 8. A LOCK PREG instruction can be executed even when the position registers are already locked. (Nothing occurs, however, when the LOCK PREG instruction is executed for a second time.) Similarly, the UNLOCK PREG instruction can be executed even when the position registers are not locked. (Nothing occurs, however, when the UNLOCK PREG instruction is executed for a second time.)
Notes Note the following when using this function: ● The LOCK PREG and UNLOCK PREG instructions are not executed in backward program execution mode. ● Look-ahead execution is not performed for the LOCK PREG and UNLOCK PREG instructions. This means that when one of these instructions is encountered, look-ahead execution is stopped temporarily; after the instruction is executed, look-ahead execution is again enabled.
- 523 -
9.UTILITY
9.7
B-82594EN-4/01
OPERATION GROUP DO OUTPUT FUNCTION The operation group DO output function outputs information about the operation groups that are capable of jog feed, and about the operation groups of the programs being executed/temporarily stopped, to an external device with a digital output signal (DO) or robot output signal (RO). This allows devices other than the teach pendant to recognize the currently effective operation groups, thus improving safety. This function is effective when the multigroup option is used.
Function This function allows the allocation of two DOs (jog signal and program signal) to a single operation group. For DOs, any digital output signals or robot output signals of the robot can be used. Each allocated DO signal turns on/off under the following conditions:
- Jog signals When the teach pendant is disabled, all signals turn off. When the teach pendant is enabled, the signal for the currently selected operation group on the teach pendant turns on, while the other signals turn off.
- Program signals Regardless of whether the teach pendant is enabled or disabled, the signal for the operation group of the program currently being executed/temporarily stopped turns on. (The signal does not turn on when the program is merely selected.) If other programs are being executed/temporarily stopped with the multitask option, the signals for the operation groups of these programs also turn on.
Setup To set up the operation group DO output function, use the [Set up operation group DO] screen. To change the signal number for an operation group, move the cursor to the signal number and enter a new value.
To change the type of a signal, position the cursor to the signal number and press function key F4 ”RO” or F5 ”DO.” To disable a signal, set the number of the signal to ”0.”
- 524 -
9.UTILITY
B-82594EN-4/01
The same signal can be set for both the program and jog signals for the same operation group. In this case, the output signal is the OR of the two signals. That is, the signal turns on if either the program or jog signal turns on. (The signal turns off only if both the program and jog signals turn off.)
Example of using this function with the multitask option This section explains the operation of this function when a subprogram call or the multitask option is used. The output program signal is the OR of the signals for all the operation groups of the program currently being executed or temporarily stopped. If a program without an operation group calls a program having an operation group by using a subprogram call, the signal for the operation group of the subprogram turns on only while the subprogram is being executed. (The signal does not turn on when the main program without an operation group is merely selected/executed.) If the execution instruction of the multitask function is to start another program that operates the robot (the main program that has the execution instruction does not have an operation group), the signal for the operation group of the program started by the execution instruction does not turn on when the main program is merely selected/executed. The program signal turns on when the program that operates the robot is actually started. Consider the following three example programs: PROGRAM MAIN : Operation group[*,*,*,*,*] 1:RUN PRG A 2:RUN PRG B : PROGRAM PRG A : Operation group[1,*,*,*,*] 1:J P[1] 100% FINE : PROGRAM PRG B : Operation group[*,1,*,*,*] 1:L P[1] 500mm/sec CNT100 :
Program MAIN, which does not have an operation group, starts PRG A and PRG B having operation groups by using execution instructions. PRG A uses operation group 1 and PRG B uses operation group 2. ● The program signals for the groups do not turn on when program MAIN is merely selected. ● When line 1 of MAIN is executed, PRG A is started and the signal for operation group 1 turns on. ● When line 2 of MAIN is executed, PRG B is started and the signal for operation group 2 turns on. ● When PRG A and PRG B terminates, the respective signals for operation groups 1 and 2 turn off.
Notes Note the following when using this function: ● The same signal cannot be defined for different operation groups. ● While a program is being executed/temporarily stopped, the type (DO or RO) and number of the program signal cannot be changed. - 525 -
9.UTILITY
9.8
B-82594EN-4/01
TIME BEFORE FUNCTION This function calls a subprogram and output a signal before or after the specified time at which robot operation is to terminate. For example, if a signal output instruction is specified in a subprogram, this function allows a signal to be output during robot operation. It can also eliminate the wait time associated with the transfer of data to and from peripheral devices, thus reducing the cycle time.
Function This function allows a main program to call and execute a subprogram before or after the specified operation termination time. Signal output is executed before or after the specified operation termination time. Using an instruction in a program, specify the time at which a subprogram is to be called (in seconds). (This specified time is called the execution start time.) The time at which operation terminates is assumed to be 0 seconds, which differs depending on the positioning type (FINE or CNT). Using an instruction in a program, specify the name of the subprogram to be called. The TIME BEFORE (or AFTER) instruction is an operation add instruction. Both the subprogram name and execution start time must be specified with the operation add instruction.
Instruction statement Specify the execution start time and subprogram after an operation statement.
Fig. 9.8 (a) TIME BEFORE/AFTER Instruction (Operation Add Instruction)
Example
1:J P[1] 100% FINE :TIME BEFORE 1.0sec CALL OPEN HAND 1:J P[1] 100% FINE :TIME AFTER 1.0sec CALL OPEN HAND
Description of execution start time According to the specified execution start time, the subprogram is executed at the following time: If execution start time, ”n” seconds, is specified with a TIME BEFORE instruction, the subprogram is executed n seconds before operation termination.
- 526 -
9.UTILITY
B-82594EN-4/01
Fig. 9.8 (b) Timing of Subprogram Execution (TIME BEFORE Instruction)
If execution start time, ”n” seconds, is specified with a TIME AFTER instruction, the subprogram is executed n seconds after operation termination.
Fig. 9.8 (c) Timing of Subprogram Execution (TIME AFTER Instruction)
If the execution start time specified with a TIME BEFORE instruction exceeds the operation time, the subprogram is executed as soon as operation starts.
Fig. 9.8 (d) Timing of Subprogram Execution (TIME BEFORE Instruction)
The execution start time that can be specified in a program is 0 to 30 seconds for a TIME BEFORE instruction 0 to 0.5 seconds for a TIME AFTER instruction
CAUTION Even if the robot operation time is changed due to a change in the override, the time at which subprogram execution is to start depends on the execution start time. The execution start position of the subprogram is, therefore, changed due to a change in the override.
- 527 -
9.UTILITY
B-82594EN-4/01
Search/replace functions - Search function By selecting CALL program for search item CALL, the search function searches for the call instructions of TIME BEFORE instructions.
- Replace function ● ●
By selecting replace item TIME BEFORE/AFTER, TIME BEFORE/AFTER replacement and execution start time replacement can be performed. By selecting CALL program of replace item CALL, the subprogram names for TIME BEFORE instructions can be replaced.
Single step When an operation statement with an execution start TIME BEFORE instruction specified is executed in single-step mode, operation stops temporarily at the time when the subprogram is called. Subsequently, the rest of the operation is executed in sync with single-step execution of the subprogram.
Power failure handling If power failure handling is enabled and the power is removed during subprogram execution, execution starts with the remaining instructions of the subprogram due to a restart after the power is turned on again. In this case, the subprogram is executed with the position the robot was located when the power was removed. Thus, the subprogram is executed with timing different from the usual timing. Great care must be taken regarding this point.
WARNING Be sure you know the point where the robot is going to begin robot motion when power is restored after a power failure. Otherwise, you could injure personnel or damage equipment.
- 528 -
9.UTILITY
B-82594EN-4/01
Procedure 9-11
Specifying the TIME BEFORE instruction
Step 1
Position the cursor to the operation add instruction specification area (space following an operation instruction).
2
Press function key F4 CHOICE. A list of operation add instructions appears.
3
Select item TIME BEFORE.
- 529 -
9.UTILITY
B-82594EN-4/01
4
Specify the time and press the Enter key. Example: 2 seconds.
5
Select item CALL program. Select item CALL program to use AR.
6
Select item Open hand.
Program example Main program: PNS0001 1:J P[1] 100% FINE 2:J P[2] 100% CNT100 :TIME BEFORE 1.0sec CALL Open hand 3:CALL Close hand
Subprogram: Hand open 1:DO[1]=on
- 530 -
9.UTILITY
B-82594EN-4/01
Operation performed when the main program is executed
Fig. 9.8 (e) Program Example Using a TIME BEFORE Instruction
Notes/restrictions In the subprogram specified for Call, operation statements cannot be specified. (The operation group in the subprogram must be [*, *, *, *, *].) Since the called sub routine and the main program are concurrently executed, the main program is sometimes executed earlier than the called sub routine. When you do not want to proceed with the execution of the main program ahead until the execution of the called sub routine is finished, please change a system variable as follows. $TIMEBF_VER=3 (the standard value) → 2
No limit is imposed on the number of instructions that can be specified in a subprogram. The TIME BEFORE/AFTER add instructions can be used together with other operation add instructions (except application instructions such as spot [] and skip instructions). If the positioning specification for an operation statement is Smooth, the time of operation termination changes depending on the degree of Smooth. The time at which the subprogram is called changes accordingly. Depending on the situation, even if the execution time is set to 0 seconds with a TIME BEFORE instruction, the subprogram may be executed too quickly. If this occurs, use a TIME AFTER instruction. If a TIME BEFORE instruction is specified on the last line of a main program, the execution of the main program may terminate before the subprogram is called, in which case, the subprogram is not called. Do not, therefore, specify a TIME BEFORE instruction on the last line of a program. For direct specification of signal output, only DO, RO, GO, and AO are supported.
- 531 -
9.UTILITY
B-82594EN-4/01
9.9
DISTANCE BEFORE FUNCTION
9.9.1
Overview This function calls program or outputs signal when TCP is going into a region which is within specified distance from destination point. This program call and signal output is done on a parallel with main program execution. Example 1 J P[1] 100% FINE 2 L P[2] 1000mm/sec FINE DB 100mm,CALL A
Fig. 9.9.1 Execution timing of Distance Before
9.9.2
Specification Item
Specification
Distance value
0.0 to 999.9[mm]
Trigger condition (*1)
Available instructions
TCP goes into a region, which is within specified distance from destination point. Please refer to Chapter 4 for details. ● Signal output (ex. DO[1] = ON) ● CALL program
Limitation Distance value and actual execution timing is different. The error depends on speed of TCP. Distance value and actual execution timing is different. The error depends on speed of TCP. Program to be called cannot use motion group. Only logic instruction is available.
NOTE (*1) This is condition to process instruction part.
9.9.3
Configuration Before using Distance Before, set following system variable. $SCR_GRP[1].$M_POS_ENB = TRUE - 532 -
9.UTILITY
B-82594EN-4/01
9.9.4
Instruction
1 Format Distance Before is taught in following format. Motion statement + DB distance value, instruction part
Example L P[2] 1000mm/sec FINE DB 100mm, CALL A
Instruction part (Please refer to 3.) distance value (Please refer to 2.)
NOTE Distance Before is a motion option. You cannot use DB as a standard instruction.
2 Distance value (i) Distance value Distance Before executes instruction part when TCP goes into a spherical region whose center is destination point. Distance value decides the radius of this sphere. Distance value is taught in millimeter. Distance value is from 0 to 999.9mm. This sphere is referred as trigger region hereafter. 1: 2:
L P[1] 2000mm/sec FINE DB 100.0mm L P[2] 2000mm/sec FINE DB 100.0mm
Fig. 9.9.4 (a) Cyclical checks if TCP goes into trigger region.
- 533 -
DO[1] = ON DO[1] = ON
9.UTILITY
B-82594EN-4/01
Internally, Robot controller calculates current position to judge if TCP is in trigger region or not. Instruction part is executed when this calculated position is in trigger region.
CAUTION Execution timing of instruction part is decided by distance (in millimeter). Because judgment to trigger is done by calculating distance between current position and destination point, actual execution timing is different from distance value. (Error in case of 2000mm/sec is estimated around 16mm) (ii) Radius of trigger region. Radius of trigger region is as follows. Radius = (distance value or $DB_MINDIST)+$DB_TOLERENCE
Fig. 9.9.4 (b) The size of trigger region
If distance value is less than $DB_MINDIST, $DB_MINDIST is used as distance value. Example Suppose following motion statement is taught with $DB_MINDIST = 5.0 L P[1] 2000mm/secFINE DB 0.0mm DO[1]=ON
In this case, Robot controller interprets it as DB 5.0mm.Then $DB_TOLERENCE is added to decide radius of trigger region. Consequently, radius of trigger region is 5.05mm with default system variables.
- 534 -
9.UTILITY
B-82594EN-4/01
3 Instruction part This part shows what is done when TCP goes into trigger region. DB can do following action. • CALL program • Signal output
(i) DB Call program Specified program is executed when condition is triggered. Program to be called cannot use motion group. (Change group mask to [*,*,*,*,*] in program header information screen.) You can use arguments to call program. Example) L P[2] 1000mm/sec FINE DB 100mm, CALL A (1,2)
(ii) DB signal output You can teach following signal output. You can use one signal output for one DB.
DO[] RO[]
=
GO[] AO[]
=
ON OFF R[] pulse Constant R[] AR[ ]
You can also output signal by calling program which use signal output instruction. But to output only one signal with one DB, this direct signal output is better. It’s easier to read and maintain.
4 Changing trigger condition Instruction part is executed when Robot controller recognizes that TCP is in trigger region. But in some cases like following “going away” and “penetrate”, robot controller doesn’t recognize that TCP is in trigger region. These cases are described in this section. Case 1 Trajectory of CNT motion doesn’t go through trigger region.(“going away”)
- 535 -
9.UTILITY
B-82594EN-4/01
Case 2 Trigger region is too small for controller to check current position in time.(“penetrate”)
For these case, the condition for instruction part to be executed (referred as DB condition) is changed by $DB_CONDTYP. $DB_CONDTYP 0
1 (default value)
2
DB condition TCP is in trigger region. (“region trigger”) + end of motion (*2) “region trigger” +“going away” +“penetration” +end of motion “region trigger” +“penetration” +end of motion
When alarm is posted. “going away” +“penetrate” +end of motion end of motion +(“going away”) (*1) “going away” end of motion
“going away” and “penetration ” is defined in (i), (ii) and (iii) respectively. Distance Before executes instruction part when DB condition is satisfied. Otherwise, posts alarm. There are two alarms for not-triggered DB. They are INTP-293 and INTP-295. $DBCONDTRIG decides which alarm is posted. Message is same but severity is different. Please refer to 5 for details.
NOTE (*1) When Distance Before is triggered by “going away” in case of $DB_CONDTYP = 1, you can post alarm in addition to execution of instruction part. Please refer to 4 (i) for details. (*2) By default configuration, if motion statement with Distance Before completes and robot stops before neither “region trigger” nor “going away” nor “penetration” trigger happens, Distance Before executes instruction part and post alarm. Please refer to 4 (iii).
- 536 -
9.UTILITY
B-82594EN-4/01
(i) In case of going away. If termination type is CNT and distance value is small, TCP may not go into trigger region.
Fig. 9.9.4 (c) TCP doesn’t go into trigger region.
In case of Fig. 9.9.4 (c), TCP doesn’t go into trigger region. TCP starts to go away from destination point (P[2]). Robot controller cyclically judges if TCP is going away from destination point or not in addition to DB condition. Robot controller recognizes that TCP is going away when calculated distance between current position and destination point is greater than previous one by more than ($DB_AWAY_TRIG) millimeter. This case is referred as “going away” in this manual. ● To post alarm in addition to execution of instruction part only when the DB is triggered by “going away” trigger, set $DB_AWAY_ALM to TRUE. DB executes instruction part and post following alarm. INTP-295 (program name, line number) DB too small (away) (%dmm) This is warning.
(ii) Penetration This function cyclically checks if DB condition is triggered or not. Because of this cyclical check, CNT motion with high-speed may cause for Robot controller to omit cyclical check in small trigger region. See Fig.9.9.4 (d).
Fig. 9.9.4 (d) Penetration
- 537 -
9.UTILITY
B-82594EN-4/01
In this case, TCP moves too fast for robot to check DB condition in small trigger region. Because cyclical check is done outside of trigger region, the fact TCP is in trigger region is not recognized by the robot controller. This case is referred as “ penetration” in this manual. To handle cases like Fig. 9.9.4 (d), Distance Before checks if TCP went through trigger region or not. If trajectory of TCP penetrated trigger region (penetration), instruction part is executed by default configuration. But in this case, execution of instruction part is done after TCP passed away destination point. ● Motion with termination type FINE doesn’t cause trigger by “penetration”.
(iii) End of motion If motion statement with DB completes and robot stops before “region”, “going away” and “penetration” is satisfied, DB executes instruction part and post following alarm. INTP-297 (program name, line number) DB too small (done) (mm). This alarm is not posted by FINE motion. If you don’t want this trigger, set $DB_MOTNEND to FALSE (default value: TRUE). Distance displayed by this alarm is distance to destination.
CAUTION 1 If you stop your robot by E-stop when motion statement is about to complete, Distance Before may be trigger just after resume of the program. 2 If you halt a program when motion statement with DB is near its completion, DB may not be triggered. In this case, Distance Before executes its instruction part after resume of program.
5 Alarms for not -triggered Distance Before Distance Before posts alarm if condition is not triggered. What is posted depends on $DBCONDTRIG. $DBCONDTRIG 0 (default value)
1
Alarm to be posted INTP-295 WARN (Program name, line number)DB condition was not triggered. INTP-293 PAUSE.L (Program name, line number)DB condition was not triggered.
By default configuration, INTP-295 is posted. Because severity of this alarm is WARN, execution of program doesn’t stop.
- 538 -
9.UTILITY
B-82594EN-4/01
If you want to halt program when condition was not triggered, set $DB_CONDTRIG to 1.INTP-293 is posted when condition was not triggered. Program is halted for severity of this alarm is PAULSE.L .Robot decelerates to stop. Displayed distance is recommended value for the DB to be triggered by region trigger.
6 Step execution If Distance Before CALL program is executed by step execution, program is halted at the timing sub program is called. The rest of motion statement is done by next step execution that executes sub program step by step. Step execution of motion statement with DB signal output is just same as motion statement with out DB except signal output is done.
CAUTION If distance value is small, program may be halted before completion of motion and before DB conditions are satisfied. In this case, Distance Before is not triggered by step execution of the line it is taught. The DB is triggered by execution of next line.
7 Halt and resume Halt and resume of motion statement with DB changes its radius of trigger region. After resume, radius of trigger region is changed to minimum radius ($DB_MINDIST +$DB_TORELENCE). The purpose of this process is to execute instruction part after TCP reaches to its destination point. This prevents earlier trigger because of halt and resume. This means that halt and resume of program changes trigger timing of Distance Before. Not to change radius of trigger region, set $DISTBF_TTS to 0 (default value: 1). Example Default configuration Suppose following program is executed. 1: L P[1] 2000mm/sec FINE 2: L P[2] 2000mm/sec CNT100 DB 100.0mm CALL SUB 3: L P[3] 2000mm/sec CNT100
Fig. 9.9.4 (e) Trigger timing after resume of program.
- 539 -
9.UTILITY
B-82594EN-4/01
Example Resume with $DISTBF_TTS = 0
Fig. 9.9.4 (f) $DISTBF_TTS = 0
8 Resume after JOG If you halt motion statement with DB, JOG robot and resume program, execution timing depends on TCP position at the instant of program resume. Because this procedure is accompanied by program halt, execution timing depends on $DISTBF_TTS, too.
(i) Default configuration ($DISTBF_TTS = 1) After resume of program, radius of trigger region changed to minimum value ($DB_MINDIST +$DB_TOLERENCE). If TCP is in new (diminished) trigger region, DB is triggered just after resume of program. If not, DB is triggered when DB condition is satisfied. Example Suppose following program is executed and halted on line two. DB condition is not triggered yet. 1: L P[1] 2000mm/sec FINE 2: L P[2] 2000mm/sec CNT100 DB 100.0mm DO[1] = ON 3: L P[3] 2000mm/sec CNT100
Fig. 9.9.4 (g) Resume after JOG
- 540 -
9.UTILITY
B-82594EN-4/01
(ii) $DISTBF_TTS = 0 Radius of trigger region is not changed. If TCP is in trigger region, DB is triggered just after resume of program. If not, DB is triggered when DB condition is satisfied. Example) Suppose following program is executed and halted on line two. DB condition was not satisfied yet. 1: L P[1] 2000mm/sec FINE 2: L P[2] 2000mm/sec CNT100 DB 100.0mm DO[1] = ON 3: L P[3] 2000mm/sec CNT100
If TCP is distant from P[2] enough not to trigger(more than 100mm away), DO[1] turns ON when DB condition is triggered by motion after resume, at point A in left diagram in Fig.9.9.4 (h). If TCP is in trigger region when you resume program, DO[1] turns ON just after resume. (right diagram in Fig. 9.9.4 (h).
Fig. 9.9.4 (h) Resume after JOG($DISTBF_TTS = 0)
9 Power failure recovery If power is turned down during sub program execution and power failure recovery is enabled, resume after power failure recovery executes the rest of sub program. In this case, sub program is executed where TCP was at power failure. Execution timing is different from usual one.
- 541 -
9.UTILITY
9.9.5
B-82594EN-4/01
Entering Distance before
1 DB call program 1)
Move cursor to motion option area.
2)
Press F4.List of motion option is displayed.
3)
Select DISTANCE BEFORE.DB is added to program.
4)
Input distance value and press Enter. Submenu to select instruction part is displayed.
- 542 -
9.UTILITY
B-82594EN-4/01
5)
To use argument, select CALL program( ).If you don’t, select CALL program. Program list is displayed anyway.
6)
Select program to call.
7)
To specify argument, following procedure is needed. Select argument type. Screen displayed below is example to use Constant.
- 543 -
9.UTILITY
B-82594EN-4/01
8) ● ●
Input value of argument. To use more than 2 arguments, move cursor to “)” and press F4[CHOICE]. Submenu to select argument type is displayed. Teach argument by procedure 7) and 8) described above. To delete argument, move cursor to argument you want to delete and press F4. Then select . To add argument to CALL without argument, following procedure is needed. 1 Move cursor to program name.
2
Press PREV key 2 times. Following submenu is displayed.
3
Select CALL program ().
4
Select program to call and teach argument.
2 DB Signal output 1)
Do just same procedure 1)-4) for DB CALL program. Submenu to select instruction is displayed.
- 544 -
9.UTILITY
B-82594EN-4/01
2)
Select signal output instruction.
3)
Input index and output value just as you do for normal I/O instruction.
3 Finding/Replacing Instructions ●
●
Finding Instructions You can find program which is used for DB by “find” on F5 pull-up menu. By selecting “CALL” then “Call program” to find program used in DB. You can find signal output instruction by this function, too. Select item “I/O” on submenu. Replacing Instructions Distance Before can be replaced to TIME BEFORE/AFTER by “replace” on F5 pull-up menu. Select “TIME BEFORE/AFTER” on replace item submenu. You can also replace CALL and signal output in instruction part just as you do when you replace usual CALL and DO etc.
- 545 -
9.UTILITY
9.9.6
B-82594EN-4/01
Caution and Limitations ● ● ●
● ● ● ● ● ● ● ● ● ● ● ● ● ● ●
Distance Before cannot be used with TIME BEFORE/AFTER. More than 6 motion statement with Distance Before cannot be processed at the same time. Distance Before calculates distance between current position and destination point cyclically. Because trigger condition is judged by this cyclical check, actual execution timing of instruction part is different from distance value. Instruction part may be executed inside of trigger region. This means the point where instruction is executed is closer than distance value. Degree of error depends on speed of robot. The slower TCP moves, the more accurate execution timing. Distance Before is not recovered by power failure recovery if it was attached to CNT motion statement and power is down when the motion is about to complete. Distance Before cannot be used with INC, skip and quick skip in a motion statement. Multi group is not supported. Robots that don’t have Cartesian coordination are not supported. Position data in matrix form is not supported. Integrated axis is not supported. FANUC Robot F-200i is not supported. Line tracking is not supported. If CJP or ACCUPATH is used, use this function with $DB_MOTNEND = TRUE. If program ends before DB condition triggers, execution instruction is not processed even if DB condition is triggered after program execution completed. During deceleration due to program halt, “going away” trigger may not work. In this case. DB is triggered after program resume. After E-stop, DB doesn’t work. If TCP passes by destination point, DB is triggered after resume of program. After E-stop and resume or program, DB may be triggered just after resume. Single step execution of DB of small distance value may fail for program is paused before motion statement completes and DB condition satisfied. The DB is triggered by execution of next line. If DB condition is satisfied after pause of program, DB is not triggered by step execution of the line. In this case, the DB is triggered by execution of next line.
- 546 -
9.UTILITY
B-82594EN-4/01
9.9.7
System Variables
System variable $DISTBF_VER
$DB_AWAYTRIG
$DB_AWAY_ALM
$DB_TOLERENCE
$DB_CONDTYP
$DBCONDTRIG
$DB_MINDIST
$DB_MOTNEND $DISTBF_TTS
Role This system variable sets execution timing of line which is just after motion statement with DB. 1 : Execution of next line doesn’t wait completion of instruction part of DB. 2 : Execution of next line waits for completion execution of instruction part. 3(default) : combination of 1 and 2. In the case of DB call, if called action routine has Wait statement or is long enough then behavior is the same as it is 2. If action routine is short and has no wait statement, then behavior is the same as it is 1. Example Suppose following program is executed. 1: L P[1] 2000mm/sec FINE 2: L P[2] 2000mm/sec CNT 100 DB 1.0mm CALL SUB 3: L P[3] 2000mm/sec FINE With $DISTBF_VER=1, line 3 is executed without waiting SUB is finished. With $DISTBF_VER=2, execution of line 3 doesn’t start until SUB is finished. With $DISTBF_VER=3, if SUB doesn’t have Wait instruction, line 3 is executed without waiting SUB is finished. If SUB has Wait instruction, execution of line 3 doesn’t start until SUB is finished. Distance Before calculate distance between current position and destination cyclically. robot controller recognize TCP is “going away” from destination point if this calculated distance is greater previous value by $DB_AWAYTRIG millimeters. Please refer to 9.9.4, 4 (i) for details. This system variable decides whether INTP-295 is posted or not when DB is triggered by “going away” with $DB_CONDTYP = 1. Please refer to 9.9.4, 4 (i) for details. The radius of trigger region is distance value +$DB_TOLERENCE. (If distance value <$DB_MINDIST, radius is $DB_MINDIST +$DB_TOLERENCE) Please refer to 9.9.4, 2 (ii) for details. This system variable defines DB trigger condition. 0 : When TCP goes into a region which is within distance value (“region trigger”) 1 : In addition to “region trigger”, in case of “going away” 2 : In addition to “region trigger”, in case of “penetrate”. Please refer to 9.9.4, 2 and 9.9.4, 4 for details. This system variable decides alarm that is posted when DB condition was not triggered. 0 : INTP-295 WARN “(program name, line number) DB condition was not triggered.” is posted. 1 : INTP-293 PAUSE.L “(program name, line number) DB condition was not triggered.” is posted. Please refer to 9.9.4, 5 for details. Internal minimum value of distance value. If distance value is smaller than this value by $DB_MINDIST or more, $DB_MINDIST is used as distance value instead of distance value user taught. Please refer to 9.9.4, 2 (ii) for details. This system variable decides if motion completion trigger DB or not. Please refer to 9.9.4, 4 (iii). This system variable decides execution timing of instruction part after motion statement with DB is halted. Please refer to 9.9.4, 7 for details.
- 547 -
Default value 3
0.08(mm)
FALSE
0.05(mm)
1
0
5.0(mm)
TRUE 1
9.UTILITY
9.9.8
B-82594EN-4/01
Error Codes Following alarms are related to Distance Before. INTP-292 PAUSE.L More than 6 motion with DB executed. [Cause] more than 6 Distance Before were processed at the same time. Example 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11:
L L L L L L L L L L L
P[1] 2000mm/sec CNT100 DB 10mm DO[1] = ON P[2] 2000mm/sec CNT 100 DB 10mm DO[2] = ON P[3] 2000mm/sec CNT 100 DB 10mm DO[3] = ON P[4] 2000mm/sec CNT 100 DB 10mm DO[4] = ON P[5] 2000mm/sec CNT 100 DB 10mm DO[5] = ON P[6] 2000mm/sec CNT 100 P[7] 2000mm/sec CNT 100 DB 10mm DO[7] = ON P[8] 2000mm/sec CNT 100 DB 10mm DO[8] = ON P[9] 2000mm/sec CNT 100 DB 10mm DO[9] = ON P[10] 2000mm/sec CNT 100 DB 10mm DO[10] = ON P[11] 2000mm/sec CNT 100 DB 10mm DO[11] = ON
If CNT motion statement with DB frequently like this example, more than 6 calculation for Distance Before may be done at the same time. [Remedy]Change termination type from CNT to FINE. Otherwise, change structure of program not to execute DB frequently. INTP-293 PAUSE.L (program name, line number) DB too small (away) (distance mm) [Cause] Condition of Distance Before was not triggered. [Remedy] Change program for TCP to move into trigger region. INTP-295 WARN (program name, line number) DB too small (away)(distance mm) [Cause] Condition of Distance Before was not triggered. [Remedy] Change program for TCP to move into trigger region. INTP-296 WARN (program name, line number) $SCR_GRP[1].$M_POS_ENB is FALSE. [Cause] $SCR_GRP[1].$M_POS_ENB is FALSE. [Remedy] Change $SCR_GRP[1].$M_POS_ENB to TRUE INTP-297 WARN (program name, line number) DB too small(done) (distance mm) [Cause ] DB is triggered by completion of motion statement to which it is attached. [Remedy] Use greater distance value. This is best solution. If you do not want this trigger, set $DB_MOTNEND to FALSE.
- 548 -
9.UTILITY
B-82594EN-4/01
9.10
STATE MONITORING FUNCTION This function accepts, as conditions, the values of the input/output signals, alarms, and registers of the robot controller (referred to simply as the controller), and executes the specified programs if the conditions are satisfied. The controller itself monitors these conditions. This function consists of the following instructions and programs: ●
Monitor start instruction Specifies the condition program to be monitored and the start of monitoring. Example: 1:MONITOR WRK FALL
Condition program name
●
Monitor stop instruction Specifies the condition program to terminate. 9:MONITOR END WRK FALL
Condition program name
●
Condition program Describes the condition to be monitored and specifies the program to be executed if the condition is satisfied. Program example: 1:WHEN DI[2]=Off, CALL STP RBT
*1 *2 This condition program states that when RI[2] turns off, STP RBT is to be called. *1 Describe the desired monitoring condition by following instruction WHEN. The types of monitoring condition are explained in the WHEN section. *2 Specify the program to be executed if the condition described in *1 is satisfied. The action program can be created and named in the same way as a normal program. ●
Action program Called if the condition is satisfied. The same instructions as those used in normal programs can be used. Program example: 1:DO[2]=On ! Notification to a peripheral device 2:R[8]=R[8]+1 ! Drop count 3:UALM[1] ! Alarm and robot stop $UALRM_MSG[1]=WORK HAS FALLEN
- 549 -
9.UTILITY
B-82594EN-4/01
With the following program example, if the robot performing handling drops a workpiece, the user is alerted with an error message and the robot is stopped. Sample. TP (program for handling operation) 1:MONITOR WRK FALL 2:J P[1] 100% FINE : : Handling : : 8:J P[7] 100% FINE 9:MONITOR END WRK FALL 10:Open hand
operation State monitoring
Workpiece drop. condition (condition program) 1:WHEN DI[2]=Off, CALL STP RBT
Robot stop. TP (action program) 1:DO[2]=On ! Notification to a peripheral device 2:R[8]=R[8]+1 ! Drop count 3:UALM[1] ! Alarm and robot stop [End]
Monitor types There are two main types of monitors: the program monitor and system monitor. ● The program monitor starts/stops from a mnemonic program (referred to simply as a program). When the program terminates, monitoring also terminates. ● The system monitor is started/stopped from the dedicated screen. It performs monitoring constantly regardless of the execution state of the program. (Monitoring continues even after the program terminates.)
- Program monitor This type of monitor depends on the execution state of the program. It is suitable for state monitoring within a separate program. Monitoring starts with an instruction (monitor start instruction) in the program. Monitoring terminates with a monitor stop instruction or program termination. The program monitor can be switched between two settings: setting 1 in which the monitor stops when the program stops temporarily, and setting 2 in which the monitor continues monitoring.
NOTE Settings 1 and 2 cannot be used at the same time.
- 550 -
9.UTILITY
B-82594EN-4/01
- System monitor This type of monitor does not depend on the execution state of the program. It is suitable for monitoring the state of the entire system. The monitor is started and stopped from the state screen. It cannot be operated with instructions in the program. The system monitor can be switched between two settings: setting 1 in which the monitor stops after a cold start, and setting 2 in which the monitor continues monitoring.
NOTE The program monitor and the system monitor can be used at the same time. The monitors can be switched between the settings using the following system variables: $TPP_MON.$LOCAL_MT = 1D Switches the program monitor to setting 1 (default). $TPP_MON.$LOCAL_MT = 2D Switches the program monitor to setting 2 (same specification as that for KAREL) $TPP_MON.$GLOBAL_MT= 0D Enables the system monitor (default). $TPP_MON.$GLOBAL_MT= 1D Switches the system monitor to setting 1. $TPP_MON.$GLOBAL_MT= 2D Switches the system monitor to setting 2.
Monitor state transition The states of the monitors assumed when each operation is performed are listed in the table below: Program monitor Setting 1 Setting 2
Operation MONITOR instruction RESTART (state screen) START (state screen) Program Stop Program End/Enforced End MONITOR END PAUSE (state screen) END (state screen) RESUME Power failure handling Power off with monitoring state Power failure handling Power off without monitoring state START (COLD) CONTROLLED START Other operation
A B C D D C D B E E D D E
A B E *1) D D C D B E E D D E
System monitor Setting 1 Setting 2 E
E
A E E E D
A E E E D
E E E D D E
E E E E D E
Meanings of symbols A : State monitoring is started. / B : State monitoring is restarted if it is stopped. C : State monitoring is stopped. / D : State monitoring is deleted. (Cannot be restarted) E : The state of state monitoring does not change due to the operation. *1 : Monitoring continues, but the action program will pause even if the conditions are satisfied. - 551 -
9.UTILITY
B-82594EN-4/01
Operation-by-operation description Operation MONITOR instruction RESTART (state screen) START (state screen) Program Stop
Program End/Enforced End
MONITOR END
PAUSE (state screen)
END (state screen) RESUME Power failure handling
Cold start
Other
State When a monitor start instruction in the program is executed, monitoring with the specified program monitor starts. When function key RESTART is pressed on the Program monitor screen of the state screen, monitoring with the program monitor specified with the cursor restarts. When function key START is pressed on the System monitor screen of the state screen, monitoring with the system monitor specified with the cursor starts. When the temporary stop key is pressed or if the program stops temporarily due to the occurrence of an alarm, state monitoring with the program monitor previously started by the temporarily stopped program stops, if the program monitor is set to 1. When the program terminates due to program termination, forced termination, or the occurrence of an alarm, the program monitor previously started by the terminated program is deleted. The deleted program monitor does not start unless a monitor start instruction is executed. When a monitor stop instruction in the program is executed, the specified program monitor is terminated. The terminated program monitor does not start unless a monitor start instruction is executed. When function key PAUSE is pressed on the Program monitor screen of the state screen, monitoring with the program monitor specified with the cursor stops. The stopped monitor restarts when the “Restart” key is pressed or the program restarts. When function key PAUSE is pressed on the System monitor screen of the state screen, monitoring with the system monitor specified with the cursor stops. When function key END is pressed on the Program monitor screen of the state screen, the program monitor specified with the cursor stops. When the temporarily stopped program restarts, the stopped program monitor restarts. If power failure handling is enabled and the monitor is monitoring, the following occurs when the power is turned OFF/ON. ● State monitoring stops if the program monitor is set to setting 1. ● State monitoring continues if the program monitor is set to setting 2. (The program stops temporarily, but state monitoring is performed.) ● The system monitor continues state monitoring. If the monitor is stopped, it remains in the stopped state when the power is turned OFF/ON. If power failure handling is disabled and the power is turned OFF/ON, all monitors terminate except the system monitor of setting 2. The system monitor of setting 2 maintains the state assumed before the power was removed. For operations other than the above, the monitor state is preserved.
Instruction statements State monitoring is performed in the section enclosed by the following instructions: ● MONITOR Monitoring starts under the condition described in the condition program. ● MONITOR END Monitoring performed under the condition described in the condition program stops. Condition program The monitoring condition program, which has the subtype called WHEN, can specify condition instructions only. ● WHEN , CALL - 552 -
9.UTILITY
B-82594EN-4/01
The following conditions can be used:
Fig. 9.10 (a) Register/System Variable Condition Compare Instruction
Fig. 9.10 (b) I/O Condition Compare Instruction 1
Fig. 9.10 (c) I/O Condition Wait Instruction 2
- 553 -
9.UTILITY
B-82594EN-4/01
NOTE Falling edge: The falling edge of a signal is regarded as being a detection condition. The condition is not satisfied when the signal remains off. The detection condition is satisfied when the signal changes from the on state to the off state. Rising edge: The rising edge of a signal is regarded to be a detection condition. The condition is not satisfied when the signal remains on. The detection condition is satisfied when the signal changes from the off to the on state.
Fig. 9.10 (d) Error Condition Compare Instruction
NOTE An error number is specified with an alarm ID followed by an alarm number. Error number = aabbb where aa = alarm ID bbb = alarm number For an explanation of alarm IDs and numbers, refer to the alarm code table in the operator’s manual. (Example) For SRVO006 Hand broken, the servo alarm ID is 11, and the alarm number is 006. Thus, Error number = 11006 In the condition compare instruction, multiple conditions can be specified on a single line in the condition statement, using the logical operators (“and” and “or”). This simplifies the program structure, allowing the conditions to be evaluated efficiently. Instruction format ● Logical product (and) WHEN AND , CALL
●
Logical sum (or) WHEN OR , CALL
If the “and” (logical product) and “or” (logical sum) operators are used in combination, the logic becomes complex, impairing the readability of the program and the ease of editing. For this reason, this function prohibits the combined use of the “and” and “or” logical operators. - 554 -
9.UTILITY
B-82594EN-4/01
If multiple “and” (logical product) or “or” (logical sum) operators are specified for an instruction on a single line, and one of the operators is changed from “and” to “or” or from “or” to “and,” all other “and” or “or” operators are changed accordingly, and the following message appears: TPIF-062 AND operator was replaced to OR TPIF-063 OR operator was replaced to AND
Up to five conditions can be combined with “and” or “or” operators on a single line. (Example) WHEN AND AND AND AND , CALL
Specification Step 1 2
Enter a condition program name. On the program list screen, press F2 CREATE and enter a program name. Select Cond as the subtype. Press F2 DETAIL to move to the program details screen. Position the cursor to the subtype item and press F4 CHOICE. Select Cond from the subwindow.
NOTE At this time, the operation group is automatically set as [*,*,*]. A condition program requires no operation group.
State monitoring screen The state of state monitoring can be monitored using the program monitor screen and the system monitor screen. Program monitor screen For the program monitor currently being executed or stopped, the name and state (under execution, stopped) of the condition program is displayed, as well as the name of the parent program(*1) of the program that started the program monitor.
NOTE If program “A” calls program “B” with a subprogram call, and program “B” executes a monitor start instruction, the name of the parent program, “A,” is displayed in the program name column.
- 555 -
9.UTILITY
B-82594EN-4/01
Table 9.10 (a) Items and Function Keys on the Program Monitor Screen Item Description CH Prog. Status Program F2 SYSTEM
F3 RESTART F4 PAUSE F5 END
Condition program name State of the program, either being executed or stopped Name of the parent program of the program that started the program monitor Switches the screen to the system monitor screen. If the system monitor is disabled ($TPP_MON.$GLOBAL_MT=0), this key is not effective. When pressed, this key restarts the stopped monitor. Stops the monitor. Terminates the monitor. The terminated monitor is cleared from the screen.
System monitor screen All condition programs are displayed. System monitors can be started and stopped.
Table 9.10 (b) Items and Function Keys on the System Monitor Screen Item Description CH.Prog. Status F2 PROGRAM F3 START F5 END
Condition program name State of the program, either being executed or not started (blank) Switches the screen to the program monitor screen. Starts the system monitor. Stops the monitor. In the “State” column, a blank is displayed for the stopped monitor.
- 556 -
9.UTILITY
B-82594EN-4/01
Notes/restrictions If multiple condition instructions are specified in a condition program, multiple monitors are started at the same time. 1:WHEN (conditional-expression1), 2:WHEN (conditional-expression2), 3:WHEN (conditional-expression3),
CALL (Program name1) CALL (Program name2) CALL (Program name3)
If, before one monitor start instruction terminates, another monitor start instruction is executed, both monitors are executed at the same time. If the condition program names specified in the monitor start instructions are the same, the first condition program is overwritten by the second. The program monitor stops state monitoring under the following conditions: ● The MONITOR END instruction is executed. ● The program terminates. ● The program stops temporarily. (State monitoring restarts when the program restarts.) Up to ten conditions can be monitored at the same time. Up to five “and” or “or” operators can be specified in a single monitoring condition instruction. Up to five condition (conditional-expression 1) and (conditional-expression 2) ......... and (conditional-expression 5) condition (conditional-expression n)or (conditional-expression m) ......... or (conditional-expression 1) : : : condition (conditional-expression o) and (conditional-expression p) ......... and (conditional-expression q)
Up to ten
While the program is being executed or while it is stopped, the condition statements (condition program) cannot be edited. In the action program for a system monitor, an operation group cannot be specified. In the action program for a system monitor, the operation group must be specified as [*,*,*,*,*]. In the action program for a program monitor, an operation group can be specified. While the robot is operating, however, the robot cannot be operated with the program. While the robot is not operating, the robot can be operated with the program. If the condition is satisfied, the condition program enters the END state. If condition monitoring is to continue, specify a monitor start instruction in the program. Clear the monitoring condition beforehand. Example MON1. TP 1:WHEN R[1]=1 CALL ACT1 ACT1.TP 1:R[1]=0 Clear the condition 2: 3:(Action) : 9:MONITOR MON1 Start the monitoring condition again
If there is no line on which the condition on line 1 is dropped, the condition is immediately satisfied on the monitor start instruction on line 9, causing a MEMO-065 error. The condition program cannot be executed directly. - 557 -
9.UTILITY
B-82594EN-4/01
9.11
AUTOMATIC ERROR RECOVERY FUNCTION
9.11.1
Overview This section consists of the following items: a) Outline of the automatic error recovery function b) Defining a resume program c) Teaching the RETURN_PATH_DSBL instruction d) Setting screen of the automatic error recovery function Enabling/disabling the automatic error recovery function Defining alarm codes to be monitored Defining the recovery switch DI Defining the error recovery information DO (indicating the conditions for executing the resume program) Enabling/disabling the alarm-time automatic start feature Setting the maximum number of automatic start repetitions Defining the automatic start count register Defining automatic error recovery alarm conditions e) Flowchart for resuming a suspended program f) Manual operation screen of the automatic error recovery function g) Execution of the resume program from the teach pendant and test mode h) Changing conditions for executing the resume program i) Other specifications and restrictions j) Warnings (Be sure to read this section for safety.) This function is an optional function.
9.11.2
Outline of the Automatic Error Recovery Function
Background Robots are sometimes stopped by various alarms even during production. If a robot is stopped, it is necessary to perform recovery operation then resume the program that was originally running. For example, suppose that a robot is performing arc welding. An alarm due to an arc start failure may be issued, stopping the robot. In such a case, the operator must jog the robot to a safe position to, for example, cut the end of the wire or clean the nozzle, then resume the original program. The automatic error recovery function is provided to support automatic operation of the above sequence.
- 558 -
9.UTILITY
B-82594EN-4/01
Fig. 9.11.2 Example:
Alarm code monitoring function In the example shown above, the robot is operated by executing Weld-1.TP to perform welding along the path from 2 to 3 to 4. Assume that an arc start failure occurs at the arc start position 2. With the automatic error recovery function, another program called the resume program, which is Wire-Cut.TP in this case, can be started at the next start signal input. After this program terminates, another start signal input resumes the original program. If the resume operation function is then enabled (which is set on the welding system setting screen), the robot automatically returns to the original position where the robot was stopped, then the original program is resumed. If the return distance for resume operation is set, the robot returns from the stop position by the set distance, then the original program is resumed. If no arc is produced, a scratch start takes place. In the above example, the automatic error recovery function operates only when an arc start miss alarm is issued. The alarm to be monitored may be changed, or the number of alarms to be monitored may be increased. For example, an arc off alarm can be added as an alarm to be monitored. Then, when an arc off alarm is issued, the same operation sequence as explained above can be performed automatically. The standard maximum number of monitored alarm codes that can be defined is ten. If no alarm code is defined, the alarm code monitoring function is disabled. In this case, before the suspended original program (Weld_1.TP in the example) is resumed, the resume program is always executed.
Recovery switch DI function With the recovery switch DI function, whether to start the resume program or not can be selected at the time of start input according to the defined DI status. If the recovery switch DI is off, the original program is resumed without executing the resume program. When this DI is not defined, this function is disabled.
- 559 -
9.UTILITY
B-82594EN-4/01
Error recovery information DO function With the error recovery information DO function, whether the next start input resumes the original program or executes the resume program can be indicated. If the error recovery information DO is on at start input, the resume program is executed. When this DO is not defined, this function is disabled.
Alarm-time automatic start feature When an alarm code is defined as explained before, and the defined alarm is issued, the program outputs an alarm signal and stops running. Input of the start signal executes the defined resume program. After the resume program terminates, another start signal input restarts the suspended original program. When the alarm-time automatic start feature is enabled, and a defined alarm is issued, the resume program is automatically executed without outputting the alarm signal and stopping the robot. When the resume program has terminated, the original program is resumed automatically. When this feature is enabled, therefore, the input of the start signal is no longer needed. Because the alarm signal is not output, other robots are not stopped when multiple robots are operating. The robot for which the alarm was issued moves by itself to the recovery station, and after recovery work, the original program is resumed.
CAUTION Basically, the automatic error recovery function is designed so that it functions when the teach pendant is disabled. When the teach pendant is enabled, the automatic error recovery function does not function unless the manual test mode is set on the automatic error recovery manual operation screen. For manual testing, see “Execution of the resume program from the teach pendant and test mode.”
DI alarm function By inputting a defined digital input signal, an automatic error recovery alarm can be issued. When this alarm is defined for the alarm-time automatic start feature, the resume program can be executed automatically by inputting the digital input signal. As the message for an automatic error recovery alarm, a message defined for a user alarm can be used. The alarm severity can be set to either LOCAL or GLOBAL selectively. When LOCAL is selected, the alarm is issued only for a program that defines the resume program. The status of a digital input signal to be monitored can be set by selecting the signal type from among DI, RI, and WI, changing the signal number, and selecting the trigger status between on and off.
- 560 -
9.UTILITY
B-82594EN-4/01
Function for disabling the resume operation function after execution of the resume program In arc tool systems, the resume operation function is generally enabled. With this function enabled, return to the original stop position is always performed then arc is produced when the original program resumes after the resume program terminates. In some systems, however, return to the original stop position should not sometimes be performed. For example, when the nozzle touch state is input through DI, a resume program is used to relieve the torch slightly in the torch direction. If the resume operation function operates, return to the original stop position is performed even when relieve operation has been performed. As a result, the nozzle touch state is observed again. In such a case, the resume operation function needs to be kept enabled, but it should be disabled only after the execution of the resume program. This can be performed with the RETURN_PATH_DSBL instruction. By using this instruction within the resume program, the resume operation function can be disabled only when the original program is resumed next. This instruction is valid only when it is executed within a resume program; the instruction is invalid when executed in a program other than the resume program.
- 561 -
9.UTILITY
9.11.3
B-82594EN-4/01
Defining a Resume Program The automatic error recovery function executes a resume program defined in an original program, in lieu of the original program. To define a resume program, use the RESUME_PROG= instruction. To erase the defined resume program, use the CLEAR_RESUME_PROG instruction. These instructions can be displayed on the edit screen by following the procedure shown below.
In the example given in Fig. 9.11.2, the following programs are used:
In the above program example, the WIRE_CUT program is taught in the second line of the WELD program and is erased in the sixth line. Since the WIRE_CUT program is defined as the resume program between the third to seventh lines, it is executed as the resume program. In the seventh and subsequent lines, the resume program has been erased, so the resume program is not executed. The resume program is erased also when: ● Backward execution is performed. ● The cursor line is changed manually. ● The program terminates.
CAUTION When the RESUME_PROG instruction is executed within the resume program, it is defined as a resume program for the original program. - 562 -
9.UTILITY
B-82594EN-4/01
9.11.4
Teaching the RETURN_PATH_DSBL Instruction The RETURN_PATH_DSBL instruction appears in the menu containing the RESUME_PROG instruction.
The RETURN_PATH_DSBL instruction is valid only when it is taught within resume program instructions. Use this instruction as shown in the sample program given below. If the instruction is taught as shown below, the resume operation function does not operate when the original program resumes after the resume program terminates, even if the resume operation function is enabled.
- 563 -
9.UTILITY
9.11.5
B-82594EN-4/01
Setting the Automatic Error Recovery Function On the setting screen of the automatic error recovery function, the following settings can be made: ● Enabling/disabling the automatic error recovery function ● Defining alarm codes to be monitored ● Defining the recovery switch DI ● Defining the error recovery information DO (indicating conditions for executing the resume program) ● Enabling/disabling the alarm-time automatic start feature ● Setting the maximum number of automatic start repetitions ● Setting the automatic start count register ● Enabling/disabling the fast exit/entry feature ● Enabling/disabling dry run exit/entry operation ● Defining a maintenance program ● Defining the maintenance DO ● Defining automatic error recovery alarm conditions
53013 indicates “ARC-013 Arc Start failed.” 53018 indicates “ARC-018 Lost arc detect.” For alarm codes, refer to the alarm code table in the operator’s manual. - 564 -
9.UTILITY
B-82594EN-4/01
Enabling/disabling the automatic error recovery function This item enables or disables the automatic error recovery function. When the automatic error recovery function is enabled, and neither monitored alarm codes nor the recovery switch DI are defined, the resume program is always executed at restart from the suspended state (except when the error recovery information DO is off). When this item is disabled, the resume program is not executed.
Defining alarm codes to be monitored To define alarm codes to be monitored, press the F2 (ALARM) key. A screen for defining alarm codes is displayed. When a defined alarm code is issued, and a program is suspended, the resume program is executed at restart. Each alarm code consists of an alarm code ID and alarm number. The alarm code ID indicates the type of alarm. For an arc start failure alarm, for example, the following alarm code is indicated: Arc Start failed = 5 3 ARC - 013 ID (53) Number ID
0 1 0 Number
For alarm numbers, refer to the alarm code table in the operator’s manual. Up to ten alarm codes can be defined as standard. To change the maximum number of alarm codes (up to 20 codes) that can be defined, change system variable $RSMPRG_SV.$NUM_ALARM, turn the power off then on. Pressing the F5 (HELP) key displays the following screen:
CAUTION Do not define any warning alarm as an alarm code. Even when a defined alarm is issued, the resume program is not executed if the recovery switch DI is off. When there is no alarm code defined, that is, when all defined values are 0, the alarm code monitoring function is disabled. The specifications of the alarm code monitoring function are listed below.
- 565 -
9.UTILITY
B-82594EN-4/01
Table 9.11.5 (a) Specifications of the Alarm Code Monitoring Function Alarm code function Issuance of defined Execution of resume Alarm code definition status alarm program at restart All 0s
Disabled
At least one alarm code is defined
Enabled
Issued Not issued
Executed Executed Not executed
Defining the recovery switch DI To use the recovery switch DI function, define an DI number. After the number is defined, power must be turned off then back on. With this function, the operator can choose whether to execute the resume program or not at the time of restart from the suspended state by using a peripheral device. If this signal number is not defined, this function is disabled. The specifications of the recovery switch DI function are listed below. Table 9.11.5 (b) Specifications of the Recovery Switch DI Function Execution of resume Recovery switch DI DI status DI number definition program at restart function status 0
Disabled
Valid number defined
Enabled
On Off
Executed Executed Not executed
CAUTION To continue a resume program at program restart after the resume program is suspended, input the on state of the recovery switch DI. If it is off, the original program is executed.
Defining the error recovery information DO (conditions for executing the resume program) When the alarm code monitoring function and recovery switch DI function are both disabled, the resume program is always executed at the time of restart after the original program is suspended. When both the functions are enabled, it is difficult to determine whether the original program or resume program is to be executed at restart. The error recovery information DO is on only when the resume program is executed at restart. When the signal is off, the original program is executed at restart. With this function, the operator can know which program is to be executed next. If the following conditions are met, the error recovery information DO goes on: ● The automatic error recovery function is enabled. ● The program to be executed is not in single step mode. The single step LED on the teach pendant indicates the single step status of a program currently selected (more precisely, the program set in $TP_DEFPROG). When the resume program is suspended, the error recovery information DO is on even if the single step LED on the teach pendant lights. This is because the resume program to be executed is not in single step mode. - 566 -
9.UTILITY
B-82594EN-4/01
● ● ● ● ● ● ●
The resume program is defined in the currently selected program (original program). The currently selected program (original program) has a motion group. The currently selected program (original program) is suspended, and the resume program is not yet completed. There is no optional function that disables the automatic error recovery function. See “Other specifications and restrictions.” The user condition parameter ($AUTORCV_ENB) is true. See “Conditions for executing the resume program.” When the teach pendant is enabled: The operation mode (on the automatic error recovery manual operation screen) is TP_TEST. When the teach pendant is disabled: The operation mode (on the automatic error recovery manual operation screen) is AUTO. The remote conditions are met when system variable $RMT_MASTER is 0. There is no alarm code defined. If any alarm code is defined, the alarm code is issued. The recovery switch DI function is disabled. If this function is enabled, the recovery switch DI signal is on.
CAUTION ● The selected program means the program to be executed by inputting the start signal. ● While the resume program is being executed, single step operation cannot be performed. ● Even if the error recovery information DO is on, the resume program is not executed when backward execution of the original program is performed. ● Backward execution in the resume program is possible. ● The update cycle period for the error recovery information DO is 300 ms. When the conditions listed above have been changed, wait 300 ms before program execution. The timing chart for the error recovery information DO status and start signal is shown below.
Fig. 9.11.5 (a) Error Recovery Information DO Output Timing Chart
- 567 -
9.UTILITY
B-82594EN-4/01
Defining the incomplete end DO When an incomplete end DO number is defined, the incomplete end DO is output if a certain forced termination alarm is issued during execution of the resume program. The output incomplete end DO is turned off by the next start signal input. Before inputting the start signal, the operator must check the incomplete end DO signal status. If this signal is on, the resume program terminates in the middle, so the robot is not in a specified position. In such a case, inputting the start signal causes the robot to perform resume operation to return from the current position to the stopped position of the original program, which may interfere with obstacles such as a jig. Therefore, before inputting the start signal, check the current robot position. If an interfering object exists, jog the robot to a position near the stopped position of the original program, then input the start signal. This signal may be added to the PLC start signal acceptance conditions. If this signal is set to 0, this function is disabled.
Fig. 9.11.5 (b) Incomplete End DO Output Timing Chart
Defining the incomplete-end reset DI When the incomplete end DO is included in the PLC start signal acceptance conditions, the operator requires a means to turn off the incomplete end DO externally. Inputting the incomplete-end reset DI signal turns off the incomplete end DO. When the incomplete end DO is output, the operator must first perform appropriate operation such as jogging the robot to near the stopped position of the original program, input the incomplete-end reset DI, then input the start signal. When this signal is set to 0, this function is disabled.
Enabling/disabling the alarm-time automatic start feature When this item is enabled, and an alarm code to be monitored is defined, this feature functions if the defined alarm is issued. If a defined alarm is issued, this feature automatically executes the resume program. In this case, the alarm signal is not output. When the execution of the resume program has terminated, the original program is resumed automatically. During then, the operator need not input the start signal. Since the alarm signal is not output, other robots operating in the same line are not stopped.
- 568 -
9.UTILITY
B-82594EN-4/01
CAUTION 1 Defined alarms must have the suspension alarm attribute. 2 If the error recovery information DO is off when the resume program is executed automatically, alarm “INTP-135 Recovery DO OFF in auto start mode” is issued. 3 While the resume program is being executed, the UOP PAUSED signal is output. This is because the original program is in the suspended state. This specification is the same as that for multitasking systems. WARNING 1 The alarm-time automatic start feature works on a program selected on the teach pendant. For example, suppose that program A having a resume program instruction has been executed from the teach pendant, then program B without a resume program instruction is selected and executed from the teach pendant. If an alarm defined in program A is then issued, the alarm signal is not output, but the resume program is not executed automatically. The reason for this is that the automatic start feature works on a selected program. In this example, program B that is currently selected does not define any resume program. 2 When the automatic start feature item is enabled, and no monitored alarm code is defined, inputting the start signal for executing the resume program automatically executes the resume program then resumes the original program. In other words, when the start signal is input while the original program is suspended, the resume program is executed. As the resume program has terminated, the original program is then restarted automatically.
Setting the maximum number of automatic start repetitions When a defined alarm is issued, the alarm-time automatic start feature automatically executes the resume program, then resumes the original program. If the defined alarm is issued again when the original program is resumed, the automatic start feature functions again. For example, the automatic start feature is activated by an alarm indicating an arc start failure, then the same alarm is issued again when the original program has resumed. To prevent such an endlessly repeated condition, set the maximum number of automatic start repetitions.
- 569 -
9.UTILITY
B-82594EN-4/01
The number of times the resume program is started repeatedly is counted internally. If the count exceeds the set value, “INTP-134 Over automatic start Max counter” is issued, and the error recovery information DO is turned off at the same time. If this occurs, eliminate the cause of the alarm issued in the original program. Then input the start signal.
CAUTION The number of repetitions counted internally is cleared when the execution of a move statement has terminated and when the CLEAR_RESUME_PROG instruction has been executed.
Defining the automatic start count register As mentioned above, the resume program may be executed several times repeatedly by the automatic start feature. When the automatic start count register is defined, a different program can be executed as the resume program each time the resume program is executed. For example, when the resume program is executed for the first time by the automatic start feature, the register value is 1. When an alarm is issued again during execution of the original program, and the resume program is then executed again by the automatic start feature, the register value is 2. By executing a different subprogram in the resume program according to the register value, different resume program operation can be performed each time the repetition count is incremented.
CAUTION When the resume program is executed by other than the automatic start feature, the register value is 0. Therefore, a resume program must be created so that the same subprogram is called when the register value is 0 and when the value is 1.
Enabling/disabling the fast exit/entry feature If an alarm is issued during operation in a complicated environment, the robot moves from the stopped position to the taught point to execute the resume program. In this case, the robot may interfere with part of a workpiece or peripheral devices. After recovery operation, similar interference may occur when an attempt is made to execute the original program. The fast exit/entry feature is provided to avoid the possibility of such interference. The feature can be enabled or disabled by setting this item. The fast exit/entry feature causes the following operation automatically: 1 From the stopped position, disable arc welding, and execute only the move statements of the original program up to the end. 2 Execute a maintenance program.
- 570 -
9.UTILITY
B-82594EN-4/01
3
Disable arc welding, execute the move statements of the original program from the beginning to move the robot to the stopped position. 4 Enable arc welding, and resume the original program operation. Even when this feature is enabled, the resume program takes priority over this feature if the resume program is enabled in the original program. In other cases, the maintenance program is executed.
Enabling/disabling dry run exit/entry In the fast exit/entry feature, this item specifies whether exit from the stopped position and return to the stopped position after maintenance program execution are to be performed at dry run speed.
Defining a maintenance program Define the name of a maintenance program used as the standard maintenance program. The maintenance program name can also be specified using the maintenance program instruction on the edit screen.
Defining the maintenance DO Define the number of the DO for indicating that the fast exit/entry feature is operating.
Defining automatic error recovery alarm conditions Define the conditions for issuing an automatic error recovery alarm on the definition screen that is displayed by pressing F3 (DI_ALARM) on the setting screen of the automatic error recovery function.
On this screen, the items shown below can be set. The alarm code of the automatic error recovery alarm is 12278. ● User alarm number When the automatic error recovery alarm is issued, the user alarm message with the set number is displayed as an alarm message. When this item setting has been changed, the new setting becomes effective immediately.
- 571 -
9.UTILITY
B-82594EN-4/01
●
Alarm severity This item can choose whether the automatic error recovery alarm is a local alarm or global alarm. When LOCAL is set, the automatic error recovery alarm is issued only for the program that defines a resume program. If there is no program that defines a resume program, the alarm is regarded as a global alarm. If the automatic error recovery alarm is issued when there is no program being executed, a warning is generated. When this item setting has been changed, the new setting becomes effective immediately. ● Signal type Choose the type of the digital signal for issuing the automatic error recovery alarm from among DI, RI, and WI. When this item setting has been changed, the power must be turned off then back on for the new setting to become effective. ● Signal number Set the number of the digital signal for issuing the automatic error recovery alarm. When this setting has been changed, the power must be turned off then back on for the new setting to become effective. ● Detection signal status Set the status of the digital signal for issuing the automatic error recovery alarm to ON (high) or OFF (low). When this setting has been changed, the power must be turned off then back on for the new setting to become effective. The standard number of automatic error recovery alarm conditions is three. This number can be increased to up to five by changing system variable $RSMPRG_SV.$NUM_DI_ALM. After this system variable has been changed, the power must be turned off then back on for the new setting to become effective.
- 572 -
9.UTILITY
B-82594EN-4/01
9.11.6
Flowchart for Resuming a Suspended Program The resume program is executed according to the following flowchart:
Fig. 9.11.6 Flowchart for Executing the Resume Program (When Automatic Start is Disabled)
CAUTION 1 When forward execution is specified while the original program is suspended, the resume program is executed if the error recovery information DO is on; if it is off, the original program resumes. 2 When forward execution is specified while the resume program is suspended, the resume program resumes if the error recovery information DO is on; if it is off, the original program is executed. 3 When backward execution is specified while the original program is suspended, backward execution is performed for the original program without executing the resume program. 4 When backward execution is specified while the resume program is suspended, backward execution is performed for the resume program.
- 573 -
9.UTILITY
9.11.7
B-82594EN-4/01
Manual Operation Screen of the Automatic Error Recovery Function A manual operation screen is supported for the automatic error recovery function. This screen contains the following: ● Error recovery information DO status ● Name of the resume program defined in the currently selected program ● Operation mode setting ● Detail information about the error recovery information DO This screen can be selected by following the procedure shown below.
Error recovery information DO status The error recovery information DO status is indicated. Even when the error recovery DO is not defined, its status can be indicated. From this information, the operator can know which program, the resume program or original program, is to be executed.
Defined resume program The name of the resume program defined in the currently selected program is indicated. From this information, the operator can check whether a wrong resume program is defined or not.
- 574 -
9.UTILITY
B-82594EN-4/01
CAUTION If a wrong program is defined as the resume program, the robot operation is unpredictable. Therefore, check that the resume program is correct.
Operation mode There are three operation modes. The standard setting is AUTO. When the display changes from this screen to another, AUTO is automatically set again. ● AUTO This mode should be set when the teach pendant is disabled. When this mode is selected, the resume program is executed according to the status of the alarm code monitoring function and recovery switch DI function. If this mode is selected when the teach pendant is enabled, the resume program is not executed. ● NO_EXEC When this mode is selected, the error recovery information DO is always off. Therefore, in this mode, the resume program is not executed. ● TP_TEST This mode should be set when the teach pendant is enabled. When this mode is selected, and when the teach pendant is enabled, the resume program is always executed regardless of the status of the alarm code monitoring function or error recovery switch DI function.
Displaying detail conditions of the error recovery information DO When F2 (DETAIL) is pressed on the manual operation screen of the automatic error recovery function, detail conditions related to the error recovery information DO status are displayed. When all items on the detail screen are set to Yes or None, the error recovery information DO is turned on. When the error recovery information DO is off, and you cannot find the cause of the DO being off, check this screen.
- Auto error recovery enabled This item indicates whether this function is enabled or disabled on the setting screen of the automatic error recovery function.
- PAUSED & resume prog incomp This item indicates the following conditions: • The selected program must exist. • The selected program must be in the suspended state. • A resume program must be defined in the selected program, and the execution of the resume program must not have been completed.
- Program has motion group This item indicates that the selected program has a motion group.
- 575 -
9.UTILITY
B-82594EN-4/01
- Not in single step mode This item indicates that the single step mode is not set. The single step LED on the teach pendant indicates the single step status of the selected program ($TP_DEFPROG). Even when the single step key is pressed while the resume program is suspended, and the single step LED goes on, the error recovery information DO is held on. This is because the selected program is the original program, and the LED indicates that the original program is in single step mode; the resume program is not in single step mode.
- Resume program is defined This item indicates that a resume program is defined in the selected program.
- Mode is (xxxx) This item indicates that the operation mode is suitable for the current status. For example, when the teach pendant is disabled, “AUTO” is indicated in the portion “xxxx.” When the teach pendant is enabled, “TP_TEST” is indicated.
- Approval DI is ON This item indicates the recovery switch DI status. When the DI number is not defined, or when the teach pendant is enabled, “None” is indicated.
- Defined alarm occurs This item indicates that an alarm code is defined, and that alarm is issued. When no alarm code is defined, or when the teach pendant is enabled, “None” is indicated.
- Remote when $RMT_MASTER is 0 This item indicates that remote conditions are met. This function is enabled only when the teach pendant is disabled, system variable $RMT_MASTER is 0, and system variable $RSMPRG_SV.$CHK_REMOTE is true.
- No disabled options There are options that cannot be used together with the automatic error recovery function. This item indicates whether such options are present or not.
- User condition param enable This item indicates the status of system variable $AUTORCV_ENB for user conditions. For how to use this system variable, see “Changing conditions for executing the resume program.”
- 576 -
9.UTILITY
B-82594EN-4/01
9.11.8
Execution of the Resume Program from The Teach Pendant and Test Mode Normally, the automatic error recovery function is used when production is started with the teach pendant disabled. When checking the resume program during teaching, set the operation mode to TP_TEST on the manual operation screen. In TP_TEST mode, the resume program can be executed regardless of the recovery switch DI status and whether a defined alarm is issued or not.
9.11.9
Changing Conditions for Executing the Resume Program To use resume program execution conditions other than alarm codes, use user condition system variable $AUTORCV_ENB and the status monitoring function (A05B-2400-J628). For example, to execute the resume program when R[1] is 1, create the following monitor program, and start MONIT1.CH on the system monitor screen. MONIT1.CH 1: WHEN R[1]=1,CALL DO_RESUME 2: WHEN R[1]<>1,CALL NO_RESUME
DO_RESUME. TP 1: $AUTORCV_ENB=1 2: MONITOR MONIT_3
MONITI2.CH 1: WHEN R[1]=1,CALL DO_RESUME
DO_RESUME. TP 1: $AUTORCV_ENB=0 2: MONITOR MONIT_2
MONITI3.CH 1: WHEN R[1]<>1,CALL NO_RESUME
The start conditions can be changed by modifying the monitor program. For how to use the status monitoring function, refer to the operator’s manual on the status monitoring function. In this case, the automatic start function is unavailable.
9.11.10
Other Specifications and Restrictions ● ● ●
While the resume program is being executed, single step operation is not performed. Single step mode is valid only for the original program. When the cursor line is changed and executed while the original program is suspended, the resume program is not executed. While the resume program is being executed, the resume program execution status cannot be checked on the program edit screen. On the edit screen, the suspended original program is displayed.
- 577 -
9.UTILITY
B-82594EN-4/01
●
When a multitasking program (a main program and subprogram) is being executed with the alarm code monitoring function disabled and the recovery switch DI undefined, pressing the hold button causes both the main program and subprogram to stop. Suppose that a resume program is defined in the subprogram, but that no resume program is defined in the main program. In this case, when the main program is selected and re-executed, the resume program for the subprogram is not executed. This is because the selected program is the main program, and the error recovery information DO is off.
In this case, when the subprogram is selected and executed, the error recovery information DO is turned on, so the resume program is executed.
CAUTION When using the automatic error recovery function in multitasking systems, define a resume program only in the main program. Even when a resume program is defined in a subprogram, that resume program cannot be executed. Definitions in the main program and subprogram are shown below. Main.TP
Sub.TP
1: RUN Sub 2: RESUME_PROG=WIRECUT
● ●
● ●
●
No resume program defined
While the resume program is being executed, the suspended original program is displayed on the edit screen. When the cursor line in the original program is moved while the resume program is suspended, then program re-execution is performed, the resume program is resumed. After the resume program terminates, specifying program execution displays a popup menu confirming the cursor movement. When Yes is entered in response, the original program is executed starting from the new cursor line. In a single task system, when the resume program is suspended, selecting a program other than the original program on the program directory screen causes the original program to terminate. Never teach the arc and weaving instructions in the resume program. If an arc instruction is executed in the resume program while arc welding is being performed by the original program, alarm “ARC-034 Task does not control welding” is issued. In addition, weaving operation is not performed within the resume program. The automatic error recovery function supports the power failure handling function.
- 578 -
9.UTILITY
B-82594EN-4/01
●
9.11.11
The automatic error recovery function is disabled when one of the following options is loaded: Arc sensor AVC (TIG arc length control) MIG EYE option Root path memorization Line tracking Soft float Continuous turn Coordinated motion Remote TCP Accurate path function Constant joint path function (path not overridden) Multi robot control
Warnings When using the automatic error recovery function, observe the following safety precautions: ● If a wrong program or a program causing wrong operation is defined as a resume program, the robot moves in a direction the operator cannot predict. Define a correct program. ● Before inputting the start signal and before pressing the execution key on the teach pendant, for safety, check the error recovery information DO status to confirm whether the original program or resume program is to be started. ● If the operation mode is set to TP-TEST on the manual operation screen of the automatic error recovery function, the resume program is started even when a defined alarm is not issued or when the recovery switch DI is off. ● When an operation mode other than AUTO is set on the manual operation screen of the automatic error recovery function, then the display is changed to another screen, the operation mode is set to AUTO again automatically. To use an operation mode other than AUTO, always keep displaying the manual operation screen of the automatic error recovery function.
- 579 -
9.UTILITY
B-82594EN-4/01
9.12
REMOTE TCP FUNCTION
9.12.1
Summary The REMOTE TCP function is used to process the work by moving the work which is placed on the robot hand. Robot can keep the relation between the tool fixed on the ground and work. Example of using REMOTE TCP function (by Sealing application)
Advantage of Remote TCP ● ● ●
The gun is fixed on the ground, then the cabling of tool is easy. It is not necessary to take the heavy gun. Even if you do not use the REMOTE TCP function, you could process the work by moving the work which is placed on the robot hand. But if you rotate the work against the TCP, the tool can not do the coordinate motion against the work.
Case of using REMOTE TCP function
- 580 -
9.UTILITY
B-82594EN-4/01
Case of NOT using REMOTE TCP function
●
You can get the easy teaching operation by remote TCP jog function.
●
You can reduce teaching point drastically.
- 581 -
9.UTILITY
B-82594EN-4/01
●
You can do uniform sealing against work.
●
Remote TCP (A05B-2500-J624)
Required option Limitation The Specification of REMOTE TCP is as follows. ● Support 6-axes robot and M-410i only. ● Support Spot, Sealing, Handling tool only. ● Not support Arc tool function and tracking function. The limitation of REMOTE TCP is as follows. ● This function is applied to the linear and circular motion. ● REMOTE TCP supports incremental motion. However, the incremental motion is relative the uframe frame. ● REMOTE TCP does not support Wrist joint motion. The motion option of wrist joint REMOTE TCP do not coexist in the one TPE motion instruction. ● When the robot motion changes from REMOTE TCP to normal, you can not use Speed Prediction function.
9.12.2
Setup
Setting up If you use the REMOTE TCP function, you need to teach the tool center point which is fixed on the ground to the robot.
You can set REMOTE TCP position by using the same method for User frame. - 582 -
9.UTILITY
B-82594EN-4/01
1 2 3 4 5 6
7 8
Press MENUS. Select SETUP. Press F1[TYPE]. Select Frames. If user frame is not displayed, press F3[OTHER], and select User Frame. If F3,[OTHER], is not displayed, press PREV. Move the cursor to the REMOTE TCP frame to use.
Press F2,[DETAIL]. Select the method from Direct Entry, Three Point or Four Point, and set the frame by using the same method for User frame.
Remote TCP jog When you do transitional jogging under the remote TCP mode, the robot behaves the same as it is under normal jogging. REMOTE TCP jogging is done by using the following procedure. 1 Enter to REMOTE TCP jogging mode. 2 Select the frame. JOINT, REMOTE TCP USER, REMOTE TCP TOOL, REMOTE TCP JOG 3 Jog the robot. 4 Return from REMOTE TCP jogging mode. < Change to REMOTE TCP jogging mode > Please perform the following procedure to enter to REMOTE TCP jogging mode. 1 Press FCTN. Select “TOGGLE REMOTE TCP”. The screen is changed as follows.
The robot motion is performed according to REMOTE TCP TOOL No.1 R1/TOOL REMOTE TCP motion is performed according to the tool frame. Please perform the following procedure to return from REMOTE TCP jogging mode. - 583 -
9.UTILITY
B-82594EN-4/01
1 2
Press FCTN. Select “TOGGLE REMOTE TCP”.
Select frame You change the coordinate system by pressing the COORD key. Please select the frame except for JOINT.
The display status is changed as follows. JOINT → R1/JFRM → R1/WRLD → R1/TOOL → R1/USER
Select REMOTE TCP frame When the robot enters to REMOTE TCP mode, you can select REMOTE TCP frame by using how to select the normal frame. 1 Press FCTN. 2 Select “CHANGE RTCP FRAME”.
Programming and running by using REMOTE TCP If you specify REMOTE TCP motion option, the robot moves remote TCP instead of robot TCP. Please perform the following procedure to specify REMOTE TCP motion option. 1 Move the cursor to end of program line. 2 Press F4,[CHOICE]. 3 Select “RTCP”. Please perform the following procedure to remove REMOTE TCP motion option. 1 Move the cursor to end of program line. 2 Press F4,[CHOICE]. 3 Select “No Option”. You can not use RTCP with JOINT motion.
- 584 -
9.UTILITY
B-82594EN-4/01
L
P[1] 100mm/sec FINE RTCP
C
P[1] P[2] 100mm/sec FINE RTCP
The work is moved to P[1] by the relative speed 100 mm/sec between the work and the remote tool. The work is moved to P[2] via P[1] by the relative speed 100 mm/sec between the work and the remote tool.
- 585 -
9.UTILITY
B-82594EN-4/01
9.13
HIGH-SENSITIVITY COLLISION DETECTION
9.13.1
Overview High-sensitivity collision detection is intended to quickly detect when the tool or robot collides with the workpiece and to stop the robot. This function has greatly been improved in detection sensitivity from the conventional collision detection function. It can detect a collision more quickly, thus greatly reducing possible damage to the tool and robot itself. This high-sensitivity collision detection function makes unnecessary shock sensors and similar devices that have conventionally been used to protect the hand of the robot.
9.13.2
Specification 1) 2) 3) 4)
9.13.3
When a collision is detected, the function issues an alarm and stops the robot quickly by decelerating it in such a way that shocks to the robot can be decreased. With the function, the user need not adjust detection sensitivity, which has previously been adjusted for an individual robot. Program instructions can be used to enable/disable the function. The function increases its detection sensitivity automatically during a teach operation, making it possible to reduce the possible damage that may occur due to an incorrect manipulation especially during a teach operation, during which it is likely that the robot is caused to collide with a workpiece.
High-Sensitivity Collision Detection
(1) Overview ● ●
● ●
The function is enabled the moment the power is turned on. Set the function with load information and the information about devices installed on the robot. Since the function uses the load information and device information to detect a collision, it is necessary to set the function with these pieces of information. Be sure to specify the weight of the load, the position of its gravity center, and the weight of each device on the robot accurately. If the inertia (shape) of the load is large, it may be necessary to specify the inertia around the gravity center of the load. (If the tool is big, and simply specifying its weight and gravity center does not assure accurate detection, specify its inertia.) See Section 9.14, “LOAD SETTING,” or Section 9.15, “LOAD ESTIMATION,” for how to specify load information. If it is previously anticipated that a strong force will be exerted during an operation, disable the function for that operation, using program instructions. (See (2).) The function increases its detection sensitivity automatically during a teach operation. - 586 -
9.UTILITY
B-82594EN-4/01
(2) Program instructions ●
COL DETECT ON / OFF This instruction can enable/disable collision detection during program execution.
Example 10: J P[1] 100% FINE 11: COL DETECT OFF 12: L P[2] 2000mm/sec CNT100 13: L P[3] 2000mm/sec CNT100 14: L P[4] 2000mm/sec CNT100 15: COL DETECT ON 16: J P[2] 50% FINE This program disables collision detection with lines 12 to 14.
CAUTION Collision detection is usually enabled. When the program ends its operation or is aborted, collision detection is enabled automatically.
9.13.4
Cautions (1) Under the following conditions, the function may detect a collision when it should not: ● The load or device information is incorrect. ● The weight or inertia of the load exceeds the capacity of the robot. ● The power supply voltage is too low. ● Heavy work caused by using acceleration override ● Heavy work such as reversing based on smooth interpolation ● Linear operation near a cardinal point where the axis is subjected to high-speed rotation Action: If a collision is detected when it should not because of any of these causes, first try to remove the cause. If it cannot be removed, enclosing the portion that results in an incorrect detection between COL DETECT ON / OFF instructions may be able to avoid an alarm and stop. (2) Collision detection is disabled under the following conditions: ● A soft flow is enabled. ● Brake control is in effect (the brake is locked). (3) Axis drop after detection ● To reduce the force caused in a collision to the robot, the collision detection function keeps position control disabled for 200 ms after the collision. So, a slight axis drop may occur after the collision is detected.
- 587 -
9.UTILITY
B-82594EN-4/01
9.14
LOAD SETTING
9.14.1
Overview Setting the information about the load on the robot appropriately can cause the following effects: ● Increase in motion performance (such as lower vibration and shorter cycle time) ● More effective reaction of functions related to dynamics (such as increase in performance related to collision detection and gravity compensation) For effective use of the robot, it is recommended to appropriately set information about loads such as the hand, workpiece, and devices mounted on the robot. A load estimation function is optionally available. This function enables the robot to calculate load information automatically.
9.14.2
Motion Performance Screens There are three motion performance screen types: List screen, load setting screen, and device setting screen. They are used to specify load information and the information about devices on the robot. These screens let you easily specify the information that has conventionally been set in system variables ($PAYLOAD, $PAYLOAD_X, $PAYLOAD_Y, $PAYLOAD_Z, $PAYLOAD_IX, $PAYLOAD_IY, and $PAYLOAD_IZ in the $PARAM_GROUP). They also let you switch the load setting among two or more loads. 1 Press MENUS to display the screen menu. 2 Select “6 SETUP” described on the next page. 3 Press F1 (TYPE) to display the screen switch menu. 4 Select Motion. The list screen appears. (If any other screen appears, press [PREV] several times until the list screen appears.) For a multigroup system, the list screen of another group can be reached by pressing F2 (GROUP).
- 588 -
9.UTILITY
B-82594EN-4/01
5
Load information can be specified for condition No. 1 to No. 10. As stated later, an appropriate condition number can be selected as the load is changed by a hand change. Move the cursor to the desired No., and press F3 (DETAIL) to display the related load setting screen.
6
Specify the mass and gravity center of the load, and inertia around its gravity center. The X, Y, and Z directions displayed on the load setting screen are in reference to the default tool coordinate system (which is valid when no other tool coordinate system is set up).
NOTE 1 [kgf cm s2] = 980 [kg cm2]
7 8
9
When a value is entered, the confirmation message Path and Cycletime will change. Set it? appears. Press F4 (YES) or F5 (NO) whichever is necessary. Pressing F3 “NUMBER” lets you go to the load setting screen for another condition No. For a multigroup system, pressing F2 “GROUP” lets you move to the setting screen of another group. Press PREV to go back to the list screen. Press F5 “SETIND”, and enter a desired load setting condition No. The last condition No. selected is used during program execution and jog operation. (The initial condition No. is 0. Using the condition without changing from the initial setting causes the initial system variable setting to be used. Using the setting on the load setting screen requires enabling that setting.) Pressing F4 “ARMLOAD” on the list screen lets you move to the device setting screen.
- 589 -
9.UTILITY
B-82594EN-4/01
10
9.14.3
Specify the mass of the devices on the J1 and J3 arms. Entering values displays the message Path and Cycletime will change. Set it?. Press F4 (YES) or F5 (NO) whichever is necessary. After setting the mass of a device, turn the power off and on again.
Program Instructions Pressing F5 “SETIND” on the list screen lets you switch the screen, using program instructions rather than selecting a desired load setting condition No. (Even after program execution is finished, the last condition No. selected is used during later program execution and jog operation.)
(1) Additional setting [i] This instruction changes the load setting condition No. to be used to i.
Example 1:
Additional setting [i]
This program selects load setting condition 1.
- 590 -
9.UTILITY
B-82594EN-4/01
Multi-operation group environment The PAYLOAD[i] instruction usually selects a load setting condition No. for all operation groups enabled for the program. For a multigroup system, however, it is possible for this instruction to specify what group to be subjected to load setting condition No. switching.
Pressing F1 (GROUP) displays a menu that contains choices for specifying a group. You can select a group from the menu. Example PAYLOAD[i] This program selects load setting condition No. 1 for groups 2 and 3.
- 591 -
9.UTILITY
B-82594EN-4/01
9.15
LOAD ESTIMATION
9.15.1
Overview Load estimation is a function for estimating the weight of the load, such as tool and workpiece, mounted on the hand of the robot. The function enables the information stated above to be estimated automatically by running the robot. Using the load estimation function requires the load estimation option (A05B-****-J669)(*). Using the function also requires that your model support the load estimation function. If your model does not support the function, you cannot use it.
NOTE (*) The portion indicated **** is a four-digit number that varies with the series. For the 7D70 series, for example, the option code is A05B-2400-J669.
9.15.2
Operating Procedure Load is estimated in the following flow: 1 Set the range of motion to be subjected to load estimation 2 Execute load estimation. Once a mechanical part such as a motor is replaced, it becomes necessary to make calibration. If no calibration is made after mechanical part replacement, the precision of load estimation becomes lower.
9.15.3
Load Estimation Procedure (for 6-Axis Robots) This procedure is performed on the load estimation screen. This screen is entered from the motion performance screen. 1 Press MENUS to display the screen menu. 2 Select “6 SETUP” described on the next page. 3 Press [F1] (TYPE) to display the screen switching menu.
- 592 -
9.UTILITY
B-82594EN-4/01
4
Select Motion. The list screen appears. (If any other screen appears, press [PREV] several times until the list screen appears.) For a multigroup system, the list screen of another group can be reached by pressing F2 (GROUP).
5
Press NEXT, then [F2] F2 “IDENT”. The load estimation screen appears.
- 593 -
9.UTILITY
B-82594EN-4/01
6
Place the robot in the position where load estimation is to be performed.
CAUTION 1 Only the J5 and J6 axes move during load estimation. The other axes stay in the position where they are when load estimation begins. The range of motion is defined as an interval between two points specified on estimation position 1 and 2 screens. (See steps 10 and 12.) 2 Put the J5 rotation axis in a horizontal position. The more vertical posture the J5 rotation axis takes, the lower the precision of estimation becomes. 7 8
Press F3 “NUMBER”, and select the load setting condition No. for which a load estimate is to be set up. If the mass of the load for which load estimation is to be performed is known, move the cursor to line 2, select “YES”, and specify (enter) the mass.
- 594 -
9.UTILITY
B-82594EN-4/01
NOTE The estimation precision becomes higher when a mass is specified. Specify the mass as much as possible. Even if no mass is specified, estimation is possible provided that the following condition is satisfied. However the precision becomes lower. ● The moment around the J5 and J6 axes must be sufficiently high.
● The mass must be sufficiently great, and the distance between points A and B must be sufficiently large. ● The load gravity center must be sufficiently far from the J5 and J6 rotation axes. ● As for positions set up on estimation position 1 and 2 screens, the gravity center of the load must be in or near the plane that contains the J5 and J6 rotation axes.
● As for the J6 axis, the interval between points specified on the estimation position 1 and 2 screens must be 180° in terms of angle.
- 595 -
9.UTILITY
B-82594EN-4/01
9
Press NEXT, then [F4] (DETAIL). The estimation position 1 screen appears.
10
Specify estimation position 1. (Alternatively, the initial value can be used.) Specify the positions of the J5 and J6 axes by entering their values directly. Alternatively, move the robot to the desired position by jogging, then press [Shift] + F5 “RECORD” to record the position. Now pressing [Shift] + F4 “MOVE_TO” moves the robot to estimation position 1. Use this procedure to identify the set position. Pressing [F2] POS.2 displays the estimation position 2 screen.
11
12
13
Specify estimation position 2. (Alternatively, the initial value can be used.) Specify the positions of the J5 and J6 axes by entering their values directly. Alternatively, move the robot to the desired position by jogging, then press [Shift] + F5 “RECORD” to record the position. Now pressing [Shift] + F4 “MOVE_TO” moves the robot to estimation position 2. Use this procedure to identify the set position. Press [PREV] to return to the estimation screen. - 596 -
9.UTILITY
B-82594EN-4/01
14 Set the teach pendant enable switch to OFF, and press F4 “EXEC”. The message Robot moves and estimates. Ready? appears. 15 Specify whether to execute load estimation. (Selecting “YES” causes the robot to move. Pay sufficient care to avoid danger.) ● To perform load estimation by running the robot, press [F4] (YES). ● To quit execution, press [F5] (NO). 16 After low-speed and high-speed operations are finished, load information is estimated. (Operation switches automatically from low speed to high speed. Even when the robot is running at low speed, do not get close to it, because otherwise you may get in a dangerous situation when the robot suddenly starts running at high speed.) 17 Press F5 “APPLY” to set the estimate at a load setting condition No. The message Path and Cycletime will change. Set it? appears. 18 Specify whether to set the estimate. ● To set the estimate, press [F4] (YES). ● Not to set the estimate, press [F5] (NO). 19 If the value to be set is greater than the maximum allowable load (indicated in parentheses), the message Load is OVER spec ! Accept? appears. Specify whether to set this value, just as in the above step.
9.15.4
Calibration Procedure (for 6-Axis Robots) Once a mechanical part such as a motor is replaced, it becomes necessary to make calibration. If no calibration is made after mechanical part replacement, the precision of load estimation becomes lower. Calibration is controlled, using the load estimation screen. Calibration is started by setting the calibration switch to ON and executing load estimation. 1 Make sure that there is nothing on the hand of the robot. Calibration must be made without attaching anything to the hand of the robot.
NOTE If calibration is performed with anything attached to the robot hand, incorrect calibration data is set up, thus hampering a normal estimation. In this case, make calibration again, properly this time. 2 3 4
Press MENUS to display the screen menu. Select “6 SETUP” described on the next page. Press [F1] (TYPE) to display the screen switching menu.
- 597 -
9.UTILITY
B-82594EN-4/01
5
Select Motion. The list screen appears. (If any other screen appears, press [PREV] several times until the list screen appears.) For a multigroup system, the list screen of another group can be reached by pressing F2 “GROUP”.
6
Press NEXT, then F2 “IDENT”. The load estimation screen appears.
- 598 -
9.UTILITY
B-82594EN-4/01
7
Place the robot in the position where load estimation is to be performed.
NOTE 1 Only the J5 and J6 axes move during load estimation. The other axes stay in the position where they are when load estimation begins. The range of motion is defined as an interval between two points specified on estimation position 1 and 2 screens. (See steps 9, 10, and 12.) 2 Put the J5 rotation axis in a horizontal position. The more vertical posture the J5 rotation axis takes, the lower the precision of estimation becomes. 8
Press NEXT, then F4 (DETAIL). The estimation position 1 screen appears.
9
Specify estimation positions 1 and 2. Try to use default values as much as possible. Press F3 “DEFAULT”, and specify default values for estimation positions 1 and 2, speed, and acceleration. Pressing [Shift] + F4 “MOVE_TO” moves the robot to estimation position 1. Make sure that it is safe to move the robot to estimation position 1. If it is dangerous to move the robot to estimation position 1, manipulate the J1 to J4 axes by jogging to move the robot to a position where the robot can move safely.
10
- 599 -
9.UTILITY
B-82594EN-4/01
11
Pressing F2 “POS.2” displays the estimation position 2 screen.
12
Pressing [Shift] + F4 “MOVE_TO” moves the robot to estimation position 2. Make sure that it is safe to move the robot to estimation position 2. If it is dangerous to move the robot to estimation position 2, manipulate the J1 to J4 axes by jogging to move the robot to a position where the robot can move safely. If you moved any of the J1 o J4 axes, press F2 “POS.2” to go back to the estimation position 1 screen, and follow this procedure again from step 10. Press [PREV] to return to the load estimation screen. Move the cursor to CALIBRATION MODE on line 3 to turn it “on.”
13 14
NOTE Once calibration is completed, CALIBRATION MODE becomes “off” automatically. Do not change CALIBRATION MODE during calibration or load estimation. Otherwise, calibration may be made incorrectly or may not be made at all. 15 16
17
Move the cursor to line 4 (so that “EXEC” appears at [F4]), and set the teach pendant enable switch to OFF, then press “EXEC”. The message Robot moves and estimates. Ready? appears. Specify whether to perform load estimation. (Selecting “YES” causes the robot to move. Pay sufficient care to avoid danger.) ● To perform load estimation by running the robot, press [F4] (YES). ● To quit execution, press [F5] (NO). After low-speed and high-speed operations are finished, calibration is completed. (Operation switches automatically from low speed to high speed. Even when the robot is running at low speed, do not get close to it, because otherwise you may get in a dangerous situation when the robot suddenly starts running at high speed.) - 600 -
9.UTILITY
B-82594EN-4/01
9.15.5
Other Related Matters
(1) Motion range If the motion range between estimation positions 1 and 2 becomes narrower, the estimation precision may get lower. The actual motion range should preferably be as wide as the default motion range.
(2) Acceleration for motion used in load estimation The estimation precision is low for the load whose moment inertia is relatively low compared with the maximum allowable load of the robot. This is because the influence by the moment inertia to the torque of the robot motor is weak. The estimation precision for this light load may be able to be increased by increasing the acceleration used during operation for load estimation. Try to increase the acceleration by specifying a larger value in “ACCEL - High” on the estimation position 1 and 2 screens; however, do not specify so large a value that vibration becomes serious during operation.
(3) Calibration data The following system variable hold calibration data. SPLCL_GRP[group].$TRQ_MGN[axis] group : Group number axis : Axis number
If improper calibration data is set up, for example, by making calibration with a load mounted by mistake, reassigning the previous data to the system variable can restore the previous calibration data. It is recommended to keep note of the previous calibration data so as to enable restoration.
- 601 -
9.UTILITY
B-82594EN-4/01
9.16
COLLISION DETECTION for AUXILIARY AXIS
9.16.1
General The Collision Detection Function is the feature that stops the robot immediately and reduces the damage to the robot, when the robot collides with other objects. Generally, this feature has been applied for the robot axes. But, this feature has not been applied for the auxiliary axis. Because of the auxiliary axis is design by customer, then the parameters for this feature can not be set beforehand. To apply this feature to the auxiliary axis, the parameter tuning is required with tuning procedure on this manual.
NOTE To tune the collision detection parameters for auxiliary axis, Collision Detection for Auxiliary Axis Option (A05B-2500-J645) or High Sensitive Collision Detection Package Option (A05B-2500-J684) that includes above is required.
9.16.2
Caution The load ratio of auxiliary axis should be less than 5. Load ratio = (Load Inertia + Motor Inertia) / Motor Inertia When the auxiliary axis is designed, you must consider above. If the load ratio of auxiliary axis is more than 5 times, the motion performance and sensitivity for collision detection may deteriorate.
9.16.3
Initial Setting 1 2 3
4
Setup auxiliary axis (Gear ratio, acceleration time, and etc.) normally Turn power on Set the following system variables $SBR[n].$PARAM[112] = 2097152 / ($SBR[n].$PARAM[47]) $SBR[n].$PARAM[119] = 7282 $SBR[n].$PARAM[120] = -7282 n : Hardware axis number of auxiliary axis n=7~ for aux. Axis / n=1~6 for robot axes Cycle power
- 602 -
9.UTILITY
B-82594EN-4/01
9.16.4
Tuning Procedure The sensitivity of collision detection will be tuned by below procedure. It should be tuned without mis-detection. 1 Create the program that includes heavy motion like an inverse motion with CNT100 beforehand. If the program for production is already exist, It can be used to tune. In this case, the sensitivity can be optimized for production with this program. (However, if other program was run, the mis-detection might occur. Also, if this program was modified, the re-tuning might be required.) 2 Run the above program. Also this program must not be paused. Because of the disturbance torque, see below, will be cleared at just re-start the program 3 Measure the max. / min. disturbance torque on STATUS/AXIS/ DISTURB screen after running the program.
As said above, the disturbance torque will be reset at the start of each program. If there are some programs, ● make new program that call all program for tuning and run this main program. ● record the max. / min. disturbance torque for each programs and find max. / min. value in these recorded value.
- 603 -
9.UTILITY
B-82594EN-4/01
4
Move the cursor to allowed value in parentheses for the axis. Change the allowed value to same as measured max. or min. value.
CAUTION When the disturbance torque exceeds above allowed value, the following WARNING occurs SRVO-053 Disturbance excess (G:x,A:x) Following servo alarm (servo power off) occurs when the disturbance torque exceeds below ALARM LEVELs. Upper Limit = Max. allowed value + 0.3 ± Max. current of amp. Lower Limit = Min. allowed value - 0.3 ± Max. current of amp. SRVO-050 Collision Detect alarm (G:x,A:x) Part of 0.3yMax. current of amp. is the margin to prevent the mis-detection. For example in above screen with 40A amplifier, Upper Limit = 24.0 + 0.3 ± 40 = 36 A Lower Limit = -30.0 - 0.3 ± 40 = -42 A 5 6
Run the programs again with above disturbance allowed setting, and confirm that there is no mis-detection. Finished
- 604 -
9.UTILITY
B-82594EN-4/01
9.17
GRAVITY COMPENSATION Gravity compensation calculates the bending of the robot arm caused by the tool/work on the flange, the equipment on the arm, and the self weight of the arm. Then it compensates the motor position depending on the calculation of the bending, and it improves the absolute position accuracy. Gravity Compensation option (A05B-2500-J649) is necessary to use this function. This function can not be used with Soft float (A05B-2500-J612) or Small Circle (not supported).
9.17.1
System Variables Gravity Compensation $PARAM_GROUP[group].$SV_DMY_LNK[8] FALSE BOOLEAN RW PU TRUE/FALSE [Name] Gravity Compensation Enable/Disable [Meaning] TRUE Gravity Compensation Enable FALSE Gravity Compensation Disable Gravity compensation is disabled when the robot is shipped. Please set this variable to TRUE and cycle power before use. To set back to be disabled, set this variable to FALSE, do controlled start, and execute robot setup again. (By doing that, the motion parameters are set back to the default values. If the motion parameters have been modified, they need to be modified again.) $PARAM_GROUP[group].$MOUNT_ANGLE 0 REAL RW PU -100000 ~ 100000 (deg) [Name] Mount Angle of Robot [Meaning] Set 0deg for floor mount type, 180deg for upside down type, or the mount angle for wall mount or angle mount type. Cycle power after setting.
9.17.2
MOTION Screen 1 2 3
Payload and armload (equipment on the arm) parameters are set in this screen. This setting screen has three sub-screens. (MOTION screen / PAYLOAD SET screen / ARMLOAD SET screen) This screen is sub-screen in SYSTEM. MOTION Screen (Default screen)
- 605 -
9.UTILITY
B-82594EN-4/01
4
Payload information (Schedule No.1 to 10) can be setup. Move cursor to the line of one of the schedule numbers, and press F3(DETAIL) to enter the payload set screen. PAYLOAD SET Screen
5
6 7 8
Setup the payload, payload center, and payload inertia. X, Y, and Z directions in this screen mean X, Y, and Z axes of the default (the settings are all 0) tool frame. After the value is input, the message “Path and Cycletime will change. Set it ?” is displayed. Please input F4(YES) or F5(NO). To enter the payload set screen of the other schedule number, press F3(NUMBER). To enter the screen for other group, press F2(GROUP). (Only in the multi-group system) Press PREV key to go back to the motion screen (default screen). Press F5(SETIND) and input the schedule number to use. Press F4(ARMLOAD) in the motion screen (default screen) to enter the armload set screen. ARMLOAD SET Screen
9
Setup the armload on axis #1 and axis #3. After the value is input, the message “Path and Cycletime will change. Set it ?” is displayed. Please input F4(YES) or F5(NO). After setting up the armload, cycle power.
- 606 -
9.UTILITY
B-82594EN-4/01
9.18
PASSWORD FUNCTION
9.18.1
Overview of the Password Function A password is a combination of up to 12 characters, digits, and symbols. It is used to restrict various operations and screen accesses by operators. The password function is an option and, therefore, need not be used. Password protection is disabled unless an installation user is defined. There are eight password levels, and the possible operations and displayable screens differ depending on the level. Levels 3 to 7 are user-definable. For an overview of password authentication for the four levels, see Table "Password levels".
Level Install
Setup Program Operator User-Defined
Table 9.18.1 Password levels Operation Enables the user to allocate user names, passwords, and levels. Enables the user to clear user names and passwords. Enables the user to enable or disable the password log. Allows the user to set the number of password users in the system. Enables the user to execute all operations that settings users, programs, and operators can executed. Caution Only one install user can be set. Enables the user to execute operations generally performed for system setting. Enables the user to execute operations more advanced than those that production users can execute. Enables the user to execute basic operations. Enables the user to execute basic operations unless otherwise defined in the password configuration file.
CAUTION In a standard system, the user is set to the operator level when the control unit is turned ON. WARNING There are some functions that cannot be executed without the password of the install user. If the password of the install user is forgotten, contact the FANUC service representative.
Password operations To use passwords, set an install user first. To set an install user, it is necessary to assign an install user name and a password first and then log in. Once logged in, the install user can assign the user name, level, and password for each of other users.
- 607 -
9.UTILITY
B-82594EN-4/01
CAUTION The password function cannot be used unless an install user name and a password are assigned. After the install user has assigned a user name, password level, and password to a user, this user must log in to work at the assigned level. The user selects his user name and input his password to log in. Only one user can log in to one device at a time. The term device, as used here, refers to a teach pendant, CRT/keyboard, KCL, and so on. When the user has completed work, he logs out. If he does not log out, a timeout occurs when the time specified for user timeout has elapsed. When the time specified for user timeout has elapsed or the user logs out, the system returns to the operator level, so that another user can log in. If a user forgets to log out, there are cases in which the user is forced to log out by another user. If the install user enables log recording on the password setting screen, the password log can be displayed on the alarm screen. In the password log, important information about data changes (descriptions of changes made by users and the times the changes were made) is displayed. For details, see Procedure 9-19 "Displaying the password log". For information on the assignment of a user name, password level, and password by the install user, see the Subsection 9.18.2, "Password Operations by the Install User". For information on each of operator, program, and setup users, see the Subsection 9.18.4, "Password Operations by Program Users and Setup Users".
- 608 -
9.UTILITY
B-82594EN-4/01
9.18.2
Password Operations by the Install User The install user is required to perform the operations below. • Assign an install user name and a password (Procedure 9-12 "Assignment a user name and a standard password for each password level") • Assign the user names, levels, and passwords for all other users (Procedure 9-12 "Assignment a user name and a standard password for each password level") • Enable or disable the password log and display it if enabled (Procedures 9-18 "Enabling the password log" and Procedures 9-19 "Displaying the password log" in the "Password Log" section) For information on setting a password level, see Procedure 9-12 "Assignment a user name and a standard password for each password level".
Procedure 9-12 Assignment a user name and a standard password for each password level
Step 1 2 3 4
Press the MENUS key. Select "SETUP". Press F1 [TYPE]. Select "Passwords". The screen below appears.
SETUP Passwords Current user: Nobody Current level: OPERATOR 1 Default user timeout: 15 min 2 Timeout occurs in: 15 min 3 Log events: DISABLED 4 Number of users: 10 5
Press F2 "LOGIN". The screen below appears.
SETUP Passwords USERNAME PWD LEVEL TIME(min) 1 * INSTALL 0
CAUTION It is necessary to set an install user name and a password first. 6
Use the steps below to assign an install user name and a password. a Press the ENTER key. b Use the arrow keys and function keys as appropriate to input an install user name. When finished, press the input key. The screen below appears. - 609 -
9.UTILITY
B-82594EN-4/01
SETUP Passwords --Set password for Old password: ’ New password: ’ Verification: ’ Old Value:
BOB ’ ’ ’
CAUTION A password must consist of at least three characters. WARNING Take a note of the install password. There are some functions that cannot be executed without the install password. If you forget the install password, contact the FANUC service representative. C D
Input a new password, and press the input key. Input the new password again to confirm that the previous input is correct and then press the input key. The screen below appears.
Would you like to be logged in?[YES] 7
To log in, press F4 "YES". Otherwise, press F5 "NO".
CAUTION Unless logged in as an install user, the user cannot set other users. If F4 "YES" is pressed, the screen below appears. SETUP Passwords USERNAME PWD LEVEL TIME(min) 1 @BOB * INSTALL 15 2 * 0 3 * 0 4 * 0 5 * 0 6 * 0 7 * 0 8 * 0 9 * 0 10 * 0 Password has been set.
CAUTION The @, which appears when the user logs in, is a symbol indicating a login user name. - 610 -
9.UTILITY
B-82594EN-4/01
8
Use the steps below to assign the name, password, and level for a second user. a Move the cursor to the second user name input item, press the input key, and then use the function keys as appropriate to input a name. b Move the cursor to the PWD field, press the input key and then use the function keys as appropriate to input a password. c Move the cursor to the LEVEL field, press F4 [CHOICE] and then select a level. d Move the cursor to the TIME field and input a user timeout value. The user timeout value may be in the range of 0 to 10080 minutes (7 days).
CAUTION If the user logs in with a user timeout value of 0, no timeout is performed. A value greater than 0 indicates the length of time (in minutes) of the pause until the system performs a timeout. e 9 10 11
For other users that are to be permitted to access the system, perform a through d of step 8. To clear an input user name and password, press the Next key and then F2 "CLEAR". To clear the user names and passwords of all users other than the install user, press the Next key and then F3 "CLR_ALL". To change the number of users in the system, use the steps below.
WARNING If the number of users in the system is changed to a number less than the number of assigned users, some users may be deleted from the system. a
Press the PREV key to display the password setting screen, which appeared first. b Move the cursor to the number of users field and input a value. The allowable number of users is in the range of 10 to 100. If increasing the number of users c Input a new number of users and press the input key. The screen below appears. Perform COLD start to see new users. If the number of users is to be decreased, the prompt below appears. Reconfiguring. DELETE users?[NO]
- 611 -
9.UTILITY
B-82594EN-4/01
To delete users, press F4 "YES". To cancel the operation, press F5 "NO". d
12
Turn off the control unit and back on to enable the new list of users. Press F3 "LOGOUT" to log out.
CAUTION If the user timeout time elapsed or the user logs out, the device in use returns to the operator level. If the control unit is turned off, all devices return to the operator level.
- 612 -
9.UTILITY
B-82594EN-4/01
9.18.3
Disabling the Password Function In a system in which a password is set, it is possible to disable the password function. Disabling the password function causes the install user to be cleared. No other users are cleared. Disabling the password function requires the install level. For information on disabling the password function, see Procedure 9-13 "Disabling the password function".
Procedure 9-13 Disabling the password function
Condition •
The user is logged in as an install user.
1 2 3 4
Press the MENUS key. Select "SETUP". Press F1 [TYPE]. Select "Passwords". The screen below appears.
Step
SETUP Passwords Current user: JOE Current level: INSTALL 1 Default user timeout: 15 min 2 Timeout occurs: 15 min 3 Log events: DISABLED 4 Number of users: 10 5 6
Press NEXT ">". Press F3 "DISABLE". The screen below appears.
SETUP Passwords Current user: JOE Current level: INSTALL 1 Default user timeout: 15 min 2 Timeout occurs in: 15 min 3 Log events: DISABLED 4 Number of users: 10 Disable passwords?[NO]
CAUTION Disabling the password function causes the install user to be cleared. No other users are cleared. Disabling the password function requires the install level. 7
To disable the password function, press F4 "YES". To cancel disabling the password function, press F5 "NO". - 613 -
9.UTILITY
9.18.4
B-82594EN-4/01
Password Operations by Program Users and Setup Users Program users and setup users can perform the operations below. • Log in (Procedure 9-14 "Logging in") • Log out (Procedure 9-15 "Logging out") • Change their own passwords (Procedure 9-16 "Changing a password") • Displaying the password log (Procedure 9-19 "Displaying the password log" in the "Password Log" section) Table 9.18.4 (a) Items on the password setting screen - Login screen Item Explanation Current user Current level Default user timeout
Timeout occurs in Log events Number of users
This item indicates the user who is currently logged in. This item indicates the current system protection level. This item indicates the time after which the system automatically returns to the operator level if the user does not execute any operations after logged in. This item indicates the current remaining time after which the system returns to the operator level. This item indicates whether to record operations in the log. This item indicates the maximum allowable number of users in the system.
Table 9.18.4 (b) Items on the password setting screen - User screen Item Explanation USERNAME PWD LEVEL TIME
INSTALL user
This column indicates the names set as password users. This column indicates whether passwords are set for users. This column indicates password protection levels for users. This column indicates timeout values for users. A timeout value is the length of time that the login status of a user is retained for the specified password level if he does not perform any operations. Assign the user name and password for an install user, so that a user can log in as an install user. Once logged in, the install user can assign the user name, level, and password for each of other users.
- 614 -
9.UTILITY
B-82594EN-4/01
Procedure 9-14 Logging in
Condition • •
A password has been set. (See the section, "Password Operations by the Install User".) No other user is logged in. Only one user can log in at a time.
CAUTION A user who does not know his user name or password should contact the install user.
Step 1
2 3 4
Display the password setting screen. • If the full menu is used, the procedure is as follows: a Press the MENUS key. b Select "SETUP". c Press F1 [TYPE]. d Select "Passwords". • If the quick menu is used, the procedure is as follows: a Press the MENUS key. b Select "SETUP PASSWORDS". Press F2 "USERS". Move the cursor to your user name. Press F2 "LOGIN" to log in. The screen below appears.
SETUP Passwords --Password for MARY Enter password:’ ’ Old Value: 5 6
Input your password and press the input key. To change the timeout value, move the cursor to your user timeout value and input a new timeout value. The user timeout value may be in the range of 0 to 10080 minutes (7 days).
CAUTION 1 If the user logs in to the teach pendant or CRT unit by setting the user timeout value to 0, no timeout is performed. 2 Only one user can log in to one unit at a time. If one user is logged in, another user cannot log in unless that user logs out. It is necessary to determine whether to do so. On the teach pendant or CRT window only, the prompt below appears. User JACK logged in.
- 615 -
Force logout?[NO] YES NO
9.UTILITY
B-82594EN-4/01
7
To log out the user who is logged in, press F4 "YES". Otherwise, press F5 "NO". If F4 "YES" is selected, the screen below appears.
SETUP Passwords USERNAME PWD LEVEL TIME(min) 1 JACK * INSTALL 0 2 @MARY * SETUP 15 3 * 0 4 * 0 5 * 0 6 * 0 7 * 0 8 * 0 9 * 0
CAUTION The @, which appears when the user logs in, is a symbol indicating a login user name. Procedure 9-15 Logging out
Condition • •
A password has been set. (See the section, "Password Operations by the Install User".) The user is currently logged in. (See Procedure 9-14 "Logging in".)
Step 1
2
Display the password setting screen. • If the full menu is used, the procedure is as follows: a Press the MENUS key. b Select "SETUP". c Press F1 [TYPE]. d Select "Passwords". • If the quick menu is used, the procedure is as follows: a Press the MENUS key. b Select "SETUP PASSWORDS". Press F3 "LOGOUT" to log out. When the user logs out, the system returns to the operator level.
- 616 -
9.UTILITY
B-82594EN-4/01
Procedure 9-16 Changing a password
Condition • •
A password has been set. (See the section, "Password Operations by the Install User".) The user is currently logged in. (See Procedure 9-14 "Logging in".)
Step 1
Display the password setting screen. • If the full menu is used, the procedure is as follows: a Press the MENUS key. b Select "SETUP". c Press F1 [TYPE]. d Select "Passwords". • If the quick menu is used, the procedure is as follows: a Press the MENUS key. b Select "SETUP PASSWORDS" The screen below appears.
SETUP Passwords Current user: AAAA Current level: INSTALL 1 Default user timeout: 15 min 2 Timeout occurs in: 4 min 3 Log events: DISABLED 4 Number of users: 10 2
Press F4 "PASSWRD". The screen below appears.
SETUP Passwords --Set password for AAAA Old passwords:’ ’ New passwords:’ ’ Verification: ’ ’ Old Value: 3 4 5 6
Input the current password and press the input key. Input a new password and press the input key. Input the new password again to check that the password first input is correct, and then press the input key. Press F3 "LOGOUT". Then, follow Procedure 9-14 "Logging in" to log in and set the new password.
- 617 -
9.UTILITY
9.18.5
B-82594EN-4/01
Password Configuration File
9.18.5.1 Overview By using an XML file describing a password configuration, it is possible to set the password function. For information on creating password configuration XML files, refer to the supplied sample files. If iPendant or Internet Explorer is connected to the robot, the website of the robot can be displayed. From the website, select the link to "Error/Diagnostic files (MD:)" and then select "PASSCFG.DG (Password Configuration)". The screen below appears.
Fig. 9.18.5.1 Password configuration screen
Each of these links leads to an XML file sample. If the website of the robot cannot be displayed or if a file is to be copied, it is possible to copy a file from an MD:unit. To obtain a copy of a file, copy MD:PASSLVL.XML. A sample file describes the password configuration at the level of the user who is currently logged in. A password configuration is saved as FRS:PASSWORD.DT. When the control unit is turned on, this file is loaded so that passwords are configured. The FRS:PASSWORD.DT file can be saved and loaded as an application file on the file screen. For details, see Section 12.3. Table 9.18.5.1 "Password configuration settings" lists the settings that can be used for a password configuration. For information on creating a password configuration, see Procedure 9-17 "Password configuration".
Setting VERIFY
Table 9.18.5.1 Password configuration settings Explanation Analyzes a selected XML file and writes alarms to a log file. Does not create actual configuration data. It is possible to select an XML file from an external storage unit. Set the external storage unit on the file screen. (See Chapter 12.)
- 618 -
9.UTILITY
B-82594EN-4/01
Setting IMPORT
EXPORT
Explanation Selects an XML file from an external storage unit. Set the external storage unit on the file screen. (See Chapter 12.) Analyzes the selected XML file to create configuration data. Copies the current configuration data to an external storage unit, as password.xml. CAUTION It is necessary to IMPORT the file first.
Procedure 9-17 Password configuration
Condition •
The user is logged in as an install user.
1 2 3 4
Press the MENUS key. Select "SETUP". Press F1 [TYPE]. Select "Passwords". The screen below appears.
Step
SETUP Passwords Current user: JOE Current level: INSTALL 1 Default user timeout: 15 min 2 Timeout occurs: 15 min 3 Log events: DISABLED 4 Number of users: 10 5
Press the Next key and then F6 "CONFIG". The screen below appears.
Configure Passwords Password configuration is performed by importing an XML file from the default device. The XML file can be verified first. The current configuration can be exported to password.xml.
- 619 -
9.UTILITY
9.18.6
B-82594EN-4/01
XML Syntax for Password Configuration Files Name
Command start
Comment
Start tag
End tag
Level name
Table 9.18.6 XML command syntax Syntax and explanation Syntax Explanation This tag must be at the start of an XML file. Syntax Explanation Comment. Write all comments within . Syntax Explanation This tag must be the first tag in a file. Only one start tag can appear in one file. Syntax Explanation This tag must be the last tag in a file. Only one end tag can appear in one file. Syntax < LEVEL=”3” name=Maintenance” lange=”eg”/> Explanation This tag defines a level name of up to 12 characters. It can change the names of all levels including the "install" level. The standard level names are as follows: • Level 0: Operator • Level 1: Program • Level 2: Setup • Level 3: Level 3 • Level 4: Level 4 • Level 5: Level 5 • Level 6: Level 6 • Level 7: Level 7 • Level 8: Install The lang parameter is an option. It is used for multilanguage systems only. Use the lang parameter to specify a language. One level tag defines one level name in one language. To define multiple levels or one level in multiple languages, multiple tags are required.
- 620 -
9.UTILITY
B-82594EN-4/01
Name DefaultMenu type
Standard screen
Syntax and explanation Syntax Explanation This tag defines the menu type for a specified level. The standard menu type for all levels is full menu. It is possible to change it to another menu type for any level except the install level. If there is a change in level (in the event of a user login, logout, or timeout, for example), the menu type automatically changes to the standard menu type. The level parameter defines a level. The type parameter defines a menu type. Syntax < !—Passwords –> < DEFSCREEN level=”0” sp_id=”935” scrn_id=”1”/> Explanation This tag defines the standard screen for a specified level. The standard screen is not defined for any level. It is possible to change the standard screen to another for any level except the install level. If there is a change in level (in the event of a user login, logout, or timeout, for example,), the screen automatically changes to the standard screen. If no standard screen is defined, the previous screen continues to appear if screen display is permitted. If it is not permitted, the first screen appears. The level parameter defines a level. A screen is specified with a software ID and a screen ID. A screen is referenced for menu display. A complete list of software IDs and screen IDs can be displayed with the operations below. • For iPendant, press "5 Help/Diagnostics" on the view menu and "5 Menu Help". • For Internet Explorer connected to the robot, display /md/tpmenus.dg. • For a single menu, while the menu appears on the teach pendant, input md:passscrn.xml.
- 621 -
9.UTILITY Name Screen display/data input
Local label
B-82594EN-4/01
Syntax and explanation Syntax < !-- SELECT --> < SCREEN level="3" sp_id="71" scrn_id="1" access="1" rw_access="1"/> Explanation This tag defines the restrictions on screen display for a specified level. It is possible to change the permission/prohibition settings for screen display and the permission/prohibition settings for data input on screens for any level except the install level. The exception is the password setting screen. For this screen, the screen tag is ignored. The standard screen display/data input restrictions are predefined. Usually, at the operator level and levels 3 to 7, only the display of all screens is permitted. At the program level, the display of/data input on screens for programming the robot is permitted. At the setup level, the display of/data input on screens for programming the robot and screens for setting is permitted. The level parameter defines a level. The sp_id parameter and the scrn_id parameter defines a screen. Even if a screen cannot be displayed, it is shown in the popup menu that appears with the screen select key or F1 [TYPE]. For iPendant, however, it is shown gray and unselectable. For an ordinary teach pendant, the number does not appear any longer and is unselectable. Syntax < LLABEL level="3" name="[ACTION]" lang="eg" sp_id="195" scrn_id="1" access="1"/> < LLABEL level="3" name="DEFINE" lang="eg" sp_id="195" scrn_id="1" access="0”/> < LLABEL level="3" name="UNDEFINE" lang="eg" sp_id="195" scrn_id="1" access="0"/> Explanation This tag defines the restrictions on the function keys on the screens for a specified level. It is possible to change the permission/prohibition settings for function keys for any level except the install level. The level parameter defines a level. The sp_id parameter and the scrn_id parameter defines a screen. The name parameter defines the function key label for a screen or pullup menu. The lang parameter is an option. It is used for multilanguage systems only. The lang parameter defines a language. In this example, it is possible to press function key F2 [ACTION] on the host communication screen. F2 [ACTION] displays a pullup menu containing "DEFINE", "UNDEFINE", "START", and "STOP". If function key F2 [ACTION] is permitted, all items in the pullup menu become selectable. Because, however, the "DEFINE" and "UNDEFINE" selections are not permitted with a local label, it is not possible to select "DEFINE" and "UNDEFINE".
- 622 -
9.UTILITY
B-82594EN-4/01
Name Auxiliary menu selection
Global label
Function
Syntax and explanation Syntax < !-- QUICK/FULL MENUS --> < SCREEN level="3" sp_id="64" scrn_id="20" access="0”/> Explanation The screen tag can also be used to define the selection restrictions on auxiliary menus for a specified level. It is possible to change the selection permission/prohibition settings for auxiliary menus for any level except the install level. The standard settings are such that all items on auxiliary menus are selectable. The level parameter defines a level. The sp_id parameter and the scrn_id parameter defines an auxiliary menu. In some systems, other auxiliary menus may be set up to be available. For a complete list of these, refer to MD:PASSFCTN.XML. In the example below, the menu type at the operator level is always HMI quick menu and any other menu type cannot be used. Syntax < GLABEL level=”3” name=”GROUP” lang=”EG” access=”1”/> < GLABEL level=”3” name=”PU-1” lang=”JP” access=”1”/> < GLABEL level=”3” name=”GROUP” lang=”KN” access=”1”/> Explanation This tag globally defines the restrictions on the use of function keys for a specified level. It is possible to change the permission/prohibition settings of function keys for any level except the install level. Usually, on a screen that is only permitted display, function keys cannot be pressed. The standard settings are, however, such that some functions keys that are thought to present no problems when pressed are permitted to be pressed. The level parameter defines a level. The name parameter defines a function key label. A defined function key is enabled on all screens. The local label, if defined for a screen, takes precedence for that screen. The lang parameter is an option. It is used for multilanguage systems only. The lang parameter defines a language. Syntax < !––PWD_KCL_C KCL ––> < PWD level=”3” const=”1” access=”1”/> Explanation This tag defines the restrictions on the execution of functions for a specified level. It is possible to change the function execution permission/prohibition settings for any level except the install level. The level parameter defines a level. The const parameter defines a function.
- 623 -
9.UTILITY
9.18.7
B-82594EN-4/01
Password Log If the install user enables the "Password log" item on the password setting screen, the password log displays the events below. • Password event • Programming event • File operation event • SpotTool application event When user logins, program creations, and other events occur, they are all recorded in the password log. The password log screen contains the item listed in Table "Item on the password log screen".
Item
Table 9.18.7 Item on the password log screen Explanation
Password Log
Monitors password logins and logouts. If password log is enabled, it is possible to check who is logged in and what changes have been made.
Only the install user can enable the "Log events" setting. For information on enabling the password log, see Procedure 9-18 "Enabling the password log". All users can display the password log. For information on displaying the password log, see Procedure 9-19 "Displaying the password log".
Procedure 9-18 Enabling the password log
Condition •
The user is logged in as an install user. (Procedure 9-12 "Assignment a user name and a standard password for each password level")
1 2 3 4
Press the MENUS key. Select "SETUP". Press F1 [TYPE]. Select "Passwords". The screen below appears.
Step
SETUP Passwords Current user: AAAA Current level: INSTALL 1 Default user timeout: 15 min 2 Timeout occurs in: 4 min 3 Log events: DISABLE 4 Number of users: 10 5
Use the steps below to enable or disable the password log. a. Move the cursor to "Password log". b. To enable Log events, press F4 "ENABLE". c. To disable Log events, press F5 "DISABLE". - 624 -
9.UTILITY
B-82594EN-4/01
Procedure 9-19 Displaying the password log
Condition •
•
The install user has enabled Log events. (Procedure 9-18 "Enabling the password log") The user is logged in at any of the install, program, and setup levels. A full menu appears.
1 2 3 4
Press the MENUS key. Select "ALARM". Press F1 [TYPE]. Select "Password Log". The screen below appears.
•
Step
Password Log 1 PWD -035 Login (BOB) Install from CRT 2 PWD -031 QUICK MENUS forced 3 PWD -039 Logout (BOB) Install from CRT 4 PWD -052 Pwd Timeout (MARY) from Teach 5 PWD -034 Login (MARY) Install from Te 6 PWD -031 QUICK MENUS forced 7 PWD -038 Logout (MARY) Install from T 5
To display the details of a specific event, move the cursor to that event and press F5 "HELP". The screen below appears.
DETAIL Alarm PWD -035 Login (BOB) Install from CRT/Keyboard Password Log 1 PWD -035 Login (BOB) Install from CRT 2 PWD -031 QUICK MENUS forced 3 PWD -039 Logout (BOB) Install from CRT 4 PWD -052 Pwd Timeout (MARY) from Teach 5 PWD -034 Login (MARY) Install from Teach
- 625 -
9.UTILITY
9.18.8
B-82594EN-4/01
Screen Restrictions According to Password Level For each login level, the screen restrictions below are enabled. • C = The screen can be displayed, and the data on it can be changed and operated on. • D = The screen can only be displayed. (No data on it can be changed.) Table 9.18.8 "Screen restrictions according to password level" lists the screen restrictions according to password level.
Menu UTILITIES
TEST CYCLE MANUAL FCTNS ALARM
I/O
Table 9.18.8 Screen restrictions according to password level Password level Teach pendant screen Install Setup Program Operator Hints Prog Adjust Prog Toolbox Prog Adjust Program Shift Mirror Image Shift Tool offset Frame offset Group Exchg TEST CYCLE Manual Weld Macros Alarm Log Motion Log System Log Appl Log Recovery Password Log Comm Log Cell Intface Weld Intface Spot Equip Digital Analog Group Robot UOP SOP Interconnect PLC I/O DeviceNet PMC PMC Display
- 626 -
D C C C C C C C C C C C C C C C D C C C C C C C C C C C C D C C D
D D C C C C C C D D C C D D D D D D D C C C C C C C C C C C C C D
D D C D D D D D D D C C D D D D D D D D D D D D D D D D D D D D D
D D D D D D D D D D C C D D D D D D D D D D D D D D D D D D D D D
9.UTILITY
B-82594EN-4/01
Menu SETUP
FILE
SOFT PANEL USER SELECT EDIT DATA
Teach pendant screen Cell Prog Select Spot Equip Spot Adv Fctns Spot Config TP Hardkeys Servo Gun General Coll Guard Frames Macro Ref Position Port Init Ovrd Select User Alarm Error Table IPendant Setup BG Logic Resume Tol. Coord Stroke Limit Motion DO Host Comm Passwords File File Memory Auto Mackup SOFT PANEL USER SELECT EDIT Registers Position Reg KAREL Vars KAREL Posns Pressure Manual Bkup Distance
Install C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C
- 627 -
Password level Setup Program C C C C C C D C D C C C C C C C D C D D D D C C C C D C C C C C C C C D D D
D D D C D C D D D D D D D D D D D D D D D D D C C C D D C C C C C C C D D D
Operator D D D D D D D D D D D D D D D D D D D D D D D C D D D D D D D D D D D D D D
9.UTILITY
B-82594EN-4/01
Menu STATUS
POSITION SYSTEM
USER2 BROWSER DEP
Teach pendant screen Production Robot ready Servo Gun DisableFault Axis Version ID Safety Signal Exec-hist Memory Prg Timer Sys Timer Remote Diag Condition Appl-status POSITION Clock Variables Gun Master Master/Cal OT Release Axis Limit Config Motion USER2 Browser Dep Display Status Program
Install D C D C C D D C D C C C C D D C C C C C C C C C D C C C C
- 628 -
Password level Setup Program D C D C D D D D D D D D D D D C C D C C C C C C D C C C C
D C D D D D D D D D D D D D D D C D D D D D D C D C C C C
Operator D C D D D D D D D D D D D D D D D D D C D D D D D D C C D
9.UTILITY
B-82594EN-4/01
9.18.9
Password Auto Login Function If the user name for the install level of the password function is one of the user names in the table below, a login is automatically performed at the install level if the corresponding condition is met. If the corresponding condition is no longer met, a logout is automatically performed and the system is set to the operator level. User name _AUTOLOGIN_0 _AUTOLOGIN_1 _AUTOLOGIN_2
Condition The teach pendant enable switch is ON, and the 3-mode switch is in T1 or T2. The teach pendant enable switch is ON. The 3-mode switch is in T1 or T2.
The time at which a login or logout is automatically performed is when the system changes from a status in which the corresponding condition is not met to a status in which it is met or when the system changes from a status in which the corresponding condition is met to a status in which is not met. Even if one of the user names above is set, it is possible to perform a login or logout on the password screen. In this case, an automatic login or logout may be performed later, when the corresponding condition is met or when it is not met. If auto logins are enabled, the alarm message displayed if operation restrictions are imposed due to a password is not the ordinary one, "PWD-069 Operation password protected", but one of the alarm messages below. User name _AUTOLOGIN_0
TP enable switch ON OFF
_AUTOLOGIN_1 _AUTOLOGIN_2
ON OFF Not applicable
3-mode switch T1/T2 AUTO T1/T2 AUTO Not applicable Not applicable T1/T2 AUTO
Alarm message No restrictions. PWD-72 Protected in AUTO mode PWD-71 Protected in TP disable PWD-72 Protected in AUTO mode No restrictions. PWD-71 Protected in TP disable No restrictions. PWD-72 Protected in AUTO mode
If the password log is enabled, auto logins and auto logouts are recorded in the log, as follows: PWD-073 'Auto login '"(%s) %s" PWD-074 'Auto logout '"(%s) %s"
- 629 -
9.UTILITY
9.19
B-82594EN-4/01
SOFT PANEL The soft panel menus are for executing frequently used functions. There are three types of soft panel menus: • Menu of the application-specific soft panel functions and the simulated welding functions • Custom I/O menu This chapter explains how to set these soft panel functions and how to use them.
9.19.1
Application-Specific Soft Panel Function To use the soft panel, it is necessary to set the application-specific items on the soft panel to appropriate values. To set the application-specific items, follow Table 9.19.1 "Explanation of the soft panel". Table 9.19.1 Explanation of the soft panel
Item on the soft panel
Explanation
Application-specific item for handling tools Dry Run Tryout mode (Effective to the material handling/gripper option only)
This item is the same as the "Dry Run" item on the test run screen. Specifies whether to enable or disable the function that executes handling in tryout mode or dry run mode. - ENABLED - The robot enters trial mode, executing all handling outputs and ignores all parts-attached inputs. - DISABLED - Tryout mode disabled To change this item, it is necessary to allocate the tryout mode of the cell input signal. This item cannot be changed on this screen unless TP is enabled.
Procedure 9-20 Operating on the application menu on the soft panel
Step 1 2
Press [MENUS]. Select [SOFT PANEL], press [F2 (SHOW)], and select [Application]. For example, the screen below appears.
SOFT PANEL APPLICATION 1 Dry Run: 2 Tryout mode: 3
ON DISABLED
Set [SOFT PANEL] conditions.
CAUTION When the robot uses a style in manual or isolated mode or if RSR/PNS is selected, the items can be changed only if TP is enabled. - 630 -
9.UTILITY
B-82594EN-4/01
9.19.2
Custom I/O It is possible to register 20 I/O settings on the custom I/O screen on the soft panel. Table 9.19.2 "Soft panel custom I/O settings" lists the custom I/O settings. The setting procedure is explained in Procedure 9-21 "Setting custom I/O".
Custom item type DI, DO, RO, RI, GO, GI, UO, UI, AO, AI, SO, SI
Table 9.19.2 Soft panel custom I/O settings Explanation On the custom I/O screen, the I/O settings shown on the left can be made. Like the I/O setting screen, this screen allows setting of comments, simulated status, and on/off status. This screen also allows the status (STAT) to be switched. Signal names are displayed based on the comments set on the I/O screen. Signal names cannot be changed on this screen.
Procedure 9-21 Setting custom I/O
Step 1 2
Press the MENUS key and select [SOFT PANEL]. Press F2 [SHOW] and select [Custom]. A screen such as that shown below appears. SOFT PANEL CUSTOM IO E1 G1 JOINT 50 % DESCRIPTION
TYPE # S STAT
Prg running
UO[
3] U OFF
FALUT
UO[
6] U OFF
Fault reset
UI [
5] U OFF
Hold
SI [
3] U OFF
[TYPE] [SHOW] CONFIG SIM
3 4
UNSIM
Delete any unnecessary items by pressing the NEXT key and then F2 [DELETE]. To add an item, press the NEXT key and then F2 [INSERT].
- 631 -
9.UTILITY
B-82594EN-4/01
5
When F2 [INSERT] is pressed, a screen such as that below appears, so that the I/O type and I/O number to be added to custom I/O can be set. SOFT PANEL CUSTOM CONFIG E1 G1 JOINT 50 % I/O Signal Details Signal name I/O type/no : DO[ 0]
[TYPE]
6 7 8 9
VERIFY
To make settings, press F3 [CONFIG] to display the setting screen. Position the cursor on I/O type and press F4 [CHOICE] to set an I/O type. By pressing F5 [VERIFY], it is possible to check whether I/O is allocated correctly. When settings have been made, it is possible to check that I/O settings have been added to the custom I/O screen by pressing the PREV key. It is also possible to set I/O on/off and simulated status. Position the cursor on the desired column and press F5 [ON]/F5 [OFF] or F5 [SIM]/ F5 [UNSIM] as desired to set them.
- 632 -
9.UTILITY
B-82594EN-4/01
9.20
MIXED LOGIC INSTRUCTION
Overview The Mixed Logic Instruction allows the use of various operator and data combinations in assignment statements, relational statements, and wait command statements in TP programs. The mixed logic instruction supports the NOT operator "!" and parentheses "()". Mixed Logic Instructions can be specified on the [Register] menu, [I/O] menu, [IF/SELECT] menu, and [WAIT] menu. Mixed Logic Instructions must be specified in parentheses, as shown below. • • •
DO[1]=(DI[1] AND !DI[2]) IF (DI[1]) JMP LBL[1] WAIT (DI[1])
If not enclosed in parentheses, they are executed in the same way as other operation commands. The mixed logic instruction now supports Boolean data type variable flags and markers and the new command TC_Online. The mixed logic instruction enables background operations Using background operations, it is possible to execute up to eight TP programs in which only assignment statements are taught simultaneously, continuously, and repeatedly.
Data types Mixed logic instructions can use the data types below. Table 9.20 (a) Data types Type Numeric Boolean
Value
Data
Numeric values can be handled as data. Both integer and real numbers can be used. Data can assume either ON or OFF values.
Register, constant, GI/O, AI/O, position register element, argument, system variable DI/O, RI/O, UI/O, SI/O, WI/O, ON, OFF, flag, marker
CAUTION Position data and palletizing data cannot be used with mixed logic instructions.
- 633 -
9.UTILITY
B-82594EN-4/01
Operators Mixed logic instructions can use the operators below. Table 9.20 (b) Operator + * / MOD
Addition of the left side and the right side Subtraction of the right side from the left side Multiplication of the left side and the right side Division of the left side by the right side Remainder of the division of the left side by the right side Integer part of the quotient of the division of the left side by the right side
DIV
•
The arithmetic operators can be used with numeric data only. If an attempt is made to use arithmetic operators with Boolean data, "INTP-203 Variable type mismatch" is generated. The output data of an arithmetic operator is always of numeric type.
•
Table 9.20 (c) Operator AND OR !
•
Logical product of the left side and the right side Logical sum of the left side and the right side Logical negation of the left side and the right side
Operator = <> < > <= >=
•
Logical operators Operation
The logical operators can be used with Boolean data only. If an attempt is made to use logical operators with numeric data, "INTP-203 Variable Type Mismatch" is generated. The output data of a logical operator is always of Boolean type.
•
•
Arithmetic operators Operation
Table 9.20 (d) Relational operators Operation Returns an ON value if the left side is equal to the right side. Otherwise, returns an OFF value. Returns an ON value if the left side is not equal to the right side. Otherwise, returns an OFF value. Returns an ON value if the left side is less than the right side. Otherwise, returns an OFF value. Returns an ON value if the left side is greater than the right side. Otherwise, returns an OFF value. Returns an ON value if the left side is equal to or less than the right side. Otherwise, returns an OFF value. Returns an ON value if the left side is equal to or greater than the right side. Otherwise, returns an OFF value.
"=" and "<>" can be used with both numeric type data and Boolean type data. "<", ">", "<=", and ">=" can be used with numeric data only. If an attempt is made to use them with Boolean data, the error "INTP-203 Variable Type Mismatch" occurs.
- 634 -
9.UTILITY
B-82594EN-4/01
The table below indicates the priority of operators.
Priority High
Middle
Low
Table 9.20 (e) Relational operators Operator ! *, /, DIV, MOD +, — <, >, <=, >= =, <> AND OR
Expressions Mixed logic instructions can be used with assignment statements, conditional branch commands, and wait commands.
Assignment statements Mixed logic instruction assignment statement examples are given below. R[1] = ((GI[1] + R[1]) * AI[1]) DO[1] = (DI[1] AND (GI[1] = GI[2])) • • •
•
• • • •
The leftmost = is for an assignment statement. The other = signs are for relational statements. The result of the expression on the right side is assigned to the data on the left side. The output data of an arithmetic operator is always of numeric type. If the data on the left side is of Boolean type and the result of the expression on the right side is of numeric type, the data on the left side is OFF if the value on the right side is less than 1 and greater than -1 and is ON if the value on the right side is greater than 1 or less than -1. This operation is the same as that for an ordinary assignment statement. If the data on the left side is of numeric type and the result of the expression on the right side is of Boolean type, the data on the left side is 0 if the value on the right side is OFF and is 1 if the value on the right side is ON. This operation is the same as that for an ordinary assignment statement. If a real number is assigned to a GO, AO, or integer type system variable, the fractional part is truncated. "Pulse" cannot be specified with a mixed logic instruction. To specify "Pulse", an ordinary operation command must be used. Position data and palletizing data cannot be specified on the left or right side of a mixed logic instruction. To specify position data or palletizing data, an ordinary operation command must be used. The maximum number of items (data items or operators) that can be used in an assignment statement is about 20. The exact maximum number of items that can be used depends on the data type.
- 635 -
9.UTILITY
B-82594EN-4/01
The data below can be specified on the left side of an assignment statement. Table 9.20 (f) Assigning data Data
Type Boolean Numeric
DO, RO, UO, SO, WO, flag, marker Register, GO, AO, position register element, system variable
Conditional statements The following shows examples of using mixed logic instructions with conditional branch instructions. IF (R[1] = (GI[1] + R[1]) * AI[1]) JMP LBL[1] IF (DI[1] AND (!DI[2] OR DI[3])) JMP LBL[1] • • • •
A mixed logic instruction expression can be used in the conditional statement of a conditional branch command. The result of a conditional statement must be of Boolean type. If the result of a conditional statement is ON, the executable statement (JMP LBL, for example) of the conditional branch command is executed. If a mixed logic is used in a conditional statement, the statements below can be used as an executable portion of a conditional branch command. JMP LBL[ ] CALL MIXED LOGIC STATEMENT PULSE STATEMENT
•
A mixed logic assignment statement and a pulse statement can be specified in the executable statement of a conditional branch command only if the conditional statement contains a mixed logic expression. See the examples below. IF (DI[1]), DO[1]=(On) IF (DI[2]), DO[1]=Pulse
•
The maximum number of items (data items or operators) in a conditional statement is about 20. The exact maximum number of items depends on the data type.
- 636 -
9.UTILITY
B-82594EN-4/01
Wait commands The following shows an example of using mixed logic commands with a wait command. WAIT (DI[1] AND (!DI[2] OR DI[3])) • • • • •
A mixed logic expression can be specified in the conditional statement of a wait command. The result of a conditional statement must be of Boolean type. A wait command waits until the result of the expression becomes ON. It is not possible to specify "On+", "Off-", or "ERR_NUM" with a mixed logic command. To specify these, it is necessary to use ordinary operation command. The maximum number of items (data items and operators) in the conditional statement of a wait command is about 20. The exact maximum number of items depends on the data type.
Adding mixed logic commands Editing mixed logic commands is complicated than editing ordinary commands. The reason for this is that they can use various data types and operators and there can be various combinations of them. The functions below are provided to facilitate editing. • To start mixed logic command teaching, a statement containing parentheses must be selected first. • On the item selection menu, the items available according to the location of the statement appear. • If a combination of items is invalid (for example, there are adjacent operators), an empty item is automatically inserted, prompting the user to select an item. • When an item is selected, any related items are automatically deleted. For example, if an operator is deleted, the subsequent operated item is deleted at the same time. • If the cursor is on an item in a mixed logic expression, and the expression is invalid, an error message appears on the prompt line. The message below appears.
Error message Parentheses mismatch Invalid index Variable type mismatch Invalid parameter name Untaught element Invalid motion group Invalid item for output Invalid item for Mixed Logic Syntax error
Table 9.20 (g) Mixed logic error messages Explanation The number of opening parentheses is not equal to the number of closing parentheses. Invalid index number. The data type does not match the operator. Invalid system variable name. There is an un-taught item (...). A specific operation group with a PR[ ] cannot be used in a program. The item on the left side of the assignment statement is invalid. The item cannot be used in a mixed logic expression. Invalid statement.
- 637 -
9.UTILITY
B-82594EN-4/01
To add a mixed logic command to a program, use the procedure below.
Procedure 9-22 Adding a mixed logic command
Step 1 2 3 4 5 6
7
8
9
In the [Edit] menu, press [F1(INST)] to move to the [Instruction] menu. Select the type of the command to be added (Register, I/O, IF/SELECT, or WAIT). From selections, select a mixed logic statement that contains parentheses (...) Prepare a command in an ordinary way. To change an item in the mixed logic statement, press [F4 (CHOICE)] while the cursor is positioned on that item. Available items appear. Except on the left side of an assignment statement, items can be inserted into any mixed logic statement. Press [F1 ]. "..." is inserted before the cursor, and an item selection menu appears. Select an operator, and an empty item is inserted after that operator, and a data menu appears. Except on the left side of an assignment statement, items can be deleted from any mixed logic statement. Move the cursor to an item and press [CHOICE]. A key appears in [F2]. If an operator is deleted, the subsequent data item is also deleted. Except on the left side of an assignment statement, to add or delete the NOT (!), press [F5 (!)] while the cursor is on a digital I/O item in a mixed logic expression. A negation operator (!) is added or deleted. If the right side of an assignment statement contains a mixed logic command, to change the left side of the assignment statement, move the cursor to an item on the left side and press [F4 (CHOICE)]. A menu containing the items that can be specified on the left side of the assignment statement appears.
- 638 -
9.UTILITY
B-82594EN-4/01
Background operation Overview By using a background operation, it is possible to execute a TP program containing assignment statements only in the background. The program is executed repeatedly from the beginning to the end. This execution is not influenced by emergency stops, holds, or alarms. A background operation can be in two execution modes, standard mode and high-speed mode. •
•
In standard mode, all mixed logic commands can be executed in the background. In each ITP, 300 item are scanned. (One ITP is usually eight milliseconds.) "Item" as used here refer to data items and operators. If there are more than 300 items, scanning time increases. For example, if there are 800 operations, processing time is 24 milliseconds. In high-speed mode, only I/O data and logical operators can be executed. In every eight milliseconds, 8000 item are processed. The maximum allowable number of items in high-speed mode is 8000. In high-speed mode, an indirect specification of an index (for example, DO[R[1]]) is not possible.
For more information on the execution modes for a background operation, see Table 9.20 (h). To execute a background operation, use the procedure described in "Setting up a background operation". Table 9.20 (h) Execution modes for a background operation Mode
Standard mode
High-speed mode
Maximum allowable number of items
No restriction
8,000
Scanning time
Available data
F[], M[]*, DI[], DO[], AI[], AO[], GI[], GO[], (Number of items / 300) * ITP SI[], SO[], The number of items as used UI[], UO[], here refers to the total number RI[], RO[] WI[], WO[] of items in all background operation programs. One ITP ON, OFF is usually eight milliseconds. R[], PR[i.j], AR[ ] Constant Parameter Timer, timer overrun
Eight milliseconds
- 639 -
F[], M[]*, DI[], DO[], SI[], SO[], UI[], UO[], RI[], RO[] WI[], WO[]
Available operators
(, ), !, AND, OR, =, <>, <, < =, >, >=, +,—, *, /, DIV, MOD
(, ), !, AND, OR
9.UTILITY
B-82594EN-4/01
M[ ] cannot be specified on the left side of an assignment statement in a background operation. •
Up to eight programs can be executed at the same time as a background operation.
•
If the program contains other than assignment statements, "INTP-443 Invalid item for Mixed Logic" is generated at execution time.
•
While a program is being executed in the background, the program cannot be edited or executed as an ordinary task. If the program is not executed in the background, the program can be executed as an ordinary task.
•
If a program is being executed in the background, a program with the same name cannot be loaded in overwrite mode.
•
If, when the power is interrupted, a program is executed as a background operation, the program is automatically executed in the same execution mode the next time the power is turned on.
•
The execution of a background operation is started before the execution of an ordinary program. The execution of a background operation takes one millisecond per ITP. The execution of a background operation may influence the cycle time of an ordinary program.
•
To reduce the execution time of a background operation, reduce the value of $MIX_LOGIC.$ITEM_COUNT. $MIX_LOGIC.$ITEM_COUNT defines the number of items to be processed per ITP. The standard value is 300.
•
In a background operation, assignment statements with conditional expressions can be executed. If the result of a conditional expression is OFF, the corresponding assignment statement is not executed. In the example below, IF (DI[1]), DO[1]=(DI[2]) If DI[1] is ON, DI[2] is assigned to DO[1]; and if DI[1] is OFF, DO[1] is not changed. In high-speed mode, conditional expressions cannot be executed and, therefore, programs containing conditional expressions are always executed in standard mode.
- 640 -
9.UTILITY
B-82594EN-4/01
•
In a background operation, pulse commands can be used. By combining a pulse command with a conditional expression, it is possible to create a off delay timer. An example is given below. IF (DI[1]), DO[1]=Pulse 1sec If DI[1] remains ON for longer than one second, DO[1] is ON for one second. If DI[1] becomes OFF before one second elapses, DO[1] becomes OFF immediately. While DI[1] is OFF, this statement does not set DO[1]. In high-speed mode, pulse commands cannot be executed and, therefore, programs containing pulse commands are always executed in standard mode. To keep DO[1] ON for one second even if D1[1] becomes OFF within one second, use the statement below. F[1]=(DI[1] OR (F[1] AND DO[1])) IF (F[1]), DO[1]=Pulse 1sec
•
If no time is specified with a pulse command, one scan pulse is assumed in the execution of a background operation. An example is given below. IF (DI[1]), DO[1]=Pulse In this case, if DI[1] is changed from OFF to ON, DO[1] becomes ON for one scan. This can be used for edge detection.
•
If executed in an ordinary way, a time-less pulse command uses the time set for $DEFPULSE, but if the command is executed in the background, a different time is used.
CAUTION In the R-J3iB Mate controller, high-speed mode cannot be used. The mode setting is always [NORMAL], which cannot be changed on the [Background Logic] screen.
- 641 -
9.UTILITY
B-82594EN-4/01
Using the [Background Logic] screen, it is possible to set up and execute a program as a background operation. For information on each of the items on the [Background Logic] screen, see Table 9.20 (i). Table 9.20 (j) lists the operations on the [Background Logic] screen.
Item [PROGRAM] [STATUS]
[MODE]
Table 9.20 (i) Items on the [Background Logic] screen Explanation Enter the name of the program to be executed as a background operation. The statuses of the background operation programs appear. • [Stop]: The program is stopped. • [Running]: The program is executed in standard mode. • [Running(Fast)]: The program is executed in high-speed mode. This item is used to select an execution mode. • [Auto]: Executes the program in high-speed mode if it can be executed in high-speed mode. Executes the program in standard mode if it cannot be executed in high-speed mode. • [Fast]: Always executes the program in high-speed mode. If the program contains any item that cannot be used in high-speed mode, the error message "INTP-444 Invalid item for fast mode" is generated at execution time. • [Normal]: Always executes the program in standard mode. The standard value is [Auto]. If the program is to be executed in high-speed mode but is executed in standard mode, set this item to [Fast]. The numbers of the lines invalid in high-speed mode are indicated in error messages.
Function key [RUN] [STOP]
Table 9.20 (j) Operations on the [Background Logic] screen Explanation Press this key to execute a program as a background operation. An error occurs if the program contains any statement that cannot be used in a background operation. Press this key to stop the execution of a program in the background.
- 642 -
9.UTILITY
B-82594EN-4/01
Procedure 9-23 Setting up a background operation
Step 1 2 3 4
Press [MENUS]. Press [6 (SETUP)]. Press [F1 (TYPE)]. Select [BG Logic]. The screen below appears. Background logic Normal mode scan time: 8 msec PROGRAM STATUS MODE 1 LOGIC1 Running Normal 2 LOGIC2 Stop Fast 3 LOGIC3 Running(Fast) Auto 4 Stop Auto 5 Stop Auto 6 Stop Auto 7 Stop Auto 8 Stop Auto
5
6
Enter the name of the program to be executed as a background operation in the [PROGRAM] column. In the [STATUS] column, the statuses of background operation programs appear. • [Stop] : The program is stopped. • [Running] : The program is executed in standard mode. • [Running(Fast)] : The program is executed in high-speed mode. In the [MODE] column, select a mode. • [Auto] : Executes the program in high-speed mode if it can be executed in high-speed mode. Executes the program in standard mode if it cannot be executed in high-speed mode. • [Fast] : Always executes the program in high-speed mode. If the program contains any item that cannot be used in high-speed mode, the error message "INTP-444 Invalid item for fast mode" is generated at execution time. • [Normal] : Always executes the program in standard mode.
CAUTION The standard value is [Auto]. If the program is to be executed in high-speed mode but is executed in standard mode, set this item to [Fast]. The numbers of the lines invalid in high-speed mode are indicated in error messages. 7 8
To execute the program as a background operation, press [F2 (RUN)]. To stop the program in the background, press [F3 (STOP)]. - 643 -
9.UTILITY
B-82594EN-4/01
Flags A flag (F[ ]) is an internal I/O port that can be read and set up. A flag is not connected to an actual I/O device, and is similar to a Boolean type variable. The value of a flag can be recovered with the power failure recovery function (hot start). This is true of other output ports (DO, for example). All flags are set to OFF in the events below. • • • • •
Cold start Control start INIT start Hot start with the I/O allocation being changed Hot start with the I/O configuration being changed
By setting DI, DO, UI, UO, GI, and GO as those with rack 34, slot 1, start points 1 to 1024, they can be allocated to flags.
WARNING If a flag is allocated to UI, dedicated signals are controlled by changing the value of the flag from the teach pendant and a program, thereby making it possible to start the program and perform other operations. If allocating a flag to UI, design the system by satisfactorily considering safety. Otherwise, unit damage and personal injury may result. To display the [Flag] screen, use the procedure below. 1 2 3 4
Press [MENUS]. Press [5 (I/O)]. Press [F1 (TYPE)]. Select [Flag]. The screen below appears.
Flag F[ F[ F[ F[ F[ F[ F[ F[
# 1] 2] 3] 4] 5] 6] 7] 8]
STATUS ON [ OFF [ OFF [ ON [ ON [ ON [ ON [ ON [
1/1024 ] ] ] ] ] ] ] ]
On this screen, the values of the flags can be changed.
- 644 -
9.UTILITY
B-82594EN-4/01
5
To display the [Port Detail] screen, press [F2 (DETAIL)]. The screen below appears.
Port Detail Flag Comment
:[
[
1]
]
On this screen, the comment on a flag can be changed.
Edge detection, counter, and timer examples with a high-speed mode background operation Edge detection, counter, and timer examples with a high-speed mode background operation In high-speed mode, processing speed has improved over that in standard mode and, therefore, does not influence the processing speed of standard program execution. Note, however, that in high-speed mode, numeric operations and pulse commands cannot be used. Example 1: Edge detection The program below detects an edge of DI[1]. Only if DI[1] is changed from OFF to ON, DO[1] becomes ON. 1: DO[1]=(DI[1] AND !F[1]) 2:F[1]=(DI[1]) F[1] contains the value of DI[1] obtained in the previous scan. If DI[1] is ON and the previous value of DI[1] is OFF, DO[1] becomes ON. Example 2: Counter A example of a DI[1] edge 4-bit counter is given below. The counter value is set in F[41] to F[44]. If GI[1] is allocated as that with rack 34, slot 1, start point 41, and number of points 4, the counter value can be read from GI[1]. 1:F[2]=(DI[1] AND !F[1]) ; 2:F[1]=(DI[1]) ; 3:! BIT1 ; 4:F[3]=(F[41]) ; 5:F[41]=((F[2] AND !F[3]) OR (!F[2] AND F[3])) ; 6:F[2]=(F[2] AND F[3]) ; 7:! BIT2 ; 8:F[3]=(F[42]) ; 9:F[42]=((F[2] AND !F[3]) OR (!F[2] AND F[3])) ; 10:F[2]=(F[2] AND F[3]) ; 11:! BIT3 ; 12:F[3]=(F[43]) ; 13:F[43]=((F[2] AND !F[3]) OR (!F[2] AND F[3])) ; 14:F[2]=(F[2] AND F[3]) ; 15:! BIT4 ; 16:F[3]=(F[44]) ; - 645 -
9.UTILITY
B-82594EN-4/01
17:F[44]=((F[2] AND !F[3]) OR (!F[2] AND F[3])) ; 18:F[2]=(F[2] AND F[3]) ; DI[1] for edge detection and F[2] on the first two lines become ON in the first scan if DI[1] is changed from OFF to ON. Lines 4 to 6 calculate the first bit of the counter (F[41]). F[3] is a working variable for retaining the original value. On line 5, if F[2] is ON, F[41] is inverted, and if F[2] is OFF, F[41] is not changed. On line 6, if the original value of F[41] is OFF, F[2] becomes OFF, which means that no carry over has taken place. Lines 8 to 10 are for the second bit (F[42]), lines 12 to 14 are for the third bit (F[43]), and lines 16 to 18 are for the fourth bit (F[44]). Example 3: Timer In high-speed mode, scan time is always eight milliseconds and, therefore, a timer can be created using a counter. The following shows an example of 80-millisecond pulses. The operation of this program is the same as that of "IF (DI[1]), DO[1]=Pulse 80msec." 1:F[1]=(DI[1]); 2:F[2]=(F[1] AND !F[4]); 3:DO[1]=F[2] 4:! BIT1 ; 5:F[3]=(F[41]) ; 6:F[41]=(F[1] AND ((F[2] AND !F[3]) OR (!F[2] AND F[3]))) ; 7:F[2]=(F[2] AND F[3]) ; 8:! BIT2 ; 9:F[3]=(F[42]) ; 10:F[42]=(F[1] AND ((F[2] AND !F[3]) OR (!F[2] AND F[3]))) ; 11:F[2]=(F[2] AND F[3]) ; 12:! BIT3 ; 13:F[3]=(F[43]) ; 14:F[43]=(F[1] AND ((F[2] AND !F[3]) OR (!F[2] AND F[3]))) ; 15:F[2]=(F[2] AND F[3]) ; 16:! BIT4 ; 17:F[3]=(F[44]) ; 18:F[44]=(F[1] AND ((F[2] AND !F[3]) OR (!F[2] AND F[3]))) ; 19:F[2]=(F[2] AND F[3]) ; 20:! 80msec is 10 * 8msec.10=0b1010 ; 21:F[4]=(F[44] AND !F[43] AND F[42] AND !F[41]) F[1] is used as a working variable for retaining the value of DI[1]. F[2] is a working variable. If F[2] is ON, the counter increments. If the counter value is 10 (F[41]:ON, F[42]:OFF, F[43]:ON, F[44]:OFF), F[4] becomes ON and F[2] becomes OFF, so that the counter does not increment until DI[1] becomes OFF.
- 646 -
9.UTILITY
B-82594EN-4/01
Markers On the [Marker] screen, the statuses of markers can be monitored. A marker (M[ ]) is similar to a flag, but the value of a marker cannot be edited directly. If a marker (M[ ]) is specified on the left side of an assignment expression (=) in a TP program, and the statement is executed, the expression is internally defined as a background operation and is executed repeatedly. The marker (M[ ]) always contains the result of the expression. As standard, the marker function is disabled and the [Marker] menu does not appear, so that M[ ] cannot be taught in a TP program. To use the marker function, set $MIX_LOGIC.$USE_MKR to TRUE. Example: M[1]=(DI[1] AND DI[2]) After this line is executed in an ordinary TP program (not in a background operation), M[1] always contains the result of the expression on the right side. If both DI[1] and DI[2] are ON, M[1] is ON; otherwise, M[1] is OFF. •
If the marker assignment statement is executed in an ordinary TP program, the statement is registered as a background operation. The statement is executed as a background operation until another expression redefines the marker. Because the statement is a background operation, the execution of the statement is not stopped even if the program is paused or stopped.
•
As standard, there are eight markers (M[1] to M[8]). The number of markers can be changed with the system variable "$MIX_LOGIC.$NUM_MARKERS". The maximum allowable number of markers is 100. One marker occupies a permanent memory area of 300 bytes.
•
The scan time in which to calculate marker assignment statements is the same as that in a background operation in standard mode. If marker assignment statements are defined, the scan time in a background operation is influenced.
•
To stop calculation, clear the defined marker expression. To clear a defined expression, either execute an [CLEAR] operation on the [Marker detail] menu or execute the line below in a TP program. M[1]=()
•
If a marker is not allocated in an expression, and the marker is used in another statement, "INTP-438 I/O Read I/O value failed" is generated at the time when the marker value is read.
- 647 -
9.UTILITY
B-82594EN-4/01
•
It is not possible to specify M[ ] on the left side of an assignment statement in a background operation.
To display the [Marker] screen, use the procedure below. 1 2 3 4
Press [MENUS]. Press [5 (I/O)]. Press [F1 (TYPE)]. Select [Marker]. The screen below appears.
Marker M M M M M M M M
[ [ [ [ [ [ [ [
#
1] 2] 3] 4] 5] 6] 7] 8]
STATUS ON OFF OFF ON ON ON ON ON
[ [ [ [ [ [ [ [
1/ 8 ] ] ] ] ] ] ] ]
On this screen, the values of the markers can be changed. 5
To display the [Port Detail] screen, press [F2 (DETAIL)]. The screen below appears.
Port Detail Marker [ 1] Comment :[ ] Expression: M[1]=((DI[1] OR DI[2]) AND !DI[3] Monitor: M [1] ON DI[1] OFF DI[2] ON DI[3] OFF DI[4] OFF DI[5] ON On this screen, the comment on a marker can be changed. •
On the [Port Detail] screen, defined expressions appear. To clear a defined expression, press [F5 (CLEAR)]. When the message below appears, Clear expression?
Press [F4 (YES)]. •
The current values of all the data items in the defined expressions are displayed in the Monitor area.
•
On this screen, the comment on a marker can be changed. - 648 -
9.UTILITY
B-82594EN-4/01
TC_ONLINE TC_ONLINE is similar to a marker. The TC_ONLINE command defines an expression, which is, in turn, calculated as a background operation. While the result of the expression remains OFF, the execution of all TP programs and KAREL programs having motion groups is stopped. As standard, the TC_ONLINE function is disabled, and the [TC_ONLINE] menu does not appear, so that TC_ONLINE commands cannot be taught in a TP program. To use the TC_ONLINE function, set $MIX_LOGIC.$USE_TCOL to TRUE. The following shows an example. TC_ONLINE (DI[1] AND DI[2]) While DI[1] or DI[2] remains OFF after this line is executed, all TP programs are stopped. See Table 9.20 (k). Table 9.20 (k) TC_ONLINE commands TC_ONLINE (...) TC_ONLINE DISABLE* TC_ONLINE ENABLE*
Defines a specified mixed logic command as a TC_ONLINE expression and enables TC_ONLINE. Disables TC_ONLINE. If TC_ONLINE is disabled, the TP program is not stopped with TC_ONLINE (...). Enables TC_ONLINE. It is used to enable TC_ONLINE that has been disabled with TC_ONLINE DISABLE.
*
As standard, TC_ONLINE DISABLE and TC_ONLINE ENABLE cannot be used. To use these commands, set $MIX_LOGOC.$USE_TCOLSIM to FALSE.
•
When TC_ONLINE (...) is executed, the specified expression is defined as a TC_ONLINEal expression. While TC_ONLINE is enabled, the defined expression is calculated as a background operation. While the result of the expression is OFF, all TP programs and KAREL programs having motion groups are stopped.
•
If a program is started while the result of the TC_ONLINE expression is OFF, the program is immediately paused. Except [Shift] + [BWD], starts of all types are influenced by TC_ONLINE.
•
The only case in which a program can be executed when the result of the TC_ONLINE expression is OFF is when the program is executed backword using [Shift] + [BWD].
- 649 -
9.UTILITY
B-82594EN-4/01
•
Even if the scan time in a background operation is longer than an ITP, TC_ONLINE expressions are calculated in each ITP. (One TIP is usually eight milliseconds.)
•
A program that does not have a motion group and for which "ignore pause" is enabled is not paused even if the result of the TC_ONLINE expression is OFF.
•
If $MIX_LOGIC.$USE_TCOLSIM is TRUE (standard), TC_ONLINE DISABLE and TC_ONLINE ENABLE cannot be taught on the [Edit] menu. It is necessary to change the TC_ONLINE ENABLE/DISABLE setting on the [TC_ONLINE] menu. In this case, when the execution of an operation statement is completed, TC_ONLINE is automatically enabled. This means that TC_ONLINE is disabled only in those brief cases in which the operator operates the robot.
•
If $MIX_LOGIC.$USE_TCOLSIM is FALSE, TC_ONLINE DISABLE and TC_ONLINE ENABLE can be taught on the [Edit] menu. The TC_ONLINE ENABLE/DISABLE setting is not automatically changed even after the execution of an operation statement is completed.
To add a TC_ONLINE command, use Procedure 9-24. To display the [TC_ONLINE] menu, use Procedure 9-25.
Procedure 9-24 Adding a TC_ONLINE command
Step 1 2
On the [Edit] menu, press [F1 (INST)] to move to the [Instruction] menu. Select [TC_ONLINE]. If $MIX_LOGIC.$USE_TCOLSIM is TRUE, select items and create statements in an ordinary way. If $MIX_LOGIC.$USE_TCOLSIM is FALSE, follow the steps: a b
3
Select [1(...)]. Select items and create statements in an ordinary way.
To change a TC_ONLINE statement, press [F4 (CHOICE)] at the first "() of the TC_ONLINE statement, and select [2 (ENABLE)]].
- 650 -
9.UTILITY
B-82594EN-4/01
Procedure 9-25 Displaying a TC_ONLINE command
Step 1 2 3 4
Press [MENUS]. Press [5 (I/O)]. Press [F1 (TYPE)]. Select [TC_ONLINE]. The screen below appears.
TC_ONLINE 1/ 6 Status: ON Enable: TRUE Expression: ((DI[1] OR DI[2]) AND !DI[3] AND !(DI[4] AND DI[5])) Monitor: DI[1] ON DI[2] OFF DI[3] ON DI[4] OFF DI[5] OFF The "Enable" line indicates whether TC_ONLINE is currently enabled. This item can be changed on this menu. In the "Status" line, the status of TC_ONLINE is indicated. This is the result of a defined expression. The defined expression is indicated in the Expression space. 5
To clear the defined expression, move the cursor to [Monitor]. a
Press [F5 (CLEAR)]. The prompt below appears.
Clear expression? b
Press [F4 (YES)].
- 651 -
9.UTILITY
B-82594EN-4/01
Saving/Loading All data for mixed logic commands are saved as described below. •
Mixed logic commands are saved to TP files, together with programs.
•
Background operations are saved to TP files.
•
Settings on the "Background Logic" menu are saved to MIXLOGIC.SV. In MIXLOGIC.SV, the values of the system variables are saved. -
$MIX_LOGIC
-
$MIX_BG
-
$MIX_MKR
-
$DRYRUN
-
$DRYRUN_PORT
-
$DRYRUN_SUB
•
Comments on flags and markers are saved to DIOCFGSV.IO.
•
If DI/O, UI/O, or GI/O are allocated to flags , their allocations are saved to DIOCFGSV.IO.
- 652 -
9.UTILITY
B-82594EN-4/01
9.21
PMC MONITOR FUNCTION The PMC monitor function enables the program of the built-in PMC to be displayed on the teach pendant. * The built-in PMC is an option.
PMC ladder display It is possible to display a PMC ladder program using the procedure below. 1 Press Screen select (menu). 2 Select I/O. 3 Press F1 [TYPE]. 4 Select PMC Display and press the ENTER key. A screen show as that shown in the figure below appears.
Fig. 9.21 (a) PMC display
- 653 -
9.UTILITY
B-82594EN-4/01
5
Use the ↑ or ↓ key to move the cursor to the desired level or sub-program. Press F3 [DISPLAY] or the input key, and a screen such as that shown in Fig. 9.21 (b) appears.
Fig. 9.21 (b) PMC sub-program
CAUTION If a specific level or sub-program is selected, the selected program is displayed, but it is possible to display all programs by scrolling.
Switching between address and symbol displays By pressing F2 [SYMBOL] and selecting one from 1 to 4 below, it is possible to switch between address and symbol displays. 1 Address - Displays only addresses above relays or coils. (Example: X1000.2) 2 Symbol - Displays only symbols above relays or coils. (Example: U13) 3 Address & symbol - Displays addresses above relays or coils and symbols below them. 4 Symbol & address - Displays symbols above relays or coils and addresses below them.
- 654 -
9.UTILITY
B-82594EN-4/01
Address and function command search 1
Press F5 [FIND] and a screen such as that shown in Fig. 9.21 (c) appears.
Fig. 9.21 (c) Search screen
The following explains how to use the menu. 1 Select Search kind and press the ENTER key, and a popup window appears. Select which of an address or function command to search for. 2 Move the cursor to the Search string field and press the ENTER key, and a popup keyboard appears. Input the character string to search for. 3 Use the Select button to specify a search start position. The search starts at the selected level or sub-program. 4 By selecting Wildcard search (a check mark is placed), it is possible to make a wildcard search, using a wildcard (*) in the string to search for (for example, F1008.*). Only one wildcard character can be used. 5 If a search is made by selecting Search result list display (a check mark is placed), a list of all nets containing the search string is created. If a check mark is not placed, a net containing the search string appears. Press F5 [FIND] to search for another net containing the search string. 6 If the cursor is moved to the location in which to specify a search range, the selections below can be used. All - All relays, coils, and function commands Select - Selected relays, coils, and function commands Write coils - Coil only 7 Press F3 [CANCEL] or the [PREV] key to return to the PMC ladder display screen. 8 Press F4 [CLEAR] and the search string is deleted. 9 Press F2 [NEXTSRCH] to start a search and display the results.
- 655 -
9.UTILITY
9.22
B-82594EN-4/01
PMC EDIT FUNCTION The PMC edit function enables editing of PMC ladder programs on iPendant. It enables editing of relay, coil, and function instructions in all levels and all subprograms of the PMC ladder programs located on the controller. It enables changing of addresses, symbols, and all nets in a ladder program. The edit screen can be used from all three window frames of iPendant, and can also be used via remote communication by accessing CGTP.HTM or ECHO.HTM. By protecting the edit function with a password, it is possible to make it unusable via remote communication. Like the PMC display function, this function enables address and symbol searching. The PMC edit function does not permit the following: ・ Addition and deletion of nets ・ Addition and deletion of relays, coils, and connection lines ・ Changing of parameter #1 of the function instruction COD ・ Changing of parameters #1 and #2 of the function instruction CODB ・ Changing of parameter #1 of the function instruction COM ・ Changing of the parameters of the function instructions SP, SPE, JMP, JMPE, JMPB, LBL, JMPC, COME, CALL, and CALLU
Using the PMC edit function 1 2 3 4
Press the menu. Select I/O. Press F1 [TYPE]. Select PMC Display, and a screen such as that shown in Fig. 9.22 (a) appears.
Fig. 9.22 (a) PMC ladder tree
- 656 -
9.UTILITY
B-82594EN-4/01
For example, when a ladder program at level 1 or 2 is selected, ladder components are displayed. 5 Use the ↑ or ↓ key to move the cursor to the level or subprogram to be displayed and press the F4 [CHANGE] or ENTER key, and a screen such as that shown in Fig. 9.22 (b) appears.
Fig. 9.22 (b) PMC edit screen
CAUTION It is possible to start at a specific level or subprogram by selecting it, but the cursor passes through all ladder programs and moves down. 6
The cursor changes to a blue one with a 2-pixcel width, enclosing a net. The cursor can be used with the arrow keys.
CAUTION To search for an address or a function instruction, refer to the section on address and function instruction search. To edit a net, position the cursor on the next and press the F2 [MODIFY] or ENTER key. A screen such as that shown in Fig. 9.22 (c) appears.
- 657 -
9.UTILITY
B-82594EN-4/01
Fig. 9.22 (c) PMC ladder net editing
7 8 9
10
11 12
13
To set an element on contact A, press F2 [NO]. To set an element on contact B, press F3 [NC]. To modify a parameter of a function instruction, move the cursor to the upper left corner of the function instruction and press the ENTER key. The function instruction parameter screen appears. Use the arrow keys to position the cursor and press the ENTER key, so that parameters can be edited. When the cursor is at the rightmost position, the following can be performed: • Press F2 [WRT] to write a coil. • Press F3 [WRTNT] to write an inverted coil. • Press F3 [SET] to set a coil. • Press F4 [RESET] to reset a coil. To change a specific address or symbol, position the cursor on a relay and press the ENTER key. The PMC connection setup screen appears, enabling editing of addresses and symbols. When editing is finished, press F1 [EXIT] and select SUBMIT (which transfers the changes to the editor buffer). To cancel the changes, press F1 [EXIT] and select CANCEL. To continue editing, select CONTINUE. When editing of all necessary nets is finished, press F1 [EXIT] on the PMC ladder edit screen and select SUBMIT. The PMC ladder tree screen reappears, and the changes made to the PMC ladder program are saved.
- 658 -
9.UTILITY
B-82594EN-4/01
9.23
OPERATION LOG BOOK (OPTION)
9.23.1
Overview Operation Log Book automatically records teach pendant operations and alarms in a buffer that can be displayed in the Log Book menu of the teach pendant or saved as a text file. Some operations can include a screen image to help in analyzing the event. A system can have multiple Log Books and you can specify which events are recorded in each Log Book. In this way, frequent and infrequent events can be recorded to separate Log Books. When a Log Book buffer is full and a new record is added, the oldest record is deleted. The number of events that can be stored in a Log Book buffer varies based on the type of events saved because not all events are the same size. You can change the size of the buffer by setting a system variable. To use function it is necessary to order the Operation Log Book option (J695). Note This function is independent of the password log function. See the following example of a Log Book.
- 659 -
9.UTILITY
B-82594EN-4/01
Log book JOINT 10 % Operation (20.0k) 1/790 1*SHIFT,F5(TOUCHUP) is pressed, line 2 2 '+Y^(J6)' is pressed 3 SHIFT+FWD is pressed 4*Select 'YES' in 'You are in the diff 5 SHIFT+FWD is pressed 6 SHIFT+FWD is pressed 7 Single step ON 8 'STEP' is pressed 9 'LINER' is selected 10*SHIFT,F1(POINT) is pressed line 2/2 11 '-Y^(J6)' is pressed 12*'50' is entered 13*'Cnt' is selected in 'Motion modify' 14*SHIFT,F1(POINT) is pressed, line 1/1 15 '-Y^(J2)' is pressed 16 '-Y^(J3)' is pressed 17 '+Y^(J5)' is pressed 18 '-Y^(J5)' is pressed 19 Override 40% 20 '+%' is pressed 21 Override 35% 22 '+%' is pressed 23 Override 30% 24 '+%' is pressed 25 Override 25% 26 '+%' is pressed 27 Override 20% 28 '+%' is pressed 29 Override 15% 30 '+%' is pressed 31 '-Y^(J5)' is pressed 32 'RESET' is pressed 33 Menu changed 'PNS0001' 34*'PNS0001' is entered 35*F2(CREATE) is pressed, line 1/16 36 Menu changed 'SELECT' 37 'SELECT' is pressed
The lines marked with an “*” have an associated screen image, as seen in the example of line 12 below. The screen image shows the previous value of the changed item. PNS0001 1/1 1 J P[1] 100% CNT100 [END] POINT
- 660 -
9.UTILITY
B-82594EN-4/01
General Limitations Note the following general limitations for Log Book: • Log Book does not support certain iPendant operations. See following examples. Selecting a link on a web page Operations in screens for iPendant only. For example, operations in browser, panel setup, iPendant setup screen. • Operations are not recorded in controlled start just after initial start. Cold start must be performed to begin logging events. • Operations in the configuration menu are not recorded • If you change the size of a log book, all data in the log book are lost. • Some events are cyclically monitored for logging. Some of the following operations may not be recorded if they occur faster than the monitoring cycle: Override (“Override x%”) Coordination (JOINT coordinate, User Coordinate etc.) Single step (Single step ON/OFF) Motion group (“Motion group x”) Sub group (“Sub group ROBOT/EXT”) User frame number (“User frame x”) Tool frame number (“Tool frame x”) • If you change the dictionary, some entries in the LOG BOOK screen cannot be read. To read such log, you must use the language that was used when the log was recorded. • If passwords are enabled and $LOGBOOK.$LOG_ENT is a valid book number when you log in, your password input is recorded as “’x’ is entered”. Passwords for other functions are also recorded. To prevent passwords from being recorded, you can use screen filtering to filter out the screens that contain passwords. Refer to Subsection 14.13.3. • ‘y’ of “’x’ is selected in ‘y’ window” is based on the 1st line of prompt window. If the 1st line is blank, y contains nothing. Please refer to screen image for analysis. • If you press a function key that has no label, the key number followed by empty parentheses will be recorded. Example If the function key line is as follows: [TYPE]
• • •
ON
OFF
F3 has no label. If you press F3 and $LOGBOOK $LOG_FNKEY is a valid value, “F3( )” is pressed” is recorded. If you change the remote TCP number in remote TCP jog mode, this is recorded as a change of user frame. If you changed current JOG coordination by parameter instruction, the change is recorded when the group is selected. Screen image doesn’t support double height font, which is used in the “on the fly” screen of ArcTool. It is recorded as two lines which have the same characters.
- 661 -
9.UTILITY
B-82594EN-4/01
Example 0.0 Amps in “On the fly” screen is recorded as 0.0 Amps 0.0 Amps
• • • • •
9.23.2
For KAREL read instructions, screen image is recorded just after input. KCL is not supported If the TP and CRT are used at the same time, log book records the operations of both of them. It might be difficult to distinguish between TP and CRT operations in a log. Screen changes caused by the automatic backup function are not recorded. “’x’ is saved” and “’x’ is loaded” may be recorded by internal process.
Recorded Events The following is the list of all events that can be recorded by the Log Book function. Recording of individual events can be disabled by setting the system variable specified in the 'Parameter' column. If it is 0, the event is not recorded. Some of them are disabled by default. If the system variable is not 0, the value indicates the Log Book No. to which the event is recorded. Some events have a screen image. This information helps to analyze the record. However, screen images take a lot of space in the Log Book; you can disable the recording of screen images by setting the system variable specified in the 'Save screen' column. Refer to “4 Operations” later in this section. Events Recorded by Log Book
Message
Event
Parameter (Default)
Save Screen (Default)
Alarm history
$LOGBOOK. When an alarm occurs, the alarm message is recorded. This record is the same as the record of the $LOG_ER (1) alarm history menu. To choose the alarms to be recorded, the 'filtering' function is provided.
None
'x' is entered
$LOGBOOK. When a value or a word is entered, this is recorded. The 'x' in the message is the entered value or word. If $LOG_ENT (1) screen image is enabled for this event, it will contain the previous value. Values will be recorded even if they are invalid. If you cancel an input, it is not recorded.
$LOGBOOK. $IMG_ENT (TRUE)
'x' is selected 'x' is selected in 'y' menu
When a menu item is selected, this is recorded. The 'x' $LOGBOOK. in the message is the selected item. If the menu has a $LOG_SEL (1) title, the 'y' in the message shows the title. If screen image is enabled for this input, it will show the screen just before opening the menu.
$LOGBOOK. $IMG_SEL (TRUE)
- 662 -
9.UTILITY
B-82594EN-4/01
Message
Event
Parameter (Default)
$LOGBOOK. 'x' is selected in 'y' window When an item is selected in warning window, this is recorded. The 'x' in the message is the selected item. $LOG_WIN (1) The 'y' in the message is the beginning of the message in the warning window. If screen image is enabled for this event it will show the warning window.
Save Screen (Default) $LOGBOOK. $IMG_WIN (TRUE)
'x' is selected in MENU 'x' is selected in FCTN
When an item is selected by MENU key or FCTN key, $LOGBOOK. this is recorded. The 'x' in the message is the selected $LOG_MENU (1) item
None
JOG menu TOOL 'x' JOG menu USER 'x' JOG menu JOG 'x' JOG menu GROUP 'x' JOG menu ROBOT JOG menu EXT
Operations of the JOG menu are recorded with these $LOGBOOK. messages. $LOG_JGMN (1)
None
Menu changed 'x'
None When a menu is changed, this is recorded. The 'x' in $LOGBOOK. the message is the title of the new menu. Changes to $LOG_MNCHG (1) sub menus such as Config or Detail are not recorded.
'x' is pressed
When a key is pressed, this message is recorded with the key name. It is not recorded when the key is released. If SHIFT is held when the key is pressed, the word 'SHIFT,' is added to the key name(except SELECT, EDIT, DATA). The keys are grouped as follows, and you can disable recording of each group. F1, F2, F3, F4, F5
$LOGBOOK. $LOG_FNKEY (1)
$LOGBOOK. $IMG_FNKEY (TRUE)
+X(J1), -X(J1), +Y(J2), -Y(J2), +Z(J3), -Z(J3), +X^(J4), -X^(J4), +Y^(J5), -Y^(J5), +Z^(J6), -Z^(J6)
$LOGBOOK. $LOG_JGKY (1)
None
SELECT, EDIT, DATA,
$LOGBOOK. None $LOG_PRGKEY (1)
UF1, UF2, UF3, UF4, UF5, UF6, UF7
$LOGBOOK. $LOG_UFKY (1)
None
+%, -%, COORD
$LOGBOOK. $LOG_OVRKY (1)
None
FWD, BWD
$LOGBOOK. $LOG_FWDKY (1)
None
HOLD
$LOGBOOK. $LOG_HLDKY (1)
None
STEP
$LOGBOOK. $LOG_STPKY (1)
None
PREV
$LOGBOOK. $LOG_PRVKY (1)
None
ENTER
$LOGBOOK. $LOG_ENTKY (1)
None
- 663 -
9.UTILITY
B-82594EN-4/01
Message
Event
Parameter (Default)
Save Screen (Default)
ITEM
$LOGBOOK. $LOG_ITMKY (1)
None
RESET
$LOGBOOK. $LOG_RSTKY (1)
None
Override x%
When override is changed, this is recorded. The 'x' in $LOGBOOK. the message is the new override value. This records all $LOG_OVR (1) change of override by any method. For example, '+%' key, TP is enabled, override instruction of program.
None
JOINT coordinate USER coordinate TOOL coordinate JOG coordinate PATH coordinate
When coordinate is changed, this is recorded. This records all change of coordinate by any method.
$LOGBOOK. $LOG_CRD (1)
None
Single step ON Single step OFF
When single step is changed, this is recorded. This records all change of single step by any method.
$LOGBOOK. $LOG_STEP (1)
None
Motion group x
When motion group is changed, this is recorded. The $LOGBOOK. $LOG_GRP (1) 'x' in the message is the new motion group This records all change of motion group by any method.
None
Sub group ROBOT Sub group EXT
When sub group is changed, this is recorded. This records all change of sub group by any method.
None
User frame x
When user frame number is changed, this is recorded. $LOGBOOK. The 'x' in the message is the new user frame number $LOG_UF (1) This records all change of user frame number by any method.
None
Tool frame x
When tool frame number is changed, this is recorded. $LOGBOOK. The 'x' in the message is the new tool frame number $LOG_UT (1) This records all change of tool frame number by any method.
None
Save file x Load file x
$LOGBOOK. File x is saved $LOG_FILE (1) File x is loaded These events are ONLY for file save/load in following screens • File screen • Program list screen
None
WAIT is released (x, y)
The waiting WAIT instruction is canceled by WAIT RELEASE in program x line y.
$LOGBOOK. $LOG_WTRLS (0)
None
Create program x Delete program x Write line x of y Delete line x of y
TP program x is created. TP program x is deleted. Line x of TP program y is written. Line x of TP program y is deleted.
$LOGBOOK. $LOG_PGCHG (0)
None
Write P[x] of y
Position data P[x] of TP program y is written. These $LOGBOOK. None are also recorded when program is changed internally. $LOG_SETPOS(0)
- 664 -
$LOGBOOK. $LOG_SGRP (1)
9.UTILITY
B-82594EN-4/01
Message
Parameter (Default)
Event
Save Screen (Default)
TP 'x' ON TP 'x' OFF
$LOGBOOK. This records the low level key operation. All key $LOG_TPKY (0) operations of Teach Pendant are recorded. When a key is pressed, 'TP x ON' is recorded. When a key is released, 'TP x OFF' is recorded. ENABLE switch and E-STOP are also recorded. SHIFT key is treated as normal key. CRT operations are not recorded by this event. 'x' in the message is key name, the following keys are recorded. ENABLE, ESTOP PREV, F1, F2, F3, F4, F5, NEXT SHIFT, MENU, SELECT, EDIT, DATA,FCTN UP, DOWN, LEFT, RIGHT, DISP RESET, STEP, BACKSPACE, ITEM, HOLD, FWD, BWD, COORD, +%, -% 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, -/,, ., ENTER, HELP/DIAG, UF1, UF2, UF3, UF4, UF5, UF6, UF7, +X(J1), -X(J1), +Y(J2), -Y(J2), +Z(J3), -Z(J3), +X^(J4), -X^(J4), +Y^(J5), -Y^(J5), +Z^(J6), -Z^(J6),
None
Cold start Power failure recovery Control start
Start mode is recorded.
None
9.23.3
$LOGBOOK. $LOG_STMD(1)
Setting Up Book A system can have 16 books at a maximum. User can setup each book by system variable. Followings are items user can setup. • Title • Size • Memory to store buffer • Visible/invisible
System variable name $LOG_BUF[1-16]. $TITLE
$LOG_BUF[1-16]. $SIZE
Type
Default
Range
Description Title of every buffer. This string is displayed on the top line of LogBook menu. It also be displayed in pop up menu of F2([BOOK]) in LogBook menu. If the value is ‘’, the default title is displayed. Default title of BOOK1 is ‘Operation’. Default title of ‘BOOK2 is ‘I/O”. Default title of BOOK3 is ‘BOOK 3’ Size of the buffer to save log. Unit is K Bytes. One record takes about 300 bytes If this value is too big, maximum available size of Log Book buffer is allocated automatically. If there is not enough memory to make Log book buffer, SYST – 188 WARN “book(%d) was not created” is posted and the book is not created. Cycle power is needed to enable the change of this variable.
String
[1-16] ‘’
Max 13 chars
Integer
[1] 50 [2] 100 [3-16] 0
0, 2147483647
- 665 -
9.UTILITY
B-82594EN-4/01
System variable name $LOG_BUF[1-16]. $MEM_TYPE
$LOG_BUF[1-16]. $VISIBLE
9.23.4
Type
Default
Range
Description
Integer
[1] 0 [2] 1 [3-16] 0
0, 2147483647
Memory type of every buffer. 0: In SRAM, Log is kept at power down. 1: In DRAM, Log is cleared at power down.
Boolean
[1] TRUE [2] FALSE [3-16] TRUE
FALSE, TRUE
If FALSE, the buffer is not displayed in pop up menu of F2([BOOK]) in LogBook menu.
Operations
Displaying the Log Book Screen 1 2 3 4
Press MENUS. Select 4, ALARM. Press F1, TYPE. Select Log Book. You will see a screen similar to the following:
Log book Operation (20.0k) 1/790 1*SHIFT,F5(TOUCHUP) is pressed, line 2 2 '+Y^(J6)' is pressed 3 SHIFT+FWD is pressed 4*Select 'YES' in 'You are in the diff 5 SHIFT+FWD is pressed 6 SHIFT+FWD is pressed 7 Single step ON 8 'STEP' is pressed 9 'LINER' is selected 10*SHIFT,F1(POINT) is pressed line 2/2
5 6
To change to a different Log Book, press F2, BOOK. To view the screen image for a line that is marked with a “*”, select the line and press F3, DETAIL. You will see a screen similar to the following:
Log book
JOINT 10 % 1/790 *SHIFT,F5(TOUCHUP) is pressed, line 2/3 00/06/02 14:17:36 --Screen image ------------------------PNS0001 2/3 1 J P[1] 100% CNT50 2 J P[2] 100% FINE [END]
- 666 -
9.UTILITY
B-82594EN-4/01
7
To view details of an entry, select the entry and press F3, DETAIL. You will see a screen similar to the following:
Log book 5/790 SRVO-001 Operator panel E-stop 00/06/02 14:17:36
8
To clear the log, press F5, CLEAR, then press F4, YES.
Saving Log Book data as a Text File Log Book data is saved as text file LOGBOOK.LS. There are two ways to save data: • At the FILE menu, press F4, BACKUP, and select “Error Log”. LOGBOOK.LS is saved along with the error log files. • In the Log Book menu, press the FCTN key and select SAVE. LOGBOOK.LS is saved to the selected device.
- 667 -
9.UTILITY
B-82594EN-4/01
See the following example of a LOGBOOK.LS file. Operation ============================================================ *SHIFT,F5(TOUCHUP) is pressed, line 2/3 00/06/02 14:17:36 --Screen image------------------------------PNS0001\\\\\\\\\\\\\\\\\\\\\\\JOINT\\10\% 1 J P[1] 100% CNT59 2 J P[2] 100% FINE [END] POINT TOUCHUP> ============================================================ '+Y^(J6)' is pressed 00/06/02 14:17:20 ============================================================ SHIFT+FWD is pressed 00/06/02 14:17:12 ============================================================ Select 'YES' in 'The cursor is on a different' window 00/06/02 14:16:40 --Screen image------------------------------PNS0001\\\\\\\\\\\\\\\\\\\\\\\JOINT\\10\% +------------------------------+ |The cursor is on a different | |line from where the program | 1 |PAUSED [1]. | 2 |Are you sure you want to run | [END|from this line ? | | | | \\\\YES\\\\ NO | | | +------------------------------+ POINT TOUCHUP> ============================================================ SHIFT+FWD is pressed 00/06/02 14:16:30 ============================================================ SHIFT+FWD is pressed 00/06/02 14:16:28 ============================================================
- 668 -
9.UTILITY
B-82594EN-4/01
Filtering Alarms and Screens You can set system variables to filter specific alarms and screens. By default, Log Book filters out warning errors. You can filter errors to be logged by severity, type, and item number. System Variables used for Filtering System Variable Name
Type
Default
Range
Description
$LOG_ER_SEV
INTEGER
6
-2147483648 Filter by severity of error. 2147483647 When a bit in this is True, the corresponding errors are logged. • Bit 0 (1): Log warning errors. • Bit 1 (2): Log pause errors. • Bit 2 (4): Log abort errors. Ex. 6 = pause and abort errors are logged. Priority of this is lower than $LOG_ER_TYP and $LOG_ER_ITM.
$LOG_ER_TYP[1-n]
INTEGER
0
-2147483648 Filter by type of error. 2147483647 If a positive value is specified, alarms of the specified type are logged. Ex. 11 = SRVO alarms are logged. If a negative value is specified, alarms of the specified type are not logged. Ex. -11 = SRVO alarms are not logged. Priority of this is higher than $LOG_ER_SEV but lower than $LOG_ER_ITM.
$LOG_ER_ITM[1-n]
INTEGER
0
-2147483648 Filter by individual error. 2147483647 If a positive value is specified, the specified alarm is logged. Ex. 11001 = SRVO-001 is logged. If a negative value is specified, the specified alarm is not logged. Ex. -11001 = SRVO-001 is not logged. Priority of this is higher than $LOG_ER_SEV and $LOG_ER_TYP.
Control error filtering by setting the following system variables. • $LOG_ER_ITM[1-n], • $LOG_ER_SEV • $LOG_ER_TYP[1-n] The priority of the settings is: $LOG_ER_SEV < $LOG_ER_TYP < $LOG_ER_ITM See the following for an example of error filtering: SRVO-001 "Operator panel E-stop" Severity=PAUSE SRVO-038 "Pulse mismatch" Severity=ABORT TPIF-104 "Teach pendant is disabled" Severity=WARN
- 669 -
Type=11 Item=11001 Type=11 Item=11038 Type=9 Item=9104
9.UTILITY
B-82594EN-4/01
Alarm Filtering Example $LOG_ER_SEV
$LOG_ER_TYP
$LOG_ER_ITM
SRVO-001
SRVO-038
TPIF-104
6
0, 0, ..
0 ,0, ..
Logged
Logged
Not logged
6
0, 0, ..
9104, 0, ..
Logged
Logged
Logged
6
0, 0, ..
9104, -11001, ..
Not logged
Logged
Logged
7
-11, 0, ..
11001, 0, ..
Logged
Not logged
Logged
0
11, 9, ..
-11001
Not logged
Logged
Logged
Screen filtering enables Logbook to log UIF events that occur in the screens you specify. Screen filtering supports the following events (UIF events). • 'x' is entered • 'x' is pressed • 'x' is selected • 'x' is selected in 'y' menu • 'x' is selected in 'y' window • 'x' is selected in MENU • 'x' is selected in FCTN • JOG menu TOOL 1 etc
NOTE TP’x’ ON/OFF is not supported. By default, screen filtering is disabled. Screen filtering is enabled/disabled by $LOGBOOK.$SCRN_FL. • If $LOGBOOK.$SCRN_NO_ENT is TRUE, events in registered screens are recorded. If FALSE, events in NOT registered screens are recorded. • To register screens, softpart ID and screen ID must be set to $LOG_SCRN_FL[ ].$SP_ID and $LOG_SCRN[ ].$SCRN_ID. By default, no screen is registered for filter. System Variables for Screen Filtering System Variable Name
Type
Default
Range
Description
$LOGBOOK.$SCRN_FL
BOOLEAN
FALSE
FALSE/TRUE
Screen filter is disabled/enabled
$LOGBOOK.$SCRN_NO_ENT
BOOLEAN
TRUE
FALSE/TRUE
TRUE: Events on registered screens are not recorded. Events on other screens are recorded. FALSE: Events on registered screens are recorded Events on other screens are not recorded.
$LOGBOOK.$NUM_SCRN_FL
Integer
20
1,200
Number of $LOG_SCRN_FL
$LOG_SCRN_FL[ ].$SCRN_ID
ULONG
0
0,4294967295
Screen ID of screen for filter
$LOG_SCRN_FL[ ].$SP_ID
ULONG
0
0,4294967295
Softpart ID of screen for filter
- 670 -
9.UTILITY
B-82594EN-4/01
To filter screens so that passwords are not recorded, set the following: $LOGBOOK.$SCRN_FL = TRUE $LOG_SCRN_FL[1].$SP_ID = 935 $LOG_SCRN_FL[1].$SCRN_ID = 1
If you have an iPendant, you can find the softpart ID and screen ID for the menus currently loaded on your system. Go to the DISP MENU, select HELP/DIAGNOSTICS, then select Menu Help from the flyout menu.
9.23.5
Extended Alarm Log
9.23.5.1 Setup This example name BOOK3 as “ALARM” and use it for only for record of alarms. This configuration uses PERM memory of 500kbytes. The number of alarms that can be stored in the book depends on contents of alarms. Suppose user alarm with undefined alarm message occurred. The book can record the alarm about 5000 times.
NOTE Because size of book is large, please check the rest of PERM memory before using this setting. The rest of PERM memory should be more than 150KB after the book is established. If the book uses 500KB, the rest of PERM memory should be more than 650KB(500KB + 150KB). System variable
Type
Default value
System variable Value
Comment
$LOG_BUF[3]. $TITLE $LOG_BUF[3]. $SIZE $LOG_BUF[3]. $MEM_TYPE $LOG_BUF[3]. $VISIBLE
String
‘’
ALARM
Title of book
Integer
0
500
Integer
0
0
Boolean
TRUE
TRUE
$LOGBOOK. $LOG_ER $LOG_ER_SEV
Integer
1
3
Size of book is 500kbytes. The number of alarms that this book can store depends on contents of alarms. Buffer of this book is made on permanent pool. Cycle power doesn’t clear records. The book of “ALARM” is displayed in F2 ([BOOK]) pull up menu. Please note that this book is not always displayed as the 3rd item on the pull-up menu Alarms are recorded in book3.
Integer
6
7
Filter by severity of error. When a bit in this is TRUE , the corresponding errors are logged. • Bit 0 (1): Log warning errors. • Bit 1 (2): Log pause errors. • Bit 2 (4): Log abort errors. Ex. 7 = warn, pause and abort errors are logged (All alarms are recorded).
Cycle power is needed to enable these changes. - 671 -
9.UTILITY
B-82594EN-4/01
9.23.5.2 How to display alarm log 1)
Press MENU Select ALARM Press F1 and select “Log book”. Logbook screen is displayed
2)
Press F2 and select “ALARM”
- 672 -
9.UTILITY
B-82594EN-4/01
3)
Contents of book “ALARM” , which is made by setting of this example, is displayed.
4)
F3 shows detail screen.
- 673 -
9.UTILITY
9.24
B-82594EN-4/01
ORIGINAL PATH RESUME
Overview Original Path Resume works as follows: If an attempt is made to restart the program after the robot has paused or been brought to an emergency stop, the program restarts only after the robot has returned to its stop position even when the robot moves after a stop. The stop position can be the position where the robot pauses or stops at an emergency. The move of the robot from the current position to the stop position is called the “Restart Move”. If an alarm that causes the robot to stop occurs, for example, the robot decelerates to a stop, and the TP program is caused to pause. The user might then jog the robot to another position to remove the cause of the alarm. If the TP program is restarted with Original Path Resume enabled, the robot first executes a Restart Move to the stop position before the program is restarted. Path taken by the robot when it is restarted after pause with Original Path Resume disabled P[3]
P[2] Stop position
Original path
Pause Jog Resume Move P[1]
P[4]
Path taken by the robot when it is restarted after pause with Original Path Resume enabled P[2]
P[3] Stop position
Original path
Pause Resume Move Restart Move
P[1]
Jog
P[4]
- 674 -
9.UTILITY
B-82594EN-4/01
When the robot is brought to an emergency stop, the servo is turned off and the brakes are applied, possibly causing the robot to deviate from the normal path depending on the robot’s payload mass, speed, and the direction of gravity. If Original Path Resume is used in restarting the TP program, the robot executes a Restart Move to the stop position before the program is restarted. Path taken by the robot when the robot is restarted after an emergency stop with Original Path Resume enabled
P[2]
P[3] Stop position Emergency stop
Original path Brake
Restart Move
Resume Move
P[1]
P[4]
System variables The following variables are used to enable or disable Original Path Resume. $SCR.$ORG_PTH_RSM = TRUE (for enabling Original Path Resume) $SCR.$ORG_PTH_RSM = FALSE (for disabling Original Path Resume) $MCR_GRP[].$RSM_MOTYPE determines what restart move type to use. 1: Axis-specific 2: Straight line 3: Program (move type in use when the robot pauses) $MCR_GRP[].$RSM_SPEED determines the Restart Move speed (in mm/s or %) that will be suitable for the move type. $MCR_GRP[].$RSM_ORIENT determines the posture the robot has when it is restarted. 1: With wrist posture 2: Without wrist posture
- 675 -
9.UTILITY
B-82594EN-4/01
Limitations •
• •
•
If the Constant Path option is disabled, the path the robot takes during Resume Move may differ from the original path. The stop position of the robot will get close to the original path but is inaccurate. If the Constant Path option is enabled, the path the robot takes during Resume Move coincides with the original path. The Restart Move is subject to the same limitations as the other move types. If an alarm occurs during Restart Move related to, for example, “stroke limit,” restarting the program requires an operator’s intervention. If there is anything between the current and stop positions of the robot, the robot may collide against it because the Restart Move begins at the stop position. For example, the robot may have been jogged to a position where the robot will collide against the tool when it is restarted.
Resume Offset Resume Offset works as follows: When the robot is restarted, it moves back through “offset” from the stop position on the path. This option can be used in processes that are continuous along the path, such as cutting, welding, or dispensing. For example, sealant dispensing applications are sensitive to the TCP speed, so Resume Offset is used to allow the time needed for the robot to accelerate along the path before reaching the original stop position, thus resuming the normal sealant flow.
Limitations of Resume Offset • • •
Resume Offset requires Original Path Resume. It is subject to the limitations of Original Path Resume. Resume Offset uses the same Restart Move as Original Path Resume. Restart Move causes the robot to move directly to the offset stop position, not backward along the original path. The actual Resume Offset position gets close to the desired offset rather than the exact specified position.
- 676 -
9.UTILITY
B-82594EN-4/01
Constant Path Resume Offset Constant Path Resume Offset works in conjunction with the Constant Path option, which holds the TCP path in “memory,” so that at the end of pause the stop position can be offset to the position held in memory. The Resume Move causes the robot to accelerate from the offset stop position, follow the identical path to the original stop position, and then continue execution normally. Path taken by the robot when it is restarted after pause with Constant Path Resume Offset used P[2]
P[3] Pause
Resume Move
Stop position
Restart Move Original path
Offset stop position P[1]
P[4]
Limitations of Constant Path Resume Offset • • •
Constant Path Resume Offset requires the Constant Path option. Constant Path Resume Offset is subject to the limitations of the Constant Path option. Constant Path Resume Offset requires the offset distance before the robot pauses. Changing the offset distance after the robot pauses but before Resume Move is executed has no effect. Constant Path Resume Offset does not allow the robot to offset to a position where it is before positions are held in memory. If an attempt is made to move the robot to that position, the robot is moved to the earliest position to be held in memory. The amount of data that can be held in memory can be changed using the Resume Offset menu.
- 677 -
9.UTILITY
B-82594EN-4/01
Non-Constant Path Resume Offset Non-Constant Path Resume Offset computes the offset in reference to the current move statement. The computed position will not be on the original path. This is used in situations where the Constant Path option is not supported. The Resume Move path will deviate from the original path. However, it will be close to the original path if the program speed is low or its smoothness is at a low rate. Path taken by the robot when it is restarted after pause with Non-Constant Path Resume Offset in use P[2]
P[3] Resume Move
Pause Stop position
Offset stop position
Original path Restart Move
P[1]
P[4]
Limitations of Non-Constant Path Resume Offset • •
Non-Constant Path Resume Offset records a stop position on the taught move statement rather than on the path. This can lead to path deviation when the path is resumed. Non-Constant Path Resume Offset cannot move the robot to an “offset” position where the robot is before the start position of the current move statement is reached. If an attempt is made to move the robot to that “offset” position, the start position of the current move statement is set as the actual offset position.
Selecting Resume Offset type Table 9.25.1 Selecting Resume Offset type $cpcfg.$resume_ofst.$ro_enable Constant Path Resume FALSE TRUE
No Resume Offset Constant Path Resume Offset
Non-Constant Path Resume
Non-Constant Path Resume Offset Non-Constant Path Resume Offset
If the Constant Path option is loaded, Constant Path Resume is used. The value of $CPCFG.$RESUME_OFST.$RO_ENABLE determines whether to use Resume Offset. If the Constant Path option is not loaded, Non-Constant Path Resume is used. The value of $MCR_GRP[].$RSM_OFFSET determines Resume Offset. Some options do not support Constant Path Resume. Non-Constant Path Resume is used with those options, which include: • Touch Sensing • Line Tracking - 678 -
9.UTILITY
B-82594EN-4/01
• •
Servo Gun Weaving
Resume Offset setup menu Selecting [MENU]→[SETUP]→[Resume Offset] displays this menu. The Resume Offset menu is used to configure the memory to be used with Constant Path Resume. This configuration has a direct effect on the way the system memory is used. Resume Offset Status indicates whether Constant Path Resume Offset is enabled. It is equivalent to the system variable $CPCFG.$RESUME_OFST.$RO_ENABLE. Max. Res. Offset Dist specifies the maximum amount of offset that might be used. The larger the value, the more memory is required. Nominal Process Spped specifies a reference speed at which the Resume Offset process will be run. The smaller the value, the more memory is required. Once the configuration is changed, it is necessary to turn the power off and on again, so the new configuration is enabled. The display given below appears after the configuration is changed. There are two choices: Turn the power off and on again to enable the new configuration or keep the power on to preserve the old configuration.
System variables $CPCFG.$RESUME_OFST.$RO_ENABLE If the Constant Path option is loaded, Constant Path Resume is enabled. $MCR_GRP[].$RSM_OFFSET Resume Offset distance (mm) to use $MOR_GRP[].$OGDST_RATIO Actual Resume Offset ratio used in attaining the target Resume Offset = 100% 0.0 = 0% -1.0 = yet to be initialized
- 679 -
9.UTILITY
9.25
B-82594EN-4/01
PROGRAM TOOLBOX The Program Toolbox has the following features. Installing the Program Toolbox option software makes available the following Program Toolbox options: • Cross car mirror shift • Flip knuckle • Soft limit setting
9.25.1
Cross Car Mirror Shift The cross car mirror shift option allows the user to mirror a taught path from one side of a car body to the other side, without having to choose a mirror plane or defining reference points. It can be used to create a duplicate program for robots that perform the same function on different sides of a car body. Without the cross car mirror shift option, it is necessary to create two programs and teach all points on both sides of the car body. With the cross car mirror shift option, it is possible to create one program and teach the points on one side of the car, and then use the option to create another program automatically for the robot across the line. The cross car mirror shift option performs a specific mirror image function as follows: 1 2.
The cross car mirror shift option mirrors a user-selected program in the x-z plane. By default, the program is one chosen on the [SELECT] menu. See Fig. 9.25.1(a). The output of the option is written to a specified destination program. By default, the destination program is given the name MIRROR.TP.
The mirrored destination program will have mirrored tool and user coordinate definitions. These new values are written as remarks and included at the beginning of the destination program, as shown in Fig. 9.25.1(b). Note: The current version does not support circle or incremental instructions.
- 680 -
9.UTILITY
B-82594EN-4/01
Mirror plane (x-z)
Fig. 9.25.1(a) Cross car mirror shift option
1. !******************************** 2. !MIRRORED UTOOL [1] 3. !X = 4. !Y = 5. !Z = 6. !W = 7. !P = 8. !R = 9. !******************************** 10. !******************************** 11. !MIRROR UTOOL [1] 12. !X = 13. !Y = 14. !Z = 15. !W = 16. !P = 17. !R = 18. !********************************
Fig. 9.25.1(b) New tool and user coordinates displayed by a mirrored shift destination program
Additional information If user coordinate #0 is used for the entire program, the mirrored user coordinates are not written to the shift destination program. Table 9.25.1 lists and describes the items that must be set up to use the mirror shift option. Use Procedure 9-26 to perform program mirroring using the cross car mirror shift option. - 681 -
9.UTILITY
B-82594EN-4/01
Table 9.25.1 Cross car mirror shift setup items Item
Description
Conversion source program
This item is the name of the program to be processed using the cross car mirror shift option.
Shift destination program
This item is the name of the resulting program that will contain the results from performing the cross car mirror shift option.
Procedure 9-26 Performing the cross car mirror shift option
Step 1. 2. 3. 4.
Press [MENUS]. Select UTILITIES. Press [F1, [TYPE]]. Select Prog ToolBox. The following menu appears. Prog ToolBox 1 Cross Car Mirror 2 Flip Knuckle 3 Limit Set
5.
Move the cursor to Cross Car Mirror and press [ENTER]. The following menu appears. Prog ToolBox Cross Car Mirror 1 Source Program: [STYLE] 2 Destination Program: [MIRROR] 0% of program done
6.
Move the cursor to Source Program and press [F4, [CHOICE]]. Select the name of the program to be mirrored and press [ENTER]. 7. If it is necessary to use a name other than MIRROR.TP for the shift destination program, move the cursor to [Destination Program] and press [ENTER]. Type the name to be given to the resulting mirrored program and press [ENTER]. 8. To begin mirroring, press [F3, EXECUTE].
- 682 -
9.UTILITY
B-82594EN-4/01
- Additional information If the destination program already exists, a prompt is given to ask whether to continue. Selecting YES causes the existing program to be overwritten. If the existing program must be preserved, select NO and type a different program name. The percentage how much mirroring has been done is displayed as follows: X% of program done
9.
If an error occurs during the mirroring process, follow the steps below to display the FR:MIRROR.DT file and to get detailed error information. a. Press [MENUS]. b. Select [FILE]. c. Press [F1, [TYPE]]. d. Select [File]. e. Press [F5, [UTIL]]. f. Select Set Device g. Move the cursor to FROM Disk (FR:) and press [ENTER]. h. Press [F2, [DIR]]. i. Select *.* and press [ENTER]. j. Move the cursor to MIRROR.DT. k. Press [NEXT, >] and then [F3, DISPLAY]. The file is displayed on the screen. l. To keep the display, press [F4, YES]. Otherwise, press [F5, NO]. m. After displaying the file, press any key to continue. 10. If the power supply is cut off while a program is being mirrored, follow the steps below. a. Recover power. b. Delete the specified shift destination program (by default, MIRROR.TP). c. Repeat the cross car mirror shift option procedure.
- 683 -
9.UTILITY
9.25.2
B-82594EN-4/01
Flip Knuckle The flip knuckle option enables a knuckle configuration (wrist) to be rotated in the TP program. The option can be used to rotate the wide side of the robot’s wrist 180 degrees, in order to prevent hoses and cables from rubbing on it. If cables run across the narrow side of the wrist, it is less likely that they rub on it when the robot moves. See Fig. 9.25.2. If cables rub on the wrist when the flip knuckle option is not in use, it is necessary to re-teach the robot program so as to re-orient the wrist. The flip knuckle option changes the orientation of the wrist for all points in a program automatically so as to prevent possible problems in wrist rotation. The flip knuckle option is often used after the cross car mirror shift option, so that the mirrored TP program can better duplicate the original TP program and prevent hoses and cables from rubbing the wrist. When joints are flipped, all of the related positions in the specified source program are flipped. The [Flip Type] item on the [Flip Knuckle] menu can be used to specify the way the joints are flipped. If a joint error occurs when some positions in the program are flipped, try again after re-teaching those positions to suppress the error or selecting another [Flip Type].
Standard knuckle--Axis 4 is not rotated
Standard knuckle--Axis 4 is rotated 180°
Fig. 9.25.2 Flip knuckle option
- 684 -
9.UTILITY
B-82594EN-4/01
Table 9.25.2 lists and describes the items to be set up to use the flip knuckle option. Use Procedure 9-27 to perform the flip knuckle option. Table 9.25.2 Flip knuckle setup items Item
Description
Conversion source program
This item is the name of the program to be processed using the flip knuckle option.
Conversion destination program
This item is the name of the resulting program that will contain the results from performing the flip knuckle option.
Flip type
This item is the way the knuckle is flipped. • Type 1 (+ -):J4 = +180 J6 = -180 • Type 2 (- +):J4 = -180 J6 = + 180 • Type 3 (+ +):J4 = +180 J6 = +180 • Type 4 (- -):J4 = -180 J6 = -180
Procedure 9-27 Performing the flip knuckle option
Step 1. 2. 3. 4.
Press [MENUS]. Select UTILITIES. Press [F1, [TYPE]]. Select [Prog ToolBox]. The following menu appears. Prog 1 2 3
5.
ToolBox Cross Car Mirror Flip Knuckle Limit Set
Move the cursor to Flip Knuckle and press [ENTER]. The following menu appears. Prog ToolBox Flip Knuckle 1 Source Program: STYLE 2 Destination Program: FLIP 3 Flip Type: Type1(+-) 0% of program done
6. 7. 8. 9.
Move the cursor to Source Program and press [F4, [CHOICE]]. Select the name of the desired program and press [ENTER]. Move the cursor to Destination Program and press [ENTER]. Type the name of the program for containing the resulting flipped program and press [ENTER]. Move the cursor to [Flip Type] and press [F4, [CHOICE]] to select the flip type to be used. See Table 9.25.2. To begin knuckle flipping, press [F3, EXECUTE]. - 685 -
9.UTILITY
B-82594EN-4/01
- Additional information If the destination program already exists, a prompt is given to ask whether to continue. Selecting YES causes the existing program to be overwritten. If the existing program must be preserved, select NO and type a different program name. The percentage how much knuckle flipping has been done is displayed as follows: X% of program done
- Additional information If the knuckle was not flipped because of a joint limit being detected, a message is displayed to prompt to specify whether to continue. • Choosing to continue causes the destination program to be written together with the point that caused the joint limit to be detected. The point is written to the FR:FLIP.DT file. If an attempt is made to execute the destination program, a limit error occurs on the point where the joint limit was detected. It is impossible to move to the point unless the point is re-taught to suppress the limit error. • Choosing not to continue prevents the destination program from being written and enables another flip type to be selected for retry. 10. If the power supply is cut off while a program is being flipped, follow the steps below. a. Recover power. b. Delete the specified conversion destination program (by default, FLIP.TP). c. Repeat the flip knuckle option procedure.
- 686 -
9.UTILITY
B-82594EN-4/01
9.25.3
Soft Limit Setting Using the soft limit setting option enables the software axis limits for a robot to be determined automatically; so the hard stop locations for the J1 axis can be determined. Setting up axis limits without using the soft limit setting option requires executing all programs step by step, recording the maximum value for each angle before the axis joint limits can be set up manually. It also requires jogging the robot to the position limits specific to the J1 axis and determining the best hardware stop position for the J1 axis manually. The soft limit setting option reads all of the programmed positions on the robot automatically and determines the maximum and minimum taught joint angles used in all programs. It then uses the information to set up the specified joint limits automatically while taking a user-specified limit buffer into account. The soft limit setting option also reports the appropriate locations for the J1 axis hard stop according to the same maximum taught joint angle for all programs. By default, software axis limits are set up only for the J1, J2, and J3 axes. If necessary, they can be set up for other axes. A limit buffer is added to the detected limits to allow tolerance for motion between positions when a program is executed. When the robot moves from one position to another, the motion of the robot between the positions might get out of the axis limits. The limit buffer is applied to the detected maximum and minimum taught points to ease the axis limits so that a joint limit error will not occur on the robot motion between the taught points. A limit buffer can be set anywhere between 0 and 50 degrees. A limit buffer of 10 degrees is set up by default. In many cases, this limit buffer degree provides adequate ease. If many limit errors occur during program execution after the soft limit setting option is used, increase the limit buffer and try again. Before limits are set up, axes to which the limits are to be applied must be selected and, and if necessary, the limit buffer value must be re-set. Factory-set limits can be restored if newly set values become unnecessary.
Using the limit setting option Table 9.25.3 lists each soft limit setup item. Use Procedure 9-28 to calculate mounting locations for limit blocks on the robot flange. Table 9.25.3 Toolbox soft limit setup menu items Item
Description
Axis
This item is the number assigned to the axis for which limits can be set up.
Set Limit
This item indicates whether a limit has been set up.
- 687 -
9.UTILITY
B-82594EN-4/01
Procedure 9-28 Using the soft limit setting option to set up software axis limits
Step 1. 2. 3. 4.
Press [MENUS]. Select UTILITIES. Press [F1, [TYPE]]. Select Prog ToolBox. The following menu appears. Prog ToolBox 1 Cross Car Mirror 2 Fkip Knuckle 3 Limit Set
5.
Move the cursor to [Limit Set] and press following menu appears. Prog ToolBox Limit Set Axis 1 2 3 4 5 6 Limits Buffer:
6.
7.
[ENTER]. The
Set Limit Yes Yes Yes No No No 10 deg
To select an axis for limit setting, follow the steps below: a. Move the cursor to the number assigned to a desired axis. b. Press [F4, Yes] to select the axis. If [F5, No] is pressed, no limit is set up for the axis, To specify a limit buffer, move the cursor to Limits buffer, enter a degree, and press [ENTER].
- 688 -
9.UTILITY
B-82594EN-4/01
8.
To set up the axis limits, press [F3, EXECUTE]. When limit setting is completed, the following information is displayed on the screen. Prog ToolBox New Limits Axis -J1 -J2 -J3 -J4 -J5 -J6 -J7 -J8 -J9 Min Hole# for Min Hole# for Min Hole# for Max Hole# for YOU MUST COLD
LOWER UPPER -57 53 dg -15 -15 dg -15 30 dg -190 200 dg -10 90 dg -100 280 dg 0 0 dg 0 0 dg 0 0 dg J1: -4 offset toward - 3 J1: 4 offset toward 4 J2: -3 Max Hole# 0 J3: 0 Max Hole# 2 START TO TAKE EFFECT
The displayed mechanical stop numbers indicate the locations of the limit blocks on the J1, J2, and J3 axes. Mounting the limit block on the J1 axis requires aligning the hole at the center of the limit block with the reported J1 axis mechanical stop hole on the base of the robot. Additional information The displayed mechanical stop numbers indicate the positions of the center bolt hole on each mechanical stop. Note: The current version does not support the mounting positions of mechanical stops. Additional information The following operation is not supported on some robot models. 9. To reset the axis limits to their factory settings, press [F2, DEFAULT]. Additional information Enabling new software axis limit settings always requires cold-starting the controller. 10. After axis limit setting is completed, enable the new software axis limit settings by cold-starting the controller according to the following steps. a. If the controller is already on, turn it off. b. On the teach pendant, press and hold down the [SHIFT] and [RESET] keys. c. While still holding down the teach pendant keys, turn the power on. d. After the teach pendant has displayed its menu, release the teach pendant keys.
- Additional information If many joint limit errors occur during program execution, increase the limit buffer and re-run the program. - 689 -
10. PALLETIZING FUNCTION
10
B-82594EN-4/01
PALLETIZING FUNCTION This chapter explains the palletizing function. Contents of this chapter 10.1 10.2 10.3 10.4 10.5 10.6 10.7
PALLETIZING FUNCTION ...................................................691 PALLETIZING INSTRUCTIONS...........................................694 TEACHING THE PALLETIZING FUNCTION .....................696 EXECUTING THE PALLETIZING FUNCTION...................721 MODIFYING THE PALLETIZING FUNCTION...................725 PALLETIZING FUNCTION WITH EXTENDED AXES ......727 PALLETIZING ALL-POINT TEACHING .............................728
- 690 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
10.1
PALLETIZING FUNCTION
Palletizing function Palletizing is a function for the orderly stacking of workpieces by only teaching several representative points. • A stacking pattern can be created easily by teaching representative stack points. • A path pattern can be created by teaching path points (approach points and retraction points). • Multiple path patterns can be set to perform palletizing in a wide variety of patterns.
Fig. 10.1 (a) Palletizing
Structure of the palletizing function The palletizing function consists of the following two patterns: • Stacking pattern : Determines the method of stacking workpieces. • Path pattern : Determines the path along which the robot hand moves to stack workpieces.
Fig. 10.1 (b) Palletizing Pattern
- 691 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
Types of palletizing There are the following four types of palletizing according to the methods for setting stack and path patterns (See Section 10.3). • Palletizing B and palletizing BX • Palletizing E and palletizing EX
- Palletizing B Palletizing B only the palletizing-B function can be taught. Palletizing B can achieve a comparatively easy stacking pattern by one kind of path pattern.
Fig. 10.1 (c) Palletizing-B Function
- Palletizing E Palletizing E can be used for more complex stack patterns (such as when the attitudes of workpieces are to be changed or when the shape made by the stacked workpieces, as viewed from below, is not a parallelogram).
Fig. 10.1 (d) Palletizing E
- 692 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
- Palletizing BX and EX For palletizing BX and EX, multiple path patterns can be set. For palletizing B and E, only one path pattern can be set.
Fig. 10.1 (e) Palletizing BX and EX
- 693 -
10. PALLETIZING FUNCTION
10.2
B-82594EN-4/01
PALLETIZING INSTRUCTIONS The following palletizing instructions are available:
Instruction
Table 10.2 Palletizing instructions Function
Palletizing instruction
Palletizing motion instruction Palletizing end instruction
Calculates the current path based on a stacking pattern, path pattern, and the value held in the palletizing register, and rewrites the position data of a palletizing motion instruction. A motion instruction dedicated to palletizing. It has position data of an approach point, stack point, or retraction point. Increments (or decrements) the value of a palletizing register.
Palletizing instruction Based on the value held in the palletizing register, the palletizing instruction calculates the position of the current stack point from a stack pattern, and also calculates the current path from a path pattern. It then rewrites the position data of a palletizing motion instruction.
Fig. 10.2 (a) Format of the Palletizing Instruction
Palletizing motion instruction The palletizing motion instruction is a motion instruction that uses three path points ─ an approach point, stack point, and retraction point ─ as position data. This instruction is dedicated to palletizing. Each palletizing instruction rewrites such position data.
Fig. 10.2 (b) Format of the Palletizing Motion Instruction
- 694 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
Palletizing end instruction The palletizing end instruction calculates the next stack point and increments (or decrements) the palletizing register value.
Fig. 10.2 (c) Format of the Palletizing End Instruction
Example
1: 2: 3: 4: 5: 6: 7: 8:
J L L L J
PALLETIZING-B_3 PAL_3[ A_2 ] 50% CNT50 PAL_3[ A_1 ] 100mm/sec CNT10 PAL_3[ BTM ] 50mm/sec FINE hand1 open PAL_3[ R_1 ] 100mm/sec CNT10 PAL_3[ R_2 ] 50% CNT50 PALLETIZING-END_3
- Palletizing number Upon completion of the teaching of palletizing data, palletizing numbers are written automatically together with the instructions (palletizing instruction, palletizing motion instructions, and palletizing end instruction). When a new palletizing operation is taught, a palletizing number is assigned automatically.
Palletizing register instruction The palletizing register instruction is used to control palletizing. It performs stack point specification, comparison, and branch. (See Subsection 10.4.1)
(1 to 16)
Fig. 10.2 (d) Palletizing Register
- 695 -
10. PALLETIZING FUNCTION
10.3
B-82594EN-4/01
TEACHING THE PALLETIZING FUNCTION The palletizing function is taught using the following procedure:
Fig. 10.3 Procedure for Teaching the Palletizing Function
The palletizing function is taught on the palletizing edit screens. One of the palletizing edit screens appears automatically when a palletizing instruction is selected. When the palletizing function is taught, necessary palletizing instructions such as a palletizing instruction, palletizing motion instruction, and palletizing end instruction are inserted automatically. The following sections explain the teaching of palletizing EX. For palletizing B, BX, or E, assume that some functions of palletizing EX are restricted.
NOTE To improve the motion accuracy of palletizing, TCP should be accurately set. ( See Subsection 3.9.1,”Setting a Tool Coordinate System”)
- 696 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
10.3.1
Selecting a Palletizing Instruction To select a pallet instruction, select the type of palletizing to be taught (palletizing B, BX, E, or EX).
Procedure 10-1
Selecting a palletizing instruction
Condition ■ ■
Make sure that the teach pendant is enabled. Make sure that the palletizing instruction is selected on the program edit screen.
1
Press NEXT “>” to display the next page. Press F1 “[INST]” to display a submenu.
2
Select “Palletizing.”
Step
- 697 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
3
10.3.2
Select “PALLETIZING-EX.” The screen then changes to the initial data input screen automatically, one of the palletizing edit screen.
Inputting Initial Data On the initial data input screen, specify how palletizing is performed. The data set on the initial data input screen is used for subsequent teach screens. The initial data screen contains the following items:
Table 10.3.2 (a) Types of Palletizing Arrangement mode Layer pattern Attitude control B BX
2-point teaching only 2-point teaching only
Not set Not set
- 698 -
Always fixed Always fixed
Path pattern count 1 1 to 16
10. PALLETIZING FUNCTION
B-82594EN-4/01
Arrangement mode E EX
2-point teaching, all-point teaching, or interval specification 2-point teaching, all-point teaching, or interval specification
Layer pattern
Attitude control
Path pattern count
Set
Fixed or split
1
Set
Fixed or split
1 to 16
When a pallet instruction is selected, the initial data input screen corresponding to the selected type of palletizing appears. For palletizing EX, all palletizing functions can be specified. For palletizing B, BX, and E, restrictions are imposed on the specification of the functions. This section explains how to enter initial data for palletizing EX. For palletizing B, BX, or E, assume that some functions of palletizing EX are restricted. Table 10.3.2 (b) Initial Palletizing Data Palletizing number Palletizing type
Register increment Palletizing register Order Numbers of rows, columns, and layers Arrangement mode Attitude control Layer pattern count Number of approach points Number of retraction points Path pattern count
A number is assigned automatically when a palletizing statement is taught. PALLETIZING_N: 1 to 16 Specify whether the palletizing register is to be incremented or decremented by the palletizing end instruction. (See Subsection 10.4.1.) Select stacking (PALLET) or unstacking (DEPALLET). Specify the value by which the value held in the palletizing register is to be incremented or decremented by the palletizing end instruction. (See Subsection 10.4.1.) Specify the palletizing register to be used by the palletizing instruction and palletizing end instruction. Specify the stacking (unstacking) order of row, column, and layer. R: Row, C: Column, L: Layer Numbers of rows, columns, and layers for a stacking pattern. (See Subsection 10.3.3.) 1 to 127 How rows, columns, and layers are arranged for a stack pattern. The 2-point or all-point teaching, or interval specification can be specified (only for palletizing E or EX). Control the attitude at rows, columns, and layers for a stacking pattern. Select E or EX. How workpieces are stacked can be specified for each layer (only for palletizing E or EX). 1 to 16 Number of approach points in a path pattern. (See Subsection 10.3.5.) 0 to 7 Number of retraction points in a path pattern. (See Subsection 10.3.5.) 0 to 7 Number of path patterns (Subsection 10.3.4) (only for palletizing BX or EX). 1 to 16
Initial data related to the stacking method In the palletizing function, the stack point is controlled using a palletizing register. (See Subsection 10.4.1, “Palletizing Register.”) How the palletizing register is controlled can be specified as initial data. According to this data, the way of stacking is determined.
- 699 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
• •
•
For the pallet type (TYPE), specify either PALLET or DEPALLET (standard setting: PALLET). (See Subsection 10.4.1, “Palletizing Register.”) For the register increment (INCR), specify by which amount the stack (unstack) position advances or retracts. That is, specify a value by which the palletizing register is incremented or decremented by the palletizing end instruction. The standard setting is 1. (See Subsection 10.4.1, “Palletizing Register.”) As the palletizing register, specify the register number of a palletizing register used for stack control.
CAUTION Make sure that the specified palletizing register number is not used by another palletizing function. •
For the order (ORDER), specify the stacking/unstacking order of row, column, and layer.
Fig. 10.3.2 Palletizing Order
Initial data related to a stacking pattern As the stacking pattern data, specify the numbers of rows, columns, and layers, attitude control type and also specify whether to provide an auxiliary position. (See Subsection 10.3.3, “Teaching a Stacking Pattern.”)
- 700 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
Initial data related to a path pattern As the initial path pattern data, specify the number of approach points and the number of retraction points. (See Subsection 10.3.5, “Teaching a Path Pattern.”)
Procedure 10-2
Inputting initial palletizing data
Step 1
As the palletizing instruction, select palletizing-EX. The initial data input screen then appears. (See Subsection 10.3.1, “Selecting a Palletizing Instruction.”)
NOTE PALLETIZING displayed on the initial data input screen indicates the fourth palletizing instruction in the program. 2
To enter a comment, follow the procedure below. a Place the cursor on the comment line, then press the ENTER key. The character input submenu appears.
b c
Select the type of character input to be used ─ upper case, lower case, punctuation or options ─ with the ↑ and ↓ keys. Press an appropriate function key, then enter characters. - 701 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
d
After a comment has been completely entered, press the ENTER key.
3
To select a palletizing type, move the cursor to the TYPE field, then select a function key.
4
To enter a numeric value, press a numeric key, then press the ENTER key.
5
Specify a palletizing order by selecting the function keys in the target order.
- 702 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
After the second item has been selected, the third item is determined automatically.
6
To specify the type of attitude control, move the cursor to the setting field and select the function key.
7
To select whether there is an auxiliary position or not, move the cursor to the setting field and select function key menu.
8
To specify whether to set auxiliary points, position the cursor at the auxiliary point field and select the desired function key menu.
NOTE When specifying the setting of auxiliary points, also select either of FIX/INTER. 9 10
Enter the approach point count and retraction point count. To stop the initial data setting, press F1 “PROG.”
- 703 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
CAUTION When the initial data setting is stopped before it is completed, the values set up to that time are invalidated.
11
When all data items have been entered, press F5 “DONE.” The initial data input screen then disappears and the palletizing stacking pattern teach screen appears.
When the palletizing stacking pattern teach screen is displayed after the setting or changing of initial palletizing data is completed with F5 “DONE,” the palletizing register is initialized automatically. (See Subsection 10.4.1, “Palletizing Register.”)
- 704 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
10.3.3
Teaching a Stacking Pattern On the palletizing stacking pattern teach screen, teach representative stack points of a stacking pattern. From these representative points, a target stack point is calculated automatically at the time of palletizing.
With or without an auxiliary position A list of the positions to be taught is displayed based on the initial palletizing data. Following this list, teach the positions of the representative stack points. For the stacking pattern without an auxiliary position, individually teach four tops of the quadrangle of the stacking pattern.
Fig. 10.3.3 (a) Stacking Pattern with No Auxiliary Position
- 705 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
For a stacking pattern with an auxiliary position, when the shape of the first layer is a trapezoid, also teach the fifth position using the function provided.
Fig. 10.3.3 (b) Stacking Pattern with an Auxiliary Position
Types of arrangement modes/2-point teaching When 2-point teaching is selected, teach the representative two points at both ends to set all the points in the row, column, and layer directions (standard).
NOTE The following explanation is not relevant to palletizing B and BX. See Subsection 10.3.4.
Fig. 10.3.3 (c) Teaching Method by 2-Point Teaching
- 706 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
All-point teaching When selecting all-point teaching, directly teach all the points in the row, column, and layer directions.
Fig. 10.3.3 (d) Teaching Method by All-Point Teaching
Interval specification When selecting the interval specification, specify the two points at both ends in each of the row, column, and layer directions, as well as the distance between workpieces, to set all points.
Fig. 10.3.3 (e) Teaching Method by Interval Specification
- 707 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
Types of attitude control When the fixed attitude is specified, workpieces at all the stack points always take the attitude taught at point [1,1,1] (standard).
Fig. 10.3.3 (f) Attitudes of Workpieces at Stack Points when the Fixed Attitude Is Specified
For the split attitude, when 2-point teaching is specified, workpieces take the attitudes obtained by splitting the attitudes taught at the two end points. When all-point teaching is specified, workpieces take the attitudes at the taught points.
Fig. 10.3.3 (g) Attitudes of Workpieces at Stack Points when the Split Attitude Is Specified
Layer pattern count To change the stack pattern every few layers, enter the number of layer patterns. The layer pattern count is valid only when 2-point teaching is specified for the layer arrangement (for other cases, the layer pattern count is always 1). For the first layer, the workpieces are always stacked at the stack points in layer pattern 1. When the layer pattern count is N, the numbers of layers and layer patterns are the same until layer N. For layer (N+1) and beyond, layer patterns starting from layer pattern 1 are repeated. Specify the height of a layer only for layer pattern 1. For the height of each layer pattern, the deviation from the position in pattern 1 is corrected.
- 708 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
Fig. 10.3.3 (h) Attitude at the stacking point in division attitude
When the total number of layers is less than 16, a number not greater than the total number can be set for the layer pattern count. If a number less than the layer pattern count is subsequently specified for the number of layers, the layer pattern count is automatically changed to the number of layers.
Procedure 10-3
Teaching a palletizing stacking pattern
Step 1
Based on the initial data setting, a list of stack points to be taught is displayed.
NOTE The number of representative stack points to be recorded depends on the numbers of rows, columns, and of layers set on the initial data input screen. In the above sample screen, four rows, three columns, and five layers are set. For each point, row, column, and then layer numbers are specified. 2
Move the robot by jog feed to a position which is to be taught as a representative stack point.
- 709 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
3
Place the cursor on the appropriate line, and press F4 “RECORD” while holding down the SHIFT key. The current robot position is then recorded.
The positions not yet taught are marked with an asterisk. The positions already taught are marked with ”-”. 4 To display detailed position data for a taught representative stack point, move the cursor to the target stack point number, then press F5 “POSITION.” The detailed position data is then indicated.
Numeric values can also be entered directly to specify position data. To return to the previous stacking pattern teach screen, press F4 “DONE.”
- 710 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
5
Pressing the FWD key while holding down the SHIFT key causes the robot to move to the representative stack point indicated by the cursor. This operation can be performed to confirm the taught point.
6
To return to the previous initial data teach screen, press F1 “BACK.”
7
Press F5 DONE to display the path pattern condition setting screen (BX or EX) or path pattern teaching screen (B or E) ( Subsection 10.3.4 or 10.3.5).
NOTE When layer patterns are used (E or EX) and F5 DONE is pressed, the screen for specifying the stack pattern for the next layer appears.
- 711 -
10. PALLETIZING FUNCTION
10.3.4
B-82594EN-4/01
Setting Path Pattern Conditions The screen explained in this section is not displayed for palletizing B or E. See Subsection 10.3.5. The palletizing path pattern condition setting screen is used to set conditions indicating which path pattern is to be used for each stack point in advance when multiple path patterns are to be set on the path pattern teaching screen (See Subsection 10.3.5). For palletizing BX and EX, multiple path patterns can be set independently for stack points. For palletizing B and E, this screen is not displayed because only one path pattern can be set.
To specify a path for each stack point, as many path patterns as required must be specified when initial data is set. For each path pattern, set a path pattern condition.
Fig. 10.3.4 (a) Palletizing Using Three Path Patterns
How to use path pattern conditions •
•
The execution of palletizing uses the path pattern with the condition number for which the row, column, and layer numbers at the stack point match the row, column, and layer (element) values of a path pattern condition. In direct specification mode, specify numbers between 1 to 127 for a stack point. An asterisk indicates an arbitrary stack point.
- 712 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
•
In the remainder specification mode, specify path pattern condition element ”m-n” using a remainder system for a stack point. Layer element ”3-1” indicates a layer corresponding to a stack point value for which a remainder of 1 is obtained by dividing the value by 3. • If the current stack point corresponds to no path pattern condition, an alarm occurs. If the current stack point corresponds to two or more path pattern conditions, a path pattern condition is used according to the following conditions: a. A path pattern condition specified in direct specification mode is used. b. When two or more path pattern conditions are specified in direct specification mode, a path pattern condition specified in the remainder specification mode is used. When two or more path pattern conditions are specified in remainder specification mode, a path pattern condition in which the greatest value is specified for m is used. c. When two or more path pattern conditions satisfy conditions a and b above, the path pattern condition having the smallest path pattern condition number is used. The following shows the priority among the sample path pattern conditions: Example PTN [1] = [ * , 1 , 2 ] PTN [2] = [ * , * , 2 ] PTN [3] = [ * , 3–2 , 4-1 ] PTN [4] = [ * , * , 4–1 ] PTN [5] = [ * , * , 2–1 ] PTN [6] = [ * , * , * ] For the example shown on the previous page, pattern 1 is used for the stack points in column 1, pattern 2 is used for the stack points on column 2, and pattern 3 is used for the stack points in column 3.
Fig. 10.3.4 (b) Box Palletizing Using Eight Path Patterns
- 713 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
Example PTN [1] = [ 1 , 1 , 2–1 ] PTN [2] = [ 2 , 1 , 2–1 ] PTN [3] = [ 1 , 2 , 2–1 ] PTN [4] = [ 2 , 2 , 2–1 ] PTN [5] = [ 1 , 1 , 2–0 ] PTN [6] = [ 2 , 1 , 2–0 ] PTN [7] = [ 1 , 2 , 2–0 ] PTN [8] = [ 2 , 2 , 2–0 ] In the above example, eight path patterns are defined and repeated for every two layers because different paths must be set according to the box position.
Procedure 10-4
Setting palletizing path pattern conditions
Step 1
Condition items to be entered are displayed according to the value set for the pattern count as initial data.
2
In direct specification mode, position the cursor to the point to be changed and enter a numeric value. To specify an asterisk (*), enter zero.
- 714 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
3
In remainder specification mode, press F4 MODULO. The target item is divided into two sub-items. Enter a value for each sub-item.
4
To specify values in direct specification mode, press F3 DIRECT.
5
Press F1 BACK to display the previous stack point teaching screen again.
6
Press F5 DONE to display the next path pattern teaching screen.
- 715 -
10. PALLETIZING FUNCTION
10.3.5
B-82594EN-4/01
Teaching a Path Pattern On the palletizing path pattern teach screen, set several path points which are passed before and after a workpiece is stacked (or unstacked) at a stack point. The path points change depending on the position of the stack point.
Fig. 10.3.5 Palletizing Path
Procedure 10-5
Teaching a palletizing path pattern
Step 1
Based on the initial data setting, a list of the path points to be taught is displayed.
- 716 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
NOTE The number of path points to be recorded depends on the number of approach points set on the initial data input screen and the number of input points. In the above sample screen, the number of approach points is 2 and the number of retraction points is 2. 2 3
Move the robot by jog feed to a position which is to be taught as a path point. Move the cursor to the setting field to be taught and teach the position using one of the following operation. a Press F2 “POINT” while holding down the SHIFT key. When pressing F2 “POINT”, without pressing and holding the SHIFT key, default logical motion menu is displayed and then you can set the motion type or feedrate, etc. (This key is displayed only at teaching route pattern points.)
b
4
Press and hold the SHIFT key and press F4 “RECORD”.
The positions not yet taught are marked with an asterisk *. To display detailed position data for a taught path point, move the cursor to the target path point number, and press F5 “POSITION.” The detailed position data is then indicated.
- 717 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
Numeric values can also be entered directly to specify position data. To return to the previous path pattern teach screen, press F4 “DONE.”
5
Pressing the FWD key while holding down the SHIFT key causes the robot to move to the path point indicated by the cursor. This operation can be performed to confirm the taught point.
6
To return to the stacking pattern teach screen, press F1 “BACK.”
7
Press F5 “DONE” to terminate the palletizing edit screen and return to the program screen. The palletizing instructions are automatically written in the program.
8
Press F1 BACK to specify the previous path pattern. Press F5 DONE to specify the next path pattern.
- 718 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
9
After teaching of all the path patterns is complete, press F5 DONE to exit from the palletizing edit screen and display the program screen again. The palletizing instruction is automatically written in the program.
10
Editing, such as modifying a hand instruction executed at a stack position or the motion format at a path point can be performed on this program screen, in the same way as for normal programs.
For details of palletizing programs, see Section 10.4, “Executing the Palletizing Function.”
- 719 -
10. PALLETIZING FUNCTION
10.3.6
B-82594EN-4/01
Notes on Teaching the Palletizing Function •
•
• •
The palletizing function is enabled only when a program contains these three instructions: A palletizing instruction, palletizing motion instruction, and palletizing end instruction. When just one of the three instructions is taught into a subprogram by another operation such as copying, normal operation cannot be performed. When all palletizing data has been taught, palletizing numbers are automatically written together with the instructions (a palletizing instruction, palletizing motion instruction, and palletizing end instruction). The user need not be concerned about the duplication of these numbers in other programs. (Each program has its own data for palletizing numbers.) In the palletizing motion instruction, C (circular motion) cannot be specified as the motion format. When palletizing, with a system with extended axes, there are some special conditions. For a system with extended axes, refer to Section 10.6 ”Palletizing Function with extended axes”
- 720 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
10.4
EXECUTING THE PALLETIZING FUNCTION The execution of the palletizing function is shown below.
Fig. 10.4 (a) Example of Palletizing
Example
5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17:
J J L L L L L J J
P[1] 100% FINE P[2] 70% CNT50 P[3] 50mm/sec FINE hand close P[2] 100mm/sec CNT50 PALLETIZING-B_3 PAL_3[ A_1 ] 100mm/sec CNT10 PAL_3[ BTM ] 50mm/sec FINE hand open PAL_3[ R_1 ] 100mm/sec CNT10 PALLETIZING-END_3 P[2] 70% CNT50 P[1] 100% FINE
Fig. 10.4 (b) Workpiece Stacking Process
- 721 -
10. PALLETIZING FUNCTION
10.4.1
B-82594EN-4/01
Palletizing Register The palletizing register manages the position of the current stack point. When a palletizing instruction is executed, the value held in the palletizing register is referenced, and the actual stack point and path points are calculated. (See Section 7.5, “PALLETIZING REGISTER.”)
Fig. 10.4.1 (a) Palletizing Register
The palletizing register indicates the row, column, and layer which are used for calculating the position of the stack point when the palletizing instruction is executed.
Fig. 10.4.1 (b) Relationship between the Palletizing Register and Stack Point
Updating the Palletizing Register The palletizing register is incremented (or decremented) by executing the palletizing end instruction. The increment (decrement) method is determined depending on the initial data setting. For 2-row, 2-column, and 2-layer palletizing with ORDER = [RCL] specified, executing the palletizing end instruction changes the palletizing register as follows:
Fig. 10.4.1 (c) Example of 2-Row, 2-Column, and 2-Layer Palletizing
- 722 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
Table 10.4.1 (a) Incrementing (Decrementing) Order of the Palletizing Register TYPE = [PALLET] TYPE = [DEPALLET] INCR = [1] INCR = [-1] INCR = [1] INCR = [-1] Initial value ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
[1, 1, 1] [2, 1, 1] [1, 2, 1] [2, 2, 1] [1, 1, 2] [2, 1, 2] [1, 2, 2] [2, 2, 2] [1, 1, 1]
[2, 2, 1] [1, 2, 1] [2, 1, 1] [1, 1, 1] [2, 2, 2] [1, 2, 2] [2, 1, 2] [1, 1, 2] [2, 2, 1]
[2, 2, 2] [1, 2, 2] [2, 1, 2] [1, 1, 2] [2, 2, 1] [1, 2, 1] [2, 1, 1] [1, 1, 1] [2, 2, 2]
[1, 1, 2] [2, 1, 2] [1, 2, 2] [2, 2, 2] [1, 1, 1] [2, 1, 1] [1, 2, 1] [2, 2, 1] [1, 1, 2]
Initializing the palletizing register When F5 “DONE” is pressed upon completion of the setting or changing of initial palletizing data, the palletizing stacking pattern teach mode is set. At this time, the palletizing register is initialized automatically. (See Subsection 10.3.2, “Inputting Initial Data.”)
Initial data TYPE PALLET
DEPALLET
Table 10.4.1 (b) Initial Value of the Palletizing Register Initial value INCR ROWS COLUMNS
Positive value
1
Negative value
Total number of rows
Positive value
Total number of rows
Negative value
1
- 723 -
1 Total number of columns Total number of columns 1
LAYERS 1 1 Total number of layers Total number of layers
10. PALLETIZING FUNCTION
10.4.2
B-82594EN-4/01
Controlling the Palletizing Function by a Palletizing Register In 5-row, 1-column, and 5-layer palletizing, suppress stack operation for the fifth workpiece in each even-numbered layer. (Stack five workpieces in odd-numbered layers, and stack four workpieces in even-numbered layers.)
Procedure 10-6
Displaying the palletizing status
Step 1
To display the palletizing status, place the cursor on the palletizing instruction, then press F5 “[LIST].” The current stack point and the value of the palletizing register are displayed.
- 724 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
10.5
MODIFYING THE PALLETIZING FUNCTION Modifying the palletizing function The palletizing data and palletizing instructions which were taught can be modified later.
Procedure 10-7
Modifying palletizing data
Step 1 2
Place the cursor on the palletizing instruction which is to be modified, then press F1 “[MODIFY]” to display the modification menu. Select a target palletizing edit screen in the modification menu.
To return to the previous palletizing edit screen, press F1 “BACK.” To proceed to the next palletizing edit screen, press F5 “DONE.”
NOTE After palletizing data has been modified, the normal edit screen can be called from any palletizing screen. In this case, the new data after modification is kept valid. 3
When the modification is completed, press NEXT “>” to display the next page. Then press F1 “PROG.”
- 725 -
10. PALLETIZING FUNCTION
Procedure 10-8
B-82594EN-4/01
Changing the palletizing number
Step 1
Place the cursor on the palletizing instruction having the palletizing number which is to be changed, then enter a new number.
At the same time the palletizing number of the palletizing instruction is changed, the palletizing numbers of the palletizing motion and palletizing end instructions are also changed.
CAUTION When changing palletizing numbers, make sure that the new numbers are not used by other palletizing instructions.
- 726 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
10.6
PALLETIZING FUNCTION WITH EXTENDED AXES This section explains the special items when using palletizing on a system with extended axes. When teaching the bottom point or route points for palletizing, which are different from the usual teaching of motion instruction, the position which is removed the position of extended axes is recorded.
Execution When palletizing is executed, palletizing will be done at the position of the extended axes at that time. (The robot does not automatically return to the position of the extended axes at teaching bottom points or route points.) For example, on a system with a linear extended axis, when the palletizing instruction is executed at a point 1000 mm away from the position at teaching palletizing, the robot will perform the same motion as taught at the position which is 1000 mm away from the teaching position.
Position teaching/modifying When teaching the bottom/route points for palletizing on a system with extended axes or modifying the position, the following attention is necessary. • When teaching bottom/route points for palletizing, it must be done at the fixed point. When the position of extended axes shifts while teaching the bottom/route points for the same palletizing, the robot will follow a different path then the taught path when the program is executed. • When modifying the position, move the robot to the position of the extended axes at teaching bottom/route points before modifying.
Fig. 10.6 Palletizing function with extended axes
- 727 -
10. PALLETIZING FUNCTION
10.7
B-82594EN-4/01
PALLETIZING ALL-POINT TEACHING Palletizing all-point teaching allows the stacking (or unloading) of workpieces without changing the taught form by changing a system variable.
Operation Set the following values to stack (or unload) workpieces without changing the taught attitude and form: 1 On the system variable screen, set system variable $PALCFG.$FREE_CFG_EN to TRUE (the initial value is TRUE). 2 On the palletizing initial data screen, set INTER for attitude control in the row, column, or layer direction for which FREE is specified as the arrangement mode. For each taught workpiece in the specified direction, all workpieces corresponding to the taught workpiece are stacked (or unloaded) with the same attitude and form as that for the taught workpiece. The following shows an example of palletizing for an irregular arrangement of four rows, two columns, and five layers.
Fig. 10.7 Palletizing All-Point Teaching
The following palletizing initial data is set: ROWS COLUMNS LAYERS
= = =
[4 [2 [5
FREE LINE LINE
INTER] FIX] FIX 1]
In this example, FREE and INTER are set in the row direction. When system variable $PALCFG.$FREE_CFG_EN is set to TRUE under this condition, the following forms are used: • Form for stacking (unloading) workpieces on row 1: Form in P[1,1,1] • Form for stacking (unloading) workpieces on row 2: Form in P[2,1,1] • Form for stacking (unloading) workpieces on row 3: Form in P[3,1,1] • Form for stacking (unloading) workpieces on row 4: Form in P[4,1,1] - 728 -
10. PALLETIZING FUNCTION
B-82594EN-4/01
Notes Note the following points when using this function: 1 FREE and INTER can be set at the same time in only one of the row, column, and layer directions (when this function is not to be used, set system variable $PALCFG.$FREE_CFG_EN to FALSE). This is because if FREE and INTER are set at the same time in two or more of the row, column, and layer directions, two or more forms to be taken at the position of an untaught workpiece (workpiece for which the stack point is calculated from the position of a taught workpiece) are made.
2
If such a setting is made in a program, the program causes the error indicated by PALT-024 Calculation error occurred and cannot be executed. Carefully teach a program so that the program is not stopped due to a form mismatch alarm. If the form in the current position differs from the form data for the destination position, the robot cannot move in Linear operation mode (a form mismatch alarm occurs and execution of the program is stopped). The form at a stack point is used for the form at an approach or retraction point during palletizing. Therefore, if the pallet operation instruction to be executed first is in Linear operation mode, a form mismatch may occur depending on the form of the robot when an attempt is made to execute the line. To avoid such a problem, specify Joint for the operation mode of the first pallet operation instruction. For example, to avoid a form mismatch alarm, the following programming can be used for palletizing with three approach points and two retraction points. : 10:PLLETIZING-EX_1 11:J PAL_1[A_3] 100% FINE 12:L PAL_1[A_2] 500mm/sec 13:L PAL_1[A_1] 300mm/sec 14:L PAL_1[BTM] 100mm/sec 15:Open hand 1 16:L PAL_1[R_1] 300mm/sec 17:L PAL_1[R_2] 500mm/sec 18:PALLETIZING-END_1 :
- 729 -
CNT50 CNT10 FINE CNT10 CNT50
11.FANUC iPendant
11
B-82594EN-4/01
FANUC iPendant Contents of this chapter 11.1 11.2 11.3 11.4 11.5
OVERVIEW.............................................................................731 APPEARANCE AND OPERATIONS.....................................732 TOUCH PANEL.......................................................................747 SETTING UP iPendant ............................................................748 RESTRICTIONS ......................................................................761
- 730 -
11.FANUC iPendant
B-82594EN-4/01
11.1
OVERVIEW The iPendant is an Internet-type robot teach pendant having a large color liquid-crystal display panel. This teach pendant allows you to reference multiple data items simultaneously and its visibility has been remarkably increased. The current user interface is also available with this teach pendant, so those who are familiar with operations of conventional teach pendants can use this teach pendant easily. This chapter mainly describes differences between the conventional teach pendant and iPendant. Operations which are not described in this manual are common to the conventional teach pendant and iPendant. The following items are different from those of the conventional teach pendant: • Software LED display While the conventional teach pendant uses 11 LEDs to display the status, the iPendant displays the status with icons in the status window on the screen. • Screen split function The iPendant can display two or three split screens as well as one screen to enable multiple data items to be checked at a time. • How to change the operation target screen when multiple screens are displayed When multiple screens are displayed simultaneously, the operation target screen can be changed in turn. • Function of displaying one screen and status subwindow This function displays information such as the current position and safety signals with icons in the status subwindow (left screen). • Screen menus displayed by pressing the MENU key and those displayed on the edit screen The screen menus which are all displayed at a time allow you to quickly move to a desired screen and quickly insert a required command. • Internet browser screen You can enter a URL to access data on the network. • Color display according to the alarm severity Each message on the alarm list screen is displayed in the color specified according to its severity. The iPendant is an optional function.
- 731 -
11.FANUC iPendant
11.2
B-82594EN-4/01
APPEARANCE AND OPERATIONS This chapter describes the appearance of the iPendant and operations specific to the iPendant.
11.2.1
Appearance and Switches Fig. 11.2.1 shows the locations of the emergency stop button, teach pendant enable switch, and deadman switches.
Emergency stop button
Deadman switches (*1)
Teach pendant enable switch
*1 Three-position switch
Fig. 11.2.1 Teach pendant switches
- 732 -
11.FANUC iPendant
B-82594EN-4/01
11.2.2
Key Switches Fig. 11.2.2 shows the iPendant key switch layout. This section describes the screen focus change/screen split key and Diagnose/Help key specific to the iPendant.
Screen focus change/ Screen split key
Diagnose/ Help key
Fig. 11.2.2 Teach pendant key switches
Key
Table 11.2.2 Menu-related key switches Function
Pressing this key singly changes the operation target screen. Pressing this key together with SHIFT key splits the screen (single Screen, double screens, triple screens, or status/single screen). Pressing this key singly moves to the hint screen.
Pressing this key together with the SHIFT key moves to the alarm screen.
- 733 -
11.FANUC iPendant
11.2.3
B-82594EN-4/01
Status Window The window at the top of the iPendant screen is called the status window. In this window, eight software LEDs, alarm indication, and override value are displayed. Each software LED is "on" when displayed together with an icon or "off" when displayed with no icon.
Table 11.2.3 Description of software LEDs LEDs (Upper: On, Lower: Off)
Description
Busy
Indicates that the robot is working. This LED is on during execution of a program. It is also on when the printer or floppy disk drive is busy.
Step
Indicates that the robot is in the step operation mode.
Hold
Indicates that the HOLD button is being held or the HOLD signal is input.
Fault
Indicates that an alarm occurs.
Run
Indicates that a program is being executed.
I/O
Application-specific LED. This is a sample LED for a handling tool.
Prod
Application-specific LED. This is a sample LED for a handling tool.
TCyc
Application-specific LED. This is a sample LED for a handling tool.
- 734 -
11.FANUC iPendant
B-82594EN-4/01
11.2.4
Splitting the Screen Pressing
key together with the SHIFT key displays the following
screen menu:
Fig. 11.2.4 (a) Screen split menu (one screen display)
Item Single Double Triple Status/Single Change focus
Table 11.2.4 Description of the screen split menu Description Displays only one data item on the screen. The screen is not split. Splits the screen into right and left screens. Splits the right screen into top and down screens and displays a total of three screens. Splits the screen into right and left screens. The right screen is slightly larger than the left screen and the status subwindow with icons is displayed on the left screen. Changes focus of the operation target screen when multiple screens are displayed.
- 735 -
11.FANUC iPendant
B-82594EN-4/01
Fig. 11.2.4 (b) Example of displaying double screens
Fig. 11.2.4 (c) Example of displaying triple screens
- 736 -
11.FANUC iPendant
B-82594EN-4/01
Fig. 11.2.4 (d) Example of displaying the status/single screen
- 737 -
11.FANUC iPendant
11.2.5
B-82594EN-4/01
Changing the Operation Target Screen Pressing the
key changes the operation target screen in turn.
The title line of the screen which can be operated is displayed in blue and the frame of the screen is displayed in red. Press the above key together with the SHIFT key. The following screen menu appears. By selecting “5. Change focus” from this menu, you can also change the operation target screen.
Fig. 11.2.5 Screen switch menu
- 738 -
11.FANUC iPendant
B-82594EN-4/01
11.2.6
Internet Browser Screen To display the internet browser screen, press the MENU key. The following screen menu appears:
Fig. 11.2.6 (a) Screen menu
Select “BROWSER” from the screen menu. The following screen appears:
Fig. 11.2.6 (b) Internet browser screen
- 739 -
11.FANUC iPendant
B-82594EN-4/01
Select ”Add a Link” and press the ENTER key. The following URL input screen appears:
Fig. 11.2.6 (c) URL input screen
Position the cursor on “Enter a Name” or”Enter an Address” in the above screen and press the ENTER key. The following software keyboard appears. Enter alphabetic and other characters. After confirming your entry, press the exit key at the lower right to exit the software keyboard.
- 740 -
11.FANUC iPendant
B-82594EN-4/01
In the following sample screen, the name and address have been entered. After you have entered the name and address, position the cursor on the continue button and press the ENTER key.
After the continue button is pressed, the registered link information is displayed as follows:
Fig. 11.2.6 (d) Link screen
- 741 -
11.FANUC iPendant
11.2.7
B-82594EN-4/01
Screen Selection Menu and Screen Menus on the Edit Screen Pressing the MENU key displays the following screen menu. Positioning the cursor on a menu item with displays its submenus at a time. Use the right arrow key to select the item corresponding to a screen to be displayed.
Fig. 11.2.7 (a) Screen selection menu
Pressing F1 “INST” on the edit screen displays the following screen menus. You can reference all commands at a time. Position the cursor on a desired command to insert it.
Fig. 11.2.7 (b) Screen menus on the edit screen
- 742 -
11.FANUC iPendant
B-82594EN-4/01
11.2.8
Status Subwindow The status subwindow displays various types of statuses graphically. To display the status subwindow, select “4 Status/Single” from the following screen menu:
The left screen of the following two screens is the status subwindow. Position the cursor on Position Display, Operator Panel or Safety Signals and press the ENTER key. The corresponding status screen appears.
Fig. 11.2.8 Status subwindow
- 743 -
11.FANUC iPendant
B-82594EN-4/01
11.2.8.1 Current position display When “Position Display” is selected, the following screen appears:
11.2.8.2 Operator panel status display When “Operator Panel” is selected, the following screen appears. Each graphic indicator is on or off according to the status of the remote device.
- 744 -
11.FANUC iPendant
B-82594EN-4/01
11.2.8.3 Safety signal status display When “Safety Panel” is selected, the following screen appears. Each graphic indicator is on or off according to the status of the corresponding safety signal.
11.2.9
Color Display According to the Alarm Severity On the following alarm history screen, each message is displayed in the color specified according to its alarm severity.
- 745 -
11.FANUC iPendant
B-82594EN-4/01
The color assigned to each alarm severity is listed below: Alarm severity NONE WARN PAUSE.L PAUSE.G
Color
Description
White
The program being executed is not affected. The program being executed stops, but can be restarted after the cause of the alarm is removed.
Yellow
STOP.L STOP.G SERVO SERVO2 ABORT.L ABORT.G SYSTEM RESET(*) SYST-026 System normal power up(*)
Yellow Red
The program being executed stops and cannot be restarted.
Red Red Blue Blue
NOTE Messages "RESET" and "SYST-026 System normal power up" are displayed in blue.
- 746 -
11.FANUC iPendant
B-82594EN-4/01
11.3
TOUCH PANEL iPendant provides a touch panel as an option. The screens on which operations can be performed using the touch panel are as follows. Note that not all operations can be performed using the touch panel. • • •
Operation Panel screen / BROWSER screen (Web browser screen) / Status subwindow screen Software keyboard Screen switching (When multiple screens are displayed, moving to the desired screen is accomplished by touching the screen.)
- 747 -
11.FANUC iPendant
11.4
B-82594EN-4/01
SETTING UP iPendant
Overview It is possible to customize various screens on iPendant. This section explains how to set up iPendant for customization.
User Views By using the screen User Views function, it is possible to save up to eight User Views statuses of frequently used user-defined single window or multi-window displays. For example, if an alarm screen, file screen, and I/O screen are usually displayed using a 3-screen window, this set of screens can be defined as screen User Views. When saved, the screen User Views is assigned a name, which is displayed as a User Views item on the display menu, so that User Views can be redisplayed by selecting it later. The User Views described earlier is displayed as Alarm｜FILE｜Cell I in the User Views list. To add a set of menus as User Views, use Procedure 11-1. To change a User Views list, use Procedure 11-2.
Procedure 13-1 Adding User Views
Step 1 On iPendant, display the set of screens to be added as User Views. 2 Press and hold down SHIFT and press the DISP key. 3 Select "User Views". For example, the screen below appears.
- 748 -
11.FANUC iPendant
B-82594EN-4/01
Fig. 11.4 (a) Adding User Views
1
2 3
Select "Add Current". The currently displayed screen set is added to the list as screen name (for a 1-screen display), screen name|screen name ([for a 2-screen display], or screen name|screen name|screen name (for a 3-screen display). For each User Views to be added, repeat steps 1 to 4. To display User Views saved in the User Views list, press and hold down Shift and press the DISP key. Move the cursor to User Views and select the User Views to be displayed from the User Views list.
- 749 -
11.FANUC iPendant
B-82594EN-4/01
Procedure 13-2 Changing User Views
Step 1 2 3 4
Press MENUS. Select SETUP. Press F1 [TYPE]. Select iPendant Setup. The iPendant General Setup screen appears. The screen below appears.
Fig. 11.4 (b) iPendant General Setup screen
- 750 -
11.FANUC iPendant
B-82594EN-4/01
5
Select iPendant User Views Setup. For example, the screen below appears.
Fig. 11.4 (c) iPendant User Views setup screen
6 7 8
To erase one item from the User Views list, move the cursor to the User Views to be erased and press F4 CLEAR. The User Views list is automatically redisplayed. To erase all items from the User Views list, press Shift and F4 ERASE. The User Views list is automatically erased. To display the main iPendant general setup screen, press F2 BACK.
- 751 -
11.FANUC iPendant
B-82594EN-4/01
Menu Favorites By using Menu Favorites, it is possible to generate and save a list of the most frequently displayed menus. To set a Menu Favorites list, use Procedure 11-3. To change a Menu Favorites list, use Procedure 11-4.
Procedure 13-3 Adding a menu to the Menu Favorites list
Step 1 2 3 4
Display the menu to be added as Menu Favorites menu. Press and hold down SHIFT and press the DISP key. Select Menu Favorites. Select "Add Current". The currently displayed menu is added to the list. See Fig. 11.4 (b).
Fig. 11.4 (d) Adding to Menu Favorites
5
To display a menu saved in the Menu Favorites list, press and hold down Shift and press the DISP key. Move the cursor to Menu Favorites and select a menu from the list. - 752 -
11.FANUC iPendant
B-82594EN-4/01
Procedure 13-4 Changing Menu Favorites
Step 1 2 3 4 5
Press MENUS. Select SETUP. Select F1 [TYPE]. Select iPendant Setup. Select iPendant Menus Favorite Setup. The screen below appears.
Fig. 11.4 (e) Changing Menus Favorites Setup screen
6 7 8
To erase one item from the Menu Favorites list, move the cursor to the item to be erased and press F4 CLEAR. The Menu Favorites list is automatically redisplayed. To erase all items from the Menu Favorites list, press Shift and F4 CLEAR. The Menu Favorites list is automatically erased. To display the main iPendant setup screen, press F2 BACK .
- 753 -
11.FANUC iPendant
B-82594EN-4/01
History The history list records the eight mostly recently displayed menus. This list is automatically generated and cannot be changed. When a name in the list is selected, the screen with that name appears.
Fig. 11.4 (f) History screen
Setting up the HMI screen When HMI is used on iPendant, it is possible to customize teach pendant screens according to application. By using the HMI screen customization function, it is possible to set up available menu options so that specific sets of HTM or STM menus are displayed. It is possible to display a default set of menus and to create a set of .HTM or .STM menus specific to the user and display it. User menus are saved to FRH:CGTP\USRHMIQK.HTM and FRH:CGTP\USRHMIFL.HTM. For remote connection, the default files are FRH:CGTP\REMHMIQK.HTM and FRH:CGTP\REMHMIFL.HTM. The default pages, which are created each time the controller is turned on, are FRH:CGTP\IPHMIQK.HTM and FRH:CGTP\IPHMIFL.HTM. Usually, operators cannot access FRH:CGTP\device, so that these files can never be changed or deleted accidentally. - 754 -
11.FANUC iPendant
B-82594EN-4/01
To create a user-defined HMI full menu or quick menu, use Procedure 11-5. To define and set up an HMI full menu, quick menu, and remote menu, use Procedure 11-6.
Procedure 13-5 Creating a user-defined HMI full menu or quick menu
Step 1 2 3 4
Press MENUS. Select SETUP Press F1 [TYPE]. Select iPendant Setup . The screen below appears.
Fig. 11.4 (g) iPendant setup screen
5
Select "iPendant HMI Setup". The screen below appears.
- 755 -
11.FANUC iPendant
B-82594EN-4/01
Fig. 11.4 (h) iPendant HMI Setup screen
6
7
With the initial settings, the iPendant HMI full menu is saved to IPHMIFL.HTM and the iPendant HMI quick menu is saved to IPHMIQK.HTM. By creating copies of these files and editing them, it is possible to create user-specific full and quick HMI menus. To create copies of the files initially set up, press F4 [BACKUP]. This causes a copy of each file to be saved to a standard device. Move the file copies to a personal computer so that they can be edited.
CAUTION The HMI full menu file (IPHMIFL.HTM) must have "iPendant Setup" as a menu item. If passwords can be used on the controller, the HMI quick menu file (IPHMIQK.HTM) must have [Passwords] as a menu item. Keep these menu items if required. If the menu item are missing, created menu files do not operate properly. 8 9
Add or delete menu items to or from these files, as required. Return the files to the controller. - 756 -
11.FANUC iPendant
B-82594EN-4/01
10
To set up and use the created files, use Procedure 11-6.
Procedure 11-6 Setting up selections on an HMI full menu, quick menu, and remote menu
Step 1 2 3 4 5 6
6
Press MENUS. Select SETUP. Press F1 [TYPE]. Select iPendant Setup. A screen similar to the one shown in Fig. 11.4 (e) appears. Select "iPendant HMI Setup". A screen similar to the one shown in Fig. 11.4 (f) appears. Then, it is possible to select the HTM or STM file to be displayed instead of a full menu, quick menu, remote full menu, and remote quick menu. a To select an HTM or STM file on the default device of the controller, click the blue bar located at the bottom of the menu to be set up. A list of available HTM and STM files appears. b Select the desired file and press "ENTER". c Continue to select files for individual menus ([User HMI Full] , [User HMI Quick] , [Remote HMI Full] , and [Remote HMI Quick]). d Press F3 [SUBMIT]. The name displayed on the blue bar is erased to indicate that setup is completed. To start a selected full or quick HMI menu mode or remote full or quick HMI menu mode, click the square next to the selection located at the bottom of the screen and press F3 [SUBMIT]. Press "F3", and the checkbox disappears to indicate that the selection is made. To set up an HMI full menu, press the "MENUS" key. The screen below appears.
- 757 -
11.FANUC iPendant
B-82594EN-4/01
Fig. 11.4 (i) iPendant HMI FULL Menu
To set up an HMI quick menu, press the "FCTN" key and select "QUICK/FULL MENUS". The screen below appears.
- 758 -
11.FANUC iPendant
B-82594EN-4/01
Fig. 11.4 (j) iPendant HMI QUICK Menu
- 759 -
11.FANUC iPendant
B-82594EN-4/01
8
To disable the "SELECT", "EDIT", or "DATA" key in HMI mode, scroll down and click the square next to the desired key name. For example, the screen below appears.
Fig. 11.4 (k) iPendant HMI setup screen, if the "DATA" key is to be disabled
After clicking the desired key, press F3 [SUBMIT]. After [F3] is pressed, the checkbox disappears to indicate that the selection is made.
CAUTION Each time the HMI setup screen appears, a check mark appears and the current settings are indicated. 9 10
To save all HMI files to the standard device, press F4 [BACKUP]. This causes all files to be copied from FRH:\CGTP\ to the standard device in overwrite mode. To display the previous menu, press F2 [BACK].
- 760 -
11.FANUC iPendant
B-82594EN-4/01
11.5
RESTRICTIONS •
•
Multiple program edit screens can be opened at a time. A screen can be opened in each window. The program to be executed is the one selected in the left window. The execution of a program from the teach pendant is possible only when the left window is the one that the user is working in. The edit screen is always displayed in the left window. When two or more screens are displayed at a time, the same menu screen may not be displayed on the screens. Example: Online position modification screen
*
NetFront by ACCESS Co. Ltd. is adopted for the Internet function of this product.
* *
NetFront is registered trademark of Access Co. Ltd. in Japan. Part of the software of this product includes modules developed by Independent JPEG Group. This product use a technology included in LZW patent of Unisys Co. Ltd. Please keep following restrictions. (1) Do not modify or copy the software of this product. Do not sale or provide the software extracted from this product. (2) Do not use the software of this product for different purpose from browser. (3) Do not use a technology included in LZW patent of Unisys Co. Ltd. without this product.
*
- 761 -
12.DISPENSE TOOL
12
B-82594EN-4/01
DISPENSE TOOL Contents of this chapter 12.1 OVERVIEW...........................................................................763 12.2 DISPENSETOOL COMMON SETUP ..................................764 12.3 SETTING UP THE CELL......................................................838 12.4 PLANNING AND CREATING A PROGRAM ....................858 12.5 PROGRAM ELEMENTS.......................................................871 12.6 TESTING A PROGRAM AND RUNNING PRODUCTION882 12.7 STATUS DISPLAYS AND INDICATORS ..........................898 12.8 PROGRAM AND FILE MANIPULATION..........................904 12.9 ADVANCED FUNCTIONS ..................................................905 12.10 NEMO PUMP ........................................................................908 12.11 ISD GEAR METER................................................................921
- 762 -
12.DISPENSE TOOL
B-82594EN-4/01
12.1
OVERVIEW
12.1.1
Controller
12.1.1.1 Type III analog output The FANUC software supports the type III signal for all of its analog output signals: Flow Command, Atomizing Air, and Prepressure. Although the type III signal can have the following three forms: 4 to 20 mA current signal, 1 to 5 volt signal, and 2 to 10 volt signal, the DispenseTool software supports only the 1 to 5 volt form. The FANUC software provides selections on the SETUP Equipment screen to select the type of analog output signals. If type III is selected, zero flow rate will have 1.0 volt output. Similarly, a full range of flow rate will have 5.0 volts output. This also applies to Atomizing Air and Prepressure output signals if type III is selected. The definition of the voltage values (bias, min, and max) in the setup screens is unchanged, regardless of the signal type selected, and is always in terms of a type II signal (0-10 volts). For example, a 1.0 volt bias is 10% of its full range. When converted into a type III signal, its effect becomes 0.4 volts in actual output, which is 10% of its full range. Use the following formula to convert a type II value to a type III value: Output_III = 1.0 + Output_II ×0.4
12.1.1.2 Motion TCP Speed Prediction (DispenseTool, DispenseTool Plug-in, and SpotTool+ only) TCP speed prediction improves the control of speed-dependent devices, such as dispensing equipment. The speed prediction lead-time can be adjusted to accommodate a variety of equipment and materials. When you set up the dispensing equipment, you can specify whether to use TCP speed prediction in the computation of the flow command.
Motion Groups DispenseTool supports one motion group only. Group mask must be set to [1,*,*,*,*] or [*,*,*,*,*]. When using SpotTool+ with dispense plug-in and multi-group motion all programs that use motion while dispensing are required to use group mask [1,*,*,*,*].
- 763 -
12.DISPENSE TOOL
B-82594EN-4/01
12.2
DISPENSETOOL COMMON SETUP
12.2.1
Setting Up DispenseTool Configuration You must set up the DispenseTool configuration you want before you use DispenseTool. Table 12.2.1 lists and describes each configuration item you can set. You set up these items only during Controlled start of the controller. Refer to Subsection B.1.3 for information on performing a Controlled start. Use Procedure 12-1 to set up DispenseTool configuration.
Item
Table 12.2.1 DispenseTool Configuration Item Description
F Number Number of Equipments default:: 1 range: 1 to 5 Number of Guns default: 13 range: 1 to 6 Equipment type: default: Var iable Orifice
This item is the robot’s F-Number. This item defines the maximum number of equipments to be set up and controlled by DispenseTool.
Beadshaping Air(Atomizing Air ) default: DISABLE Remote Start default: DISABLE Automatic Purge default: DISABLE Bubble Detect default: DISABLE Linear 2P Calibration default: DISABLE Channel 2 Analog Output default: DISABLE AccuSeal Advanced Feature
This item defines whether the dispensing system uses Beadshaping Air (Atomizing Air) in the dispensing material.
This item defines the number of guns to be set up and controlled by DispenseTool. This item defines the type of equipment you are using. (press F4, [CHOICE], to display the alternatives.) Valid alternatives are:
• ISD Servo Dispenser** (Includes variars ISD types) • Shot Meter • Gear Meter • Var iable Orifice • Press ure Regulator • Urethane Glass * • Clear Black * • IRD Dispenser**
This item defines whether the dispensing system uses the Remote Start feature. This item defines whether the dispensing system uses the Automatic Purge feature. This item defines whether the dispensing system uses the Bubble Detected feature. This item defines whether or not the Two Point Calibration feature is used. This item defines whether or not the Channel 2 Analog Output feature is used. This item defines whether or not the Adaptive Closed-Loop Flowrate Control (ACFC) is used. (AccuSeal features)
* **
These types of equipment require additional customization. These types of equipment require additional specific options to be loaded.
- 764 -
12.DISPENSE TOOL
B-82594EN-4/01
NOTE The controller interface for Shot Meter, Gear Meter, Variable Orifice, Pressure Regulator, Urethane Glass and Clear Black dispensers integrates well with the interface requirements for many dispense manufactures. However, it is strongly recommended that you verify the interface requirements before making your selection. Procedure 12-1 Setting Up DispenseTool Configuration
Steps 1
Perform a Controlled Start. a If the controller is turned on, turn it off. b Turn on the disconnect. c On the teach pendant, press and hold the PREV and NEXT keys. d While still pressing PREV and NEXT on the teach pendant, press the ON button on the operator panel. You will see a screen similar to the following. ---------- CONFIGURATION MENU --------— 1 Hot start 2 Cold start 3 Controlled start 4 Maintenance Select >
2
Select 3, Controlled start, and press ENTER. The DispenseTool Application Configuration Setup screen is displayed. You will see a screen similar to the following. Seal Config CONTROLLED START MENUS DispenseTool Application Configuration 1 F Number: F00000 2 Number of equipments: 1 3 Number of guns: 1 4 Equipment type: Variable Orifice 5 Beadshaping air: DISABLE 6 Remote start: DISABLE 7 Automatic purge: DISABLE 8 Bubble detect: DISABLE 9 Linear 2P calibration: DISABLE 10 Channel 2 analog output: DISABLE 11 AccuSeal advanced feature: DISABLE
3 4
To display help information , press NEXT, >, and then press F1, HELP. When you are finished displaying help information, press PREV. Move the cursor to the appropriate item and set it as desired.
- 765 -
12.DISPENSE TOOL
B-82594EN-4/01
5
If you want to change the number of equipment, move the cursor to Number of equipments and type in the appropriate value. You will see a prompt box similar to the following. You have changed the number of equipment. Press YES to confirm your change and wait for new sysvar reallocation. YES NO
NOTE You can configure multiple equipment of different types if you type a value larger than 1. 6 7
If you are sure that you want to change the number of equipments, select YES and press ENTER. To select a specific piece of equipment, press F3, EQUIP, and type the number of the piece of equipment. You will see a screen similar to the following. Seal Config CONTROLLED START MENUS E3 DispenseTool Application Configuration 1 F Number: F00000 2 Number of equipments: 1 3 Number of guns: 1 4 Equipment type: Variable Orifice 5 Beadshaping air: DISABLE 6 Remote start: DISABLE 7 Automatic purge: DISABLE 8 Bubble detect: DISABLE 9 Linear 2P calibration: DISABLE 10 Channel 2 analog output: DISABLE 11 AccuSeal advanced feature: DISAB
NOTE You can select different equipment types for different pieces of equipment. 8 9
When you are finished setting the DispenseTool configuration items, press FCTN. Select START (COLD). The controller will perform a Cold start. When it is finished, the UTILITIES Hints screen will be displayed.
- 766 -
12.DISPENSE TOOL
B-82594EN-4/01
12.2.2
Flow Rate Control
12.2.2.1 Overview This section includes information on concepts involved in flow rate control, including speed compensation, flow type, and flow rate calculation. This section contains descriptions of the concepts involved in flow rate control: • • •
Speed compensation Flow type Flow rate calculation
12.2.2.2 Speed compensation The rate at which material flows from the nozzle is usually proportional to robot speed in order to keep the amount of material constant along the seam. In general, • •
When the robot is moving slowly, the flow rate should be low. When the robot is moving quickly, the flow rate should be high.
Fig. 12.2.2.2 (a) shows an example of robot motion with variable robot speed.
Fig. 12.2.2.2 (a) Example of Robot Motion Variable Robot Speed
- 767 -
12.DISPENSE TOOL
B-82594EN-4/01
Fig. 12.2.2.2 (b) shows the robot speed profile.
Fig. 12.2.2.2 (b) Example Robot Speed Profile
DispenseTool uses three methods to compensate for robot speed while dispensing material: • Tool center point speed prediction (TCPP) • Prog rammed speed prediction (PROG) • No robot speed compensation (CONST) Tool center point speed prediction is the most accurate speed compensation method. This method is recommended for all applications in which it is critical that the flow rate be proportional to the robot speed. In TCP speed prediction, the robot looks ahead an amount of time equal to the EQUIPMENT anticipation time (specified in the current sealing schedule) to check what the robot speed will be. DispenseTool then adjusts the analog flow command signal to be proportional to what the robot speed will be after the EQUIPMENT anticipation time has elapsed.
- 768 -
12.DISPENSE TOOL
B-82594EN-4/01
Fig. 12.2.2.2 (c) shows an example of Tool center point speed prediction speed compensation.
Fig. 12.2.2.2 (c) Tool Center Point Speed Prediction Speed Compensation
*
The actual anticipation value is described in Subsection 12.2.4.
Programmed speed prediction is similar to TCP speed prediction in operation, but is partially accurate. In programmed speed prediction, the theoretical robot speed - the speed programmed in the PROCESS teach pendant program - is used to adjust the analog flow command signal. Programmed speed prediction is accurate when the robot is not accelerating, decelerating, going around corners, changing direction, or changing orientation.
- 769 -
12.DISPENSE TOOL
B-82594EN-4/01
Fig. 12.2.2.2 (d) shows an example of Programmed speed prediction speed compensation.
Fig. 12.2.2.2 (d) Programmed Speed Prediction Speed Compensation
Theno robot speed compensation method uses neither TCP nor programmed speed prediction. This is appropriate only for the very few applications in which the analog signal does not have to be proportional to the robot speed.
- 770 -
12.DISPENSE TOOL
B-82594EN-4/01
Fig. 12.2.2.2 (e) shows an example of no robot speed compensation.
Fig. 12.2.2.2 (e) No Robot Speed Compensation
Table 12.2.2.2 lists each method and when to use it. Refer to the sections that follow for a description of each speed compensation method.
Method
Table 12.2.2.2 Speed Compensation Methods Is it Proportional to Is it Accurate? Robot Speed?
Tool center point speed prediction (TCPP)
Yes
Programmed speed prediction (PROG)
Yes
No robot speed compensation (CONST)
No
Yes. This is the most accurate of the three methods. Only when the robot is not accelerating, decelerating, going around corners, changing direction, or changing orientation. Yes
Use this Method When... It is important for the flow rate to be proportional to the robot speed. The robot is moving at a constant speed in a straight line without changing orientation, decelerating, or accelerating. It is not important for the flow rate to be proportional to the robot speed.
NOTE The proper selection and usage of speed compensation methods depends upon the application process. - 771 -
12.DISPENSE TOOL
B-82594EN-4/01
12.2.2.3 Flow type Flow type defines how the flow of material will be measured. DispenseTool offers the following flow types: • • • • •
Bead width - measured in millimeters Percentage - of flow rate range Volume - measured in cc/meter Voltage - measured in a direct voltage to be applied to the analog output signal that controls the flow rate Pressure - measured in PSI or BAR
Table 12.2.2.3 lists the speed compensation methods that can be used for each flow type. Table 12.2.2.3 Speed Compensation Methods for Each Flow Type Flow Type Bead width (mm)
Percentage (%) Volume (cc/m)
Voltage (v) Pressure (PSI) Pressure (BAR)
Speed Compensation Method TCP speed prediction Programmed speed prediction No speed compensation No speed compensation TCP speed prediction Programmed speed prediction No speed compensation No speed compensation No speed compensation No speed compensation
You set the flow types in each Seal Schedule. Refer to Subsection 12.2.3
12.2.2.4 Flow rate calculation (traditional method) The flow rate is calculated based on the kind of speed compensation that is used. There is a separate flow rate calculation for flow types that use TCP speed prediction, programmed speed prediction, and no speed compensation. The equations for each kind of speed compensation are described as follows. Table 12.2.2.4 contains a description of each item used in these equations. Any flow type that usesTCP speed prediction uses the equation in Fig. 12.2.2.4 (a) to determine the flow rate.
Fig. 12.2.2.4 (a) Flow Rate Equation with TCP Speed Prediction
- 772 -
12.DISPENSE TOOL
B-82594EN-4/01
Any flow type that usesprogrammed speed prediction uses the equation in Fig. 12.2.2.4 (b) to determine the flow rate.
Fig. 12.2.2.4 (b) Flow Rate Equation with Programmed Speed Prediction
Any flow type that usesno speed compensation uses the equation in Fig. 12.2.2.4 (c) to determine the flow rate.
Fig. 12.2.2.4 (c) Flow Rate Equation with No Speed Compensation
NOTE To convert volts to ticks (which appear on I/O menus), multiply volts by 200.0. Item
Table 12.2.2.4 Items used in Flow Rate Calculation Equations Description
Flow_Rate_in_Seal_Schedule Scale_Factor_for_this_Flow_Type
Material_Factor_for_this_Equipment
Correction_Factor_in_Seal_Schedule
Tool_Center_Point_Predicted_Speed
This item obtains the desired flow rate in each sealing schedule. The units used correspond to the flow type you have selected in that schedule. This item is the scaling factor that is set up for each flow type during the flow rate control calibration procedure. There is a separate scale factor kept for each flow type. This factor is designed to convert the flow rate specified in each sealing schedule to a more useful internal designation for flow rate. This item is the Material Factor, as shown and edited on the SETUP Equipment screen. This is global for every sealing equipment. Material_Factor_for_this_Equipment is meant to be adjusted occasionally to increase or decrease the flow rate on a given equipment globally. This value is usually kept between 0.5 and 2.0. This item is the Correction Factor that appears in each Seal Schedule. Adjust this value when you want to change the analog flow command used when one Seal Schedule is active, but do not want to change the Flow Rate item on that schedule. This value is usually kept between 0.5 and 2.0. This item is determined by looking at what the robot speed will be after the the Equipment Delay has elapsed. The Equipment Delay is specified in each Seal Schedule. This value is very accurate and under normal circumstances, the best choice for the application. The only time this information is not accurate is when the TCP speed prediction system goes into error mode, such as from a "Speed Limit" error.
- 773 -
12.DISPENSE TOOL
B-82594EN-4/01
Item
Description
Predicted_Programmed_Speed
Flow_Rate_Bia s_for_this_Equipment
This item is the programmed speed (speed specified in your teach pendant program) that will predict the Equipment Delay. This value is not accurate when the robot is accelerating, decelerating, going around corners, changing direction, or changing orientation. TCP speed prediction is usually a better solution. This item is the Flow Rate Bias item that appears on the SETUP Equipment screen, in volts. This item is always added to the flow rate analog output. This item is 0.0 by default, and the normal range of values is between0.0 and 3.0.
12.2.2.5 Flow rate calculation: 2PNT (two point calibrated calculation method)
The 2PNT (two point) flow rate is calculated based on the type of two point calibration. Like the traditional method, 2PNT has a separate flow rate calculation for flow types that use TCP speed prediction and programmed speed prediction. The 2PNT equations for each kind of speed compensation are described as follows. Table 12.2.2.5 contains a description of each item used in these equations. Any 2PNT flow type that usesTCP speed prediction uses the equation in Fig. 12.2.2.5 (a) to determine the flow rate.
Fig. 12.2.2.5 (a) 2PNT Flow Rate Equation with TCP Speed Prediction
Any flow type that usesprogrammed speed prediction uses the equation in Fig. 12.2.2.5 (b) to determinethe flow rate output.
Fig. 12.2.2.5 (b) 2PNT Flow Rate Equation with Programmed Speed Prediction
- 774 -
12.DISPENSE TOOL
B-82594EN-4/01
NOTE 1 To convert volts to ticks (which appear on I/O menus), multiply volts by 200.0. 2 If you select this method, you must enable this in the Controlled Start configuration menu, and perform the 2PNT calibration. Refer to Subsection 12.2.6.6.
Item
Table 12.2.2.5 Items used in Flow Rate Calculation Equations Description
Flow_Rate_in_Seal_Schedule Scale_Factor_for_this_Flow_Type
Material_Factor_for_this_Equipment
Correction_Factor_in_Seal_Schedule
Tool_Center_Point_Predicted_Speed
Predicted_Programmed_Speed
Flow_Rate_Bia s_for_this_Equipment
2PNT_Bias
12.2.3
This item obtains the desired flow rate in each sealing schedule. The units used correspond to the flow type you have selected in that schedule. This item is the scaling factor that is set up for each flow type during the flow rate control calibration procedure. There is a separate scale factor kept for each flow type. This factor is designed to convert the flow rate specified in each sealing schedule to a more useful internal designation for flow rate. This item is the Material Factor, as shown and edited on the SETUP Equipment screen. This is global for every sealing equipment. Material_Factor_for_this_Equipment is meant to be adjusted occasionally to increase or decrease the flow rate on a given equipment globally. This value is usually kept between 0.5 and 2.0. This item is the Correction Factor that appears in each Seal Schedule. Adjust this value when you want to change the analog flow command used when one Seal Schedule is active, but do not want to change the Flow Rate item on that schedule. This value is usually kept between 0.5 and 2.0. This item is determined by looking at what the robot speed will be after the the Equipment Delay has elapsed. The Equipment Delay is specified in each Seal Schedule. This value is very accurate and under normal circumstances, the best choice for the application. The only time this information is not accurate is when the TCP speed prediction system goes into error mode, such as from a "Speed Limit" error. This item is the programmed speed (speed specified in your teach pendant program) that will predict the Equipment Delay. This value is not accurate when the robot is accelerating, decelerating, going around corners, changing direction, or changing orientation. TCP speed prediction is usually a better solution. This item is the Flow Rate Bias item that appears on the SETUP Equipment screen, in volts. This item is always added to the flow rate analog output. This item is 0.0 by default, and the normal range of values is between0.0 and 3.0. This item is a voltage bias obtained through 2PNT calibration. If the calibration is complete, the 2PNT_bias will be automatically added to the calculation equation.
Setting Up Schedules A dispensing sealing schedule is a list of items that specifies how you want the robot to dispense material for a specific situation. In a schedule, you specify items such as bead width, volume, atomizing air, and gun on delay. When you specify that the robot should dispense material using a particular schedule, the robot will dispense material using the information you defined in the schedule. - 775 -
12.DISPENSE TOOL
B-82594EN-4/01
You can access schedules from the DATA menu. There are two screens associated with schedules: the Seal Sched LISTING screen and the Seal Sched DETAIL screen. The LISTING screen displays limited information for all schedules in the robot (100 is the default number of schedules); information for only nine schedules can be displayed on one screen. The DETAIL screen allows you to display and change the complete information for a single schedule. You can switch between the display of each screen by pressing F2.
NOTE The selections on these screens vary depending on the type of equipment and how you configured it during the Controlled start. Table 12.2.3 lists and describes each schedule item for all types of dispensing equipment. Use Procedure 12-2 to display and modify a DispenseTool schedule. Refer to Subsection 12.2.4 for timing diagrams. Also refer to Subsection 12.2.1.
Item Schedule# default: 1 min: 1 default max: 100 Comment Flow type
Flow Model
Flow rate
Table 12.2.3 Schedule Items Description This item indicates the sealing schedule number. This information is displayed on both the LISTING and DETAIL screens.
This item describes the type of seal. The comment is displayed as part of the sealing instruction. This information is displayed on both the LISTING and DETAIL screens. This item defines how the flow of material will be measured. The following flow types are available: • TCPP Bead Width - Bead width (mm), using TCP speed prediction • PROG Bead Width - Bead width (mm), using programmed speed prediction • CONST Bead Width - Bead width (mm), using no speed prediction • Percentage • TCPP Volume - Volume (cc/min), using TCP speed prediction • PROG Volume - Volume (cc/min), using programmed speed prediction • CONST Volume - Volume (cc/min), using no speed prediction • Volts • Pressure (psi) • Pressure (bar) This information is displayed on both the LISTING and DETAIL screens. This item specifies the kind of flow model applied on the current schedule. Linear and Square flow models are available. If AccuSeal is enabled, the AccuFlow model will be available also. This item specifies the desired rate of material flow. The units used correspond to the flow type you have selected. This information is displayed on the DETAIL screen as "Flow Rate" and on the LISTING screen as "Value."
- 776 -
12.DISPENSE TOOL
B-82594EN-4/01
Item Guns used
Equip. ant-time*** default: 0 msec min: 0 msec max: 1000 msec Eq. additn ant-time***
Gun on ant-time*** default: 0 msec min: -1000 msec max: 1000 msec Gun off ant-time*** default: 0 msec min: -1000 msec max: 1000 msec Bead shaping (BS)* default: 0 psi min: 0 psi max: 999 psi BS on ant-time *,*** default: 0 msec min: -1000 msec max: 1000 msec
BS off ant-time *,*** default: 0 msec min: -1000 msec max: 1000 msec
Pre-pressure time*** default: 0 ms De-pressure time default: 0 ms Correction factor default: 1.0 min: 0.1 max: 10.0 Correction bias
Description This item specifies the guns that DispenseTool will use for dispensing. Up to six guns can be used. Guns can be used only if they have been defined during DispenseTool configuration. The Guns used item displays the status of the six possible guns using a six-character expression. The first character represents gun 1, the second character represents gun 2, the third character represents gun 3, and so forth. If a gun has not been defined, it is represented by a *. If a gun has been defined, the following symbols specify whether it will be used during calibration: • The gun number indicates that the gun will be used. • The minus symbol, "- ", indicates that the gun will not be used. This information is displayed only on the DETAIL screen. This item indicates the anticipation time between when the robot reaches the taught position and when material is dispensed from the gun. This information is displayed only on the DETAIL screen. This item indicates the additional anticipation time of the equipment. Additional anticipation times might be required when equipment receives a decreasing flow rate command signal. This item only applies to the flow type of TCPP or PROG. This item indicates the anticipation time between when the robot reaches the destination position and when the gun is turned on. If you want the gun to turn on before the robot reaches the destination position, set Gun on ant-time to a positive number. If you want the gun to turn on after the robot reaches the destination position, set Gun on ant-time to a negative number. This information is displayed only on the DETAIL screen. This item indicates the anticipation time between when the robot reaches the destination position and when the gun is turned off. If you want the gun to turn off before the robot reaches the destination position, set Gun off ant-time to a positive number. If you want the gun to turn off after the robot reaches the destination position, set Gun off ant-time to a negative number. This information is displayed only on the DETAIL screen. This item indicates the amount of Bead shaping air (atomizing air) used. This information is displayed only on the DETAIL screen.
This item indicates the anticipation time between when the robot reaches the destination position and when the atomizing air is turned on. If you want the atomizing air to turn on before the robot reaches the destination position, set BS on ant-time to a positive number. If you want the atomizing air to turn on after the robot reaches the destination position, set BS on ant-time to a negative number. This information is displayed only on the DETAIL screen. This item indicates the anticipation time between when the robot reaches the destination position and when the atomizing air is turned OFF. If you want the atomizing air to turn OFF before the robot reaches the destination position, set BS off ant-time to a positive number. If you want the atomizing air to turn OFF after the robot reaches the destination position, set BS off ant-time to a negative number. This information is displayed only on the DETAIL screen. This item is used to adjust the invoking time of the pre-pressure signal. This item is used to adjust the invoking time of the de-pressure signal. This item allows you to fine tune material flow. This is especially useful when dispensing material around corners. This information is displayed only on the DETAIL screen.
This item allows you to adjust the bead width of corners which reside within the seal segment. This value does not affect the bead width of any straight line paths.
- 777 -
12.DISPENSE TOOL
B-82594EN-4/01
Item SS time offset*** SE time offset*** Ch2 type **
Ch2 amount ** Ch2 equip ant-time * *default: 0 msec min: 0 msec max: 1000 msec Ch2 additn ant-time **
Ch2 correction factor **
Ch2 correction bias **
Description This item allows you to adjust the time interval between the gun on signal and the flow rate signal. This item allows you to adjust the time interval between the gun off signal and flow rate signal. This item defines how the Analog 2 (A2) will be measured. The following A2 types are available: • TCPP Bead Width - Bead width (mm), using TCP speed prediction • PROG Bead Width - Bead width (mm), using programmed speed prediction • CONST Bead Width - Bead width (mm), using no speed prediction • Percentage • TCPP Volume - Volume (cc/min), using TCP speed prediction • PROG Volume - Volume (cc/min), using programmed speed prediction • CONST Volume - Volume (cc/min), using no speed prediction • Volts • Pressure (psi) • Pressure (bar) • TCPP Volts • TCPP percentage • PROG volts • PROG percentage This item specifies the desired rate of Analog 2. The units used correspond to the A2 type you have selected. This item indicates the anticipation time between when the robot reaches the taught position and when material is dispensed from the gun. A larger value of equipment delay will cause the gun to turn on earlier. This information is displayed only on the DETAIL screen. This item indicates the additional anticipation time of the equipment. Additional delays might be required when equipment receives a decreasing flow rate command signal. This item only applies to the flow type of TCPP or PROG. This item allows you to fine tune material flow. This is especially useful when dispensing material around corners. This information is displayed only on the DETAIL screen. This item allows you to adjust the bead width of corners which reside within the seal segment. This value does not affect the bead width of any straight line paths.
* Displayed if Beadshaping air (atomizing air) is used. ** Displayed if Channel 2 Analog is enabled. *** This item is also a Process Signal timing parameter .
Procedure 12-2 Using Schedules NOTE If you have multiple equipment, you must set up schedules for each one.
Steps 1 2 3
Press DATA. Press F1, [TYPE]. Select Seal Sched. If the following screen is not displayed, press F2, LISTING. You will see a screen similar to the following.
- 778 -
12.DISPENSE TOOL
B-82594EN-4/01
NOTE The number of the currently selected equipment is displayed in the middle of the title line on every screen. The currently selected equipment for the screens in this procedure is equipment 1, E1. DATA Seal Sched E1 Variable Orifice System Schd Value Flow Type Comment 1 10.0 mm BW TCPP FOUR DOOR LR 2 0.0 mm BW TCPP 3 0.0 mm BW TCPP 4 0.0 mm BW TCPP 5 0.0 mm BW TCPP 6 0.0 mm BW TCPP 7 0.0 mm BW TCPP 8 0.0 mm BW TCPP 9 0.0 mm BW TCPP
4 5
Set the values for each schedule as appropriate. To display more information about a single schedule, press F2, DETAIL. You will see a screen similar to the following. DATA Seal Sched E1 Variable Orifice System 1 Schedule # 1 2 Flow type: TCPP Bead Width 3 Flow model: LINEAR 4 Flow rate: 0.00 mm 5 Guns used: 1--*** 6 Equip. ant-time: 0 ms 7 Eq. additn. ant-time: 0 ms 8 Gun on ant-time: 0 ms 9 Gun off ant-time: 0 ms 10 Bead shaping (BS): 0.0 psi 11 BS on ant-time: 0 ms 12 BS off ant-time: 0 ms 13 Pre-pressure time: 0 ms 14 De-pressure time: 0 ms 15 Correction factor: 1.0 16 Correction bias: 17 SS time offset: 18 SE time offset: Channel 2 Analog Properties 19 Ch2 type: TCPP Bead Width 20 Ch2 amount: 0.00 mm 21 Ch2 equip. ant-time: 0 ms 22 Ch2 additn. ant-time: 0 ms 23 Ch2 correction factor: 1.0 24 Ch2 correction bias: 0.0
6
To return to the LISTING screen , press F2, LISTING.
- 779 -
12.DISPENSE TOOL
12.2.4
B-82594EN-4/01
Process Timing Protocols
12.2.4.1 Overview The process timing protocols define the behavior of the following process signals: • • • • •
Gun On/Off signal (digital output) Flow rate command signal (analog output) Bead Shaping Air (Atomizing Air) signal (analog output) Pre-pressure signal (analog output) Channel 2 analog signal (analog output)
Each process signal is characterized by timing parameters. Refer to Table 12.2.3 for a listing and description of each parameter. See the following flow diagrams to view the effects of the above process parameters and the process signal protocols: • • • • • • • • • • •
Generic dispense system response time at a corner (Subsection 12.2.4.2) Effects of equipment ant-time and additional ant-time (Subsection 12.2.4.3) Effects of using positive gun on ant-time (Subsection 12.2.4.4) Effects of using negative gun on ant-time (Subsection 12.2.4.5) Effects of positive beadshaping on ant-time (Subsection 12.2.4.6) Effects of negative beadshaping on ant-time (Subsection 12.2.4.7) Effects of pre-pressure time (Subsection 12.2.4.8) Effects of seal start offset (Subsection 12.2.4.9) Effects of seal end offset (Subsection 12.2.4.10) Effects of corner adjustment (Subsection 12.2.4.11) Generic dispense process signal timing protocols (Subsection 12.2.4.12)
12.2.4.2 Generic Dispense system response time at a corner
Fig. 12.2.4.2 Generic Dispense System Response Time at a Corner
- 780 -
12.DISPENSE TOOL
B-82594EN-4/01
12.2.4.3 Equipment ant-time and additional ant-time
Fig. 12.2.4.3 Equipment Ant-Time and Additional Ant-Time
12.2.4.4 Effects of using positive gun on ant-time
Fig. 12.2.4.4 Effects of Using Positive Gun On Ant-Time
- 781 -
12.DISPENSE TOOL
B-82594EN-4/01
12.2.4.5 Effects of using negative gun on ant-time
Fig. 12.2.4.5 Effects of Using Negative Gun On Ant-Time
12.2.4.6 Effects of positive bead shaping ant-time
Fig. 12.2.4.6 Effects of Positive Bead Shaping Ant-Time
- 782 -
12.DISPENSE TOOL
B-82594EN-4/01
12.2.4.7 Effects of negative bead shaping ant-time
Fig. 12.2.4.7 Effects of Negative Bead Shaping Ant-Time
12.2.4.8 Effects of pre-pressure time
Fig. 12.2.4.8 Effects of Pre-Pressure Time
- 783 -
12.DISPENSE TOOL
B-82594EN-4/01
12.2.4.9 Effects of seal start offset
Fig. 12.2.4.9 Effects of Seal Start Offset
12.2.4.10 Effects of seal end offset
Fig. 12.2.4.10 Effects of Seal End Offset
12.2.4.11 Corner adjustment If the flow type is TCPP or PROG, the flow rate output will change in proportion to the robot speed change. Around corners of a path, the robot will usually slow down and the flow rate will decrease. The correction bias provides a means to offset the corner flow rate only.
Fig. 12.2.4.11 Corner Adjustment
- 784 -
12.DISPENSE TOOL
B-82594EN-4/01
12.2.4.12 Generic dispense process signal timing protocols
Fig. 12.2.4.12 Generic Dispense Process Signal Timing Protocols
- 785 -
12.DISPENSE TOOL
12.2.5
B-82594EN-4/01
Setting Up Equipment Information You must set up specific information about the dispensing equipment before you can use it. Equipment setup requires you to set up specific items and to perform specific calibration procedures. Table 12.2.5 lists and describes each equipment setup item. The equipment setup items vary depending on the way your system is configured. You might also need to perform the following calibration procedures to set up your dispensing equipment, depending on the way your system is configured: • •
Item
Maximum analog out calibration - Subsection 12.2.6.4 Flow rate control calibration - Subsection 12.2.6.2
Table 12.2.5 Equipment Setup Items Description
Material Factor default: 1.00 min: 0.10 max: 10.00 Flow Rate Bias default: 0.00 V min: -9.99 V max: 10.00 V
This specifies the scale factor used in computing flow control (analog output). It can be changed as material viscosity and temperature changes.
Minimum Flow Command default: 0.00 V min: 0.00 V max: 10.00 V Flow Command AOUT Type values: Volts, Current default: Volts Style ID ack time-out default: 0 msec min: 0 max: 30,000 Dispense Complete time-out default: 0 msec min: 0 max: 30,000
This specifies the minimum flow command voltage that will be sent to the dispensing equipment while sealing. If the requested flow rate specified in the current Seal Schedule ever goes below the Minimum Flow Command, the Minimum Flow Command will be sent to the dispensing equipment. This selects the type of analog output: Volts - Type II output - range 0-10 volts Current - Type III output - range 1-5 volts
This value will be added to the flow rate voltage while sealing. Most sealing equipment respond only in a linear fashion to voltages within a limited range, often 3 to 8 volts. Use Flow Rate Bias to help compensate for non-linearity in the sealing equipment flow rate response. Typical values of Flow Rate Bias are between 0.0 and 2.0 volts. To determine the appropriate value for your dispensing equipment, contact your dispensing equipment supplier or determine the value yourself by generating a voltage-in to sealant-out chart. Use the chart to find the flow rate bias by drawing a line through the region of the chart that has the most linear response. The point where this line crosses the voltage axis is the flow rate bias.
An error "SEAL-246 Style ID communication timeout (E%s)" will be posted if the dispenser does not raise the IN_PROCESS signal within the time specified by this item after Style_strobe output is turned on by the robot. "SEAL-305 Dispense complete timeout (E%s)" will be posted if the dispenser does not turn off the IN_PROCESS signal with the time specified by this item after Dispense_Complete output is turned on by the robot.
- 786 -
12.DISPENSE TOOL
B-82594EN-4/01
Item Fault Reset pulse width default: 300 msec min: 0 max: 3,000 Fault Reset time-out default: 2000 msec min: 0 max:30,000 Rmt Start/Purge time-out default: 10,000 ms: min: 0 max: 30,000 Set Task OK upon recovery values: ENABLE,DISABLE default: ENABLE Bead shaping factor* default: 1.00 min: 0.01 max: 10.00 Bead shaping AOUT type* values: Volts, Current default: Volts Bead shaping max out* default: 10.00 V min: 0.00 V max: 10.00 V Use default ACC values: ENABLE, DISABLE default: DISABLE Default ACC default: 20 min: max:
User def recvry delay default: 0.00 msec min: max: Guns Used in Calibration default: INCOMPLETE min: 1 max: 6
Description This item specifies the pulse width of the "fault reset" signal from the robot to the dispenser. Fault reset will be automatically attempted when the robot detects themajor fault signal on or the dispenser ready signal off before sending t he style ID or before resuming a paused program. "SEAL-308 Fault Reset Timeout (E%s)" will be posted if the dispenser does not turn on the dispenser ready signal or if the dispenser does not turn off the major fault signal within the time specified by this item after the fault reset signal is asserted by the robot. NOTE The time-out error will not be posted if the robot is running dry (dispensing disabled). At the beginning of a job, if dispenser ready DI is not ON, the robot initiates a remote start sequence by setting the Remote start digital output. If the dispenser ready input does not turn ON within this time, the following error is posted:“SEAL-314 Rmt Strt/Purge Request Timeout” If enabled, the robot sets the Task OK signal on when you select one of the following error recovery options: Continue Weld/Wet or FastFaultRecovery.
This specifies the global scale factor used in computing atomizing air. Changing this factor has an effect on all atomizing air values specified in sealing schedules.
This selects the type of the analog output: • Volts - Type II output - range 0-10 volts • Current - Type III output - range 1-5 volts This sets the maximum analog voltage for atomizing air for the dispensing equipment. If the intended analog voltage exceeds this value, then an alarm will occur. Maximum voltage will not exceed this value. This item enables/disables the Default Acc feature.
If Default Acc is enabled, the valued specified in this item will be used as Acc (acceleration) value for all motions that do not have the Acc modifier. If the Acc modifier is specified in the teach pendant program, the specified Acc value is used instead of the default Acc value. This feature allows the dispenser with slower response time to follow the flow command changes due to robot speed variation. This item adjusts the gun open timing when the gun is reopened after fast fault recovery. A positive value will open the gun earlier by the specified amount of time.
This specifies the guns that DispenseTool will use in equipment calibrations. Up to six guns can be used. Guns can be used only if they have been defined during DispenseTool configuration. The Gun Selection for Calibrations item displays the status of the six possible guns using a six-character expression. The first character represents gun 1, the second character represents gun 2, the third character represents gun 3, and so on. If a gun has not been defined, it is represented by a*. You cannot change the value of a gun that has not been defined. If a gun has been defined, you can specify whether it will be used during calibration: • Thegun number indicates that the gun will be used. • Theminus symbol, "- ", indicates that the gun will not be used. To change the value of a gun that has been defined, use the appropriate function keys.
- 787 -
12.DISPENSE TOOL
B-82594EN-4/01
Item Meter Max Speed default: INCOMPLETE Flow Rate Control
Channel 2 Analog Bead shaping command * default: INCOMPLETE
Description Refer to the Channel 2 Analog Control section of the application-specific Setup and Operations Manual for information on how to calibrate the meter maximum speed. Refer to the Maximum Analog Out (Meter)/Maximum Meter Speed Calibration section of the application-specific Setup and Operations Manual for information on how to calibrate the flow rate control. Refer to the Channel 2 Analog Control section of the application-specific Setup and Operations Manual for information on how to calibrate the channel 2 analog. Refer to the Bead Shaping Air (Atomizing AIr) Calibration section of the application-specific Setup and Operations Manual for information on how to calibrate the bead shaping air pressure.
* Displayed if beadshaping air is used. Use Procedure 12-3 to set up equipment items.
Procedure 12-3 Setting Up Equipment Items NOTE If you have multiple equipment, you must set up equipment items for each one.
Steps 1 2 3 4
Press MENUS. Select SETUP. Press F1, [TYPE]. Select Dispenser. You will see a screen similar to the following.
NOTE The number of the currently selected equipment is displayed in the middle of the title line on every screen. The currently selected equipment for the screen in this procedure is equipment 1, E1. Gear Meter Disp. System 1/19 1 Material factor: 2 Flow rate bias: 3 Minimum flow command: 4 Flow command AOUT type: 5 StyleID ack time-out: 6 DispenseComplete time-out: 7 Fault Reset pulse width: 8 Fault Reset time-out: 9 Rmt Start/Purge time-out: 10 Set TaskOK upon Recovery: 11 Bead shaping factor: 12 Bead shaping AOUT type: 13 Bead shaping max out: 14 Use default ACC: 15 Default ACC: 16 User def recvry delay: Calibrations: 17 Max Analog out: 18 Flow rate control 19 Bead shaping cmd:
- 788 -
¥1.00 0.00 v 0.00 v Volts 0 msec 0 msec 300 msec 2000 msec 10000 msec DISABLE 1.00 Volts 10.00 v DISABLE 20 0.00 msec INCOMPLETE INCOMPLETE
12.DISPENSE TOOL
B-82594EN-4/01
5 6
7
8 9
12.2.6
To display help information , press NEXT, >, and then press F1, HELP. When you are finished displaying help information, press PREV. To select the number of the equipment you want to set up a Check the currently selected equipment number. The equipment number is displayed to the right of the screen name as E# , where # is the equipment number. If the number displayed is the equipment number you want, go to Step 7 . b Press NEXT, >. c Press F3, EQUIP. d Type the number of the equipment and press ENTER. To select which guns will be used during calibration, a Move the cursor to Guns used in calib. b Use the right and left arrow keys to move the cursor to the position that corresponds to the gun number. c Press the function key that corresponds to the value you want: • To select a gun to be used during calibration, press F4, #, where # corresponds to the number of the gun. • To specify that a gun will not be usedduring calibration, press F5, - . Select items 1 through 8 and set them as desired. To display detailed information about acalibration, move the cursor to the calibration you want and press F2, DETAIL.
Equipment Calibration
12.2.6.1 Overview You must perform calibration procedures for the equipment you use. The calibration procedures you perform depend on the kind of equipment you have and the way your system is configured. This section contains calibration procedures that are used by all or most kinds of dispensing equipment. Perform only those calibration procedures that apply to your dispensing equipment. • Maximum analog output (meter) calibration - Subsection 12.2.6.4 • Material pressure calibration - only if material pressure monitoring is used - Subsection 12.2.6.5 • Bead shaping air (Atomizing air) calibration - only if beadshaping air is used - Subsection 12.2.6.3 Refer to Subsection 12.2.6.2 for flow rate control calibration.
- 789 -
12.DISPENSE TOOL
B-82594EN-4/01
12.2.6.2 Flow rate control calibration The flow rate control calibration sequence provides a way for the robot to translate the flow rate you specify in each sealing schedule (units of mm, %, cc/m, volts, PSI, or bar) into volts that are output to the dispensing controller. As explained in Subsection 12.2.2.4 , the robot translates the flow rate specified in the sealing schedule into volts by multiplying the flow rate you specify by the scale factor for that flow type.
Scale Factors There are ten scale factors, one for each of the following possible flow rate types: • • • • • • • • • •
Bead width with TCP speed predicted Bead width with programmed speed predicted Bead width with no speed compensation Percentage with no speed compensation Volume with TCP speed predicted Volume with programmed speed predicted Volume with no speed compensation Volts with no speed compensation Pressure (PSI) with no speed compensation Pressure (bar) with no speed compensation
All of the scale factors have a default value of 1.0 when robot software is loaded. The default value of 1.0, however, is not typical for most sealing equipment. Therefore, you must perform a flow rate control calibration sequence for each flow type you plan to use on the robot if you want the flow rate specified in each sealing schedule to be accurately reflected by the dispensing equipment.
Calibration Sequence Flow rate control calibration will lead you through a sequence of operations that will set up a scale factor for the current flow rate type. This calibration runs a sample program (MOV_SEAM, by default) and asks you to measure and enter the actual sealant dispensed. The robot uses this information to calculate the scale factor for the flow rate type. Table 12.2.6.2 lists and describes each flow rate control calibration item.
Item Calibration Status
Table 12.2.6.2 Flow Rate Control Calibration Items Description This item displays the calibration completion status for the selected flow rate type. • DEFAULT indicates that calibration has not been performed for the selected flow rate type and that the scale factor for the selected flow rate type is still 1.0. • COMPLETE indicates that calibration has been performed successfully for the selected flow rate type and that the scale factor for the selected flow rate type probably is not 1.0.
- 790 -
12.DISPENSE TOOL
B-82594EN-4/01
Item Seal Schedule in MOV_SEAM value: 30 Flow Rate Type
Desired Flow Rate
Sample Program default: MOV_SEAM
Home Program default: MOV_HOME
TCPP BW Scale Factor
Description This item indicates the sealing schedule that must be used in the current sample program, which is MOV_SEAM in this case. The information in this sealing schedule will be used to calculate the scale factor for the flow rate type in the specified schedule. This item indicates the flow rate type that will be used in this calibration. You must set this to the flow rate type you are using in the calibration. Editing this item is the same as editing Flow rate type in the specified sealing schedule, which is sealing schedule 30 by default. This item indicates the target flow rate that will be used for this calibration. Set this to the flow rate that will be used most often in your process. Editing this item is the same as editing Flow rate type in the specified sealing schedule, which is sealing schedule 30 by default. This item indicates the program that will be run as part of this calibration. The sample program should dispense a simple seam at a steady speed so that you can measure the dispensing rate manually and enter the results into the robot. The sample program must use only SS[30] (where 30 is the number defined in the Seal sched used in MOV_SEAM item) to start sealing. No other SS should be used in this program. A default MOV_SEAM program is provided that includes the appropriate instructions. To use the default program, touch up the positions. This item indicates the name of a program that moves the robot to the home position. When you perform this calibration, you have the option of running this program before and after you run the sample program, to ensure that the robot starts and ends the calibration at the home position. This item shows the result of the flow rate calibration.
Calibration Procedure Use Procedure 12-4 to perform flow rate control calibration.
Procedure 12-4 Performing Flow Rate Control Calibration NOTE 1 You should perform this calibration for each flow rate type you want to use on this robot. The example below is for TCPP Bead Width. 2 If you have multiple equipment, you must perform flow rate control calibration for each one.
Before Running the Calibration • • • • • •
A home program has been defined. (Subsection 12.4.2.2) A seal schedule SS[30] has been defined. (Section 12.2.3) A sample program has been defined. It must dispense a simple, measurable bead using SS[30]. (Subsection 12.4.2.2) All dispenser I/O has been properly defined. (Subsection 12.2.7) The Robot motion test cycle parameter is set to ENABLE. (Subsection 12.6.3.1) The WET RUN test cycle parameter is ENABLED. (Subsection 12.6.3.2)
Steps 1 2
Press MENUS. Select SETUP. - 791 -
12.DISPENSE TOOL
B-82594EN-4/01
3 4 5 6
Press F1, [TYPE]. Select the equipment you want to calibrate. Move the cursor to Flow rate control. Press F2, DETAIL. You will see a screen similar to the following.
NOTE The number of the currently selected equipment is displayed in the middle of the title line on every screen. The currently selected equipment for the screen in this procedure is equipment 1, E1. SETUP Equipment E1 Dispensing Equipment Flow Rate Calibration Calibration status: Seal sched in MOV_SEAM: 1 Flow rate type: TCPP 2 Desired flow rate: 3 Sample program: 4 Home program: TCPP BW scale factor:
7 8
9 10
11 12 13
DEFAULT 30 Bead Width 0.0 mm [MOV_SEAM] [MOV_HOME] 1.000
To display help information , press NEXT, >, and then press F1, HELP. When you are finished displaying help information, press PREV. Specify the flow rate type as follows: a Move the cursor to Flow rate type. b Press F4, [CHOICE]. c Move the cursor to the flow rate type you want and press ENTER. Move the cursor to Desired flow rate, type the desired flow rate, and press ENTER. Specify the name of the sample program and the name of the home program as follows: a Move the cursor to Sample program or Home program. b Press F4, [CHOICE]. c Move the cursor to the program name you want and press ENTER. Make sure all items on this screen are correct and that you have satisfied all of the conditions listed in the "Before Running the Calibration Section" at the beginning of this procedure. When you are ready to start the calibration , press F3, START. If the robot is not at the home position, you are prompted to move the robot to the home position, as shown in the following screen. Robot will move to HOME pos. OK to continue? YES NO
a
Select YES and press ENTER. - 792 -
12.DISPENSE TOOL
B-82594EN-4/01
b
14
Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. c Adjust the speed override to an appropriate value for the conditions. d To move the robot, press and hold SHIFT and press F5, MOVE. e Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch. To move the robot along the sample seam defined by the program MOV_SEAM, you will see a screen similar to the following. Robot will move along the ample program. aterial will be dispensed. tart calibration? YES NO
a b c
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. Adjust the speed override to 100%.
NOTE Make sure the speed override is set to 100%. Although you do not have to do this to continue, best results are obtained when running the sample seam at 100% of the programmed speed. d e
To move the robot , press and hold SHIFT and press F5, MOVE. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch. The robot will move through the positions in the sample program, turning the gun on and off when the SS[30] and SE instructions are executed. After the program has finished executing, you must measure the flow rate dispensed and enter it when prompted. You will see a screen similar to the following.
SETUP Equipment E1 Dispensing Equipment Flow Rate Calibration Calibration status: COMPLETE Seal sched in MOV_SEAM: 30 Flow rate type: TCPP Bead Width Desired flow rate: 5.0 mm Sample program: [MOV_SEAM] Home program: [MOV_HOME] TCPP BW scale factor: 1.00 Enter measured bead width (mm):
- 793 -
12.DISPENSE TOOL
B-82594EN-4/01
NOTE If your flow rate type is one of the volume flow rates (TCPP volume, PROG volume, or CONST volume), you will be prompted for both seam volume and seam length. 15 Measure the bead width, type it in millimeters, and press ENTER. The measured bead width can be zero. If it is zero, you will see the following screen. Measured bead width was zero. Check dispensing equipment. OK to increment local scale factor by 1.0? YES NO
16
17
If the measured bead width is zero, decide whether to increment the local scale factor. • To increment the local scale factor, select YES and press ENTER. • To keep the local scale factor the same, select NO and press ENTER. After entering the information at the end of the calibration, the new scale factor will be calculated and you will be prompted to approve the new scale factor. If you enable the new scale factor, this value will be used in calculating the flow rate for the currently selected flow rate type.
NOTE While running if a “SEAL-270 Flow command above maximum" error was posted, then instead of “Enable new value?” a different prompt will appear stating “WARN:SEAL-270 POSTED! Enable new value?”. This is an indication that the maximum flow command was exceeded and therefore the proposed new scaling factor may not be valid. SETUP Equipment E1 Dispensing Equipment Flow Rate Calibration Calibration status: COMPLETE Seal sched in MOV_SEAM: 30 Flow rate type: TCPP Bead Width Desired flow rate: 5.0 mm Sample program: [MOV_SEAM] Home program: [MOV_HOME] TCPP BW scale factor: 1.00 New TCPP BW scale factor: 0.500 Enable new value? YES NO
- 794 -
12.DISPENSE TOOL
B-82594EN-4/01
18
If the robot is not at the home position, you are prompted to move the robot to the home position, as shown in the following screen. Robot will move to HOME pos. OK to continue? YES NO
a b c d e
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. Adjust the speed override to an appropriate value for the conditions. To move the robot , press and hold SHIFT and press F5, MOVE. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch.
12.2.6.3 Bead shaping air (atomizing air) calibration Bead Shaping air (Atomizing air) calibration establishes a global air scaling factor. This factor is used in conjunction with programmed path speeds and tool center point speeds to provide the analog air commands that are sent to the dispenser.
NOTE You must perform bead shaping calibration only if your system is configured to use bead shaping air.
Description Many dispensing applications require the use of bead shaping air to be delivered along with the material to modify the bead characteristics. The pressure at which the air is mixed with the material will greatly affect the resulting seam. For this reason, the scaling schedules allow you to alter the bead shaping air pressure. All bead shaping air pressure programming is done in units of psi. Since no sensory feedback is given for bead shaping air pressure, the only information available is from the bead shaping air pressure gauge. Through the execution of bead shaping air calibration, a scaling factor is calculated that enables the conversion of bead shaping air commands into the analog command signals which will result in the desired air pressure. Bead shaping air calibration involves setting the bead shaping air port to a specific value, while you enter the resulting air pressure. This process is performed twice. The "Pressure per Count" scaling factor is then computed using the data you supply. Table 12.2.6.3 lists and describes each bead shaping air calibration item. - 795 -
12.DISPENSE TOOL
Item
B-82594EN-4/01
Table 12.2.6.3 Bead Shaping Air Calibration Items Description
Calibration Status
This item indicates whether the beadshaping air calibration has been completed successfully. This item indicates the program used to move the robot to the home position. You can specify the name of the home program. Refer to Section 12.4, “PLANNING AND CREATING A PROGRAM” for information on how to create a home program. This item indicates the program used to move the robot to the purge position. You can specify the name of the purge program. Refer to Section 12.4, “PLANNING AND CREATING A PROGRAM” for information on how to create a purge program. This item indicates the air pressure per analog count, in psi.
Home Program default: MOV_HOME
Purge Program default: MOV_PURG
Pressure Per Count default: 0.0000 psi min: 0.0000 psi max: 9.9999 psi
Use Procedure 12-5 to perform beadshaping air calibration.
Procedure 12-5 Performing Bead Shaping Air (Atomizing Air) Calibration NOTE If you have dual equipment, you must perform beadshaping air calibration for each one.
Before Running the Calibration • • • •
A home program has been defined. (Subsection 12.4.2.2) A purge program has been defined. (Subsection 12.4.2.2) All dispenser I/O has been properly defined. (Subsection 12.2.7) The Robot motion test cycle parameter is set to ENABLE. (Refer to Section 12.6, "Testing a Program and Running Production" for more information.)
1 2 3 4 5 6
Press MENUS. Select SETUP. Press F1, [TYPE]. Select Micro ProFlo. Move the cursor to Beadshaping air. Press F2, DETAIL. You will see a screen similar to the following.
Steps
NOTE The number of the currently selected equipment is displayed in the middle of the title line on every screen. The currently selected equipment for the screen in this procedure is equipment 1, E1.
- 796 -
12.DISPENSE TOOL
B-82594EN-4/01
SETUP Sealing E1 Dispensing Equipment Beadshaping Air Calibration Calibration status: INCOMPLETE 1 Home program: [ MOV_HOME ] 2 Purge program: [ MOV_PURG ] Pressure per count: 0.0000 psi
7 8
9 10
To display help information, press NEXT, >, and then press F1, HELP. When you are finished displaying help information, press PREV. Specify the name of the home program and the name of the purge program as follows: a Move the cursor to Home program or Purge program. b Press F4, [CHOICE]. c Move the cursor to the program name you want and press ENTER. Press F3, START, to start calibration. If the robot is not at the home position, you are prompted to move the robot to the home position, as shown in the following screen. Robot will move to HOME pos. OK to continue? YES NO
a b
11
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. c Set the speed override to an appropriate value for the conditions. d To move the robot , press and hold SHIFT and press F5, MOVE. If the robot is at the home position, you are prompted to move the robot to the purge position, as shown in the following screen. Robot will move to PURGE pos. OK to continue? YES NO
a b c d e
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. Set the speed override to an appropriate value for the conditions. To move the robot , press and hold SHIFT and press F5, MOVE. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch.
- 797 -
12.DISPENSE TOOL
B-82594EN-4/01
12
To start calibration, select YES on the following screen and press ENTER. Robot will NOT move. No material will be dispensed. Beadshaping air will be applied. Start calibration? YES NO
The analog output port for atomizing air is set to ¼ of the maximum value. You will see a screen similar to the following.
NOTE Press F3, QUIT, at any time to stop beadshaping air and abort calibration. SETUP Sealing Dispensing Equipment Beadshaping Air Calibration Calibration status: INCOMPLETE Home program: MOV_HOME Purge program: MOV_PURG Pressure per count: 0.0000 psi 1 Pressure value 1: 0 psi Enter first pressure gauge value.
13 14
Read the value on the atomizing air pressure gauge, type it and press ENTER. Press F5, CONTINUE. The analog output port for atomizing air is set to ¾ of the maximum value. You will see a screen similar to the following. SETUP Sealing E1 Dispensing Equipment Beadshaping Air Calibration Calibration status: INCOMPLETE Home program: MOV_HOME Purge program: MOV_PURG Pressure per count: 0.0000 psi Pressure value 1: 0 psi Pressure value 2: 0 psi Enter second pressure gauge value.
15
Read the value on the beadshaping air pressure gauge, type it and press ENTER, and press F5, CONTINUE. A new pressure per count scaling factor is calculated and is updated to the screen. You will see a screen similar to the following.
- 798 -
12.DISPENSE TOOL
B-82594EN-4/01
SETUP Sealing E1 New pressure per count: .0097 psi Old pressure per count: 0.0000 psi Enable new value?
16
17
Decide whether the new pressure per count value is acceptable. • If it is acceptable, press F4, YES. The scaling factor is updated and the calibration status is set to COMPLETE. • If it is not acceptable, press F5, NO. Repeat the calibration procedure until you are satisfied with the results. If the robot is not at the home position , you are prompted to move the robot to the home position, as shown in the following screen. Robot will move to HOME pos. OK to continue? YES NO
a b c d e
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. Set the speed override to an appropriate value for the conditions. To move the robot , press and hold SHIFT and press F5, MOVE. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch.
12.2.6.4 Maximum analog out (meter)/maximum meter speed calibration
Maximum analog out (meter)/maximum meter speed calibration allows you to define the maximum operating flow rate that can be used without exceeding the maximum system pressure.
NOTE If you have the Integral Servo Dispenser equipment, you will see the "Max Meter Speed Calibration" screen. For all other kinds of equipment, you will see the "Max Analog Out" screen.
Description For each dispensing system configuration, there exists a maximum operating material pressure. If this pressure is exceeded, you risk serious equipment damage and possible personal injury. Maximum analog out (meter)/maximum meter speed calibration determines the maximal "Meter Speed" that corresponds to the maximum system material pressure. This calibration involves dispensing at various flow rates while observing system pressure. - 799 -
12.DISPENSE TOOL
B-82594EN-4/01
WARNING Do not exceed the maximum operating material pressure; otherwise, you could injure personnel and damage equipment. Maximum analog out (meter)/maximum meter speed calibration should be executed several times with different speed steps. It is recommended to start with a very coarse voltage step (0.50 volts or 5%) and to establish a preliminary maximum speed. After each calibration execution, the last maximum speed value that does not result in a system overpressure should be enabled. For the next execution, the speed step should be decreased, increasing the accuracy of the maximum speed value. Typically, the best results can be attained when a maximum voltage has been established for a 0.01 V voltage step or 0.1% step. Table 12.2.6.4 lists and describes each maximum analog out (meter)/maximum meter speed calibration item. Table 12.2.6.4 Maximum Analog Out (Meter)/Maximum Meter Speed Calibration Items Item Description Calibration Status This item indicates whether maximum analog out (meter)/maximum meter speed calibration has been completed successfully. Home Program This item indicates the program used to move the robot to the home position. default: MOV_HOME You can specify the name of the home program. Purge Program This item indicates the program used to move the robot to the purge position. default: MOV_PURG You can specify the name of the purge program. This item indicates the maximum voltage allowed from the analog output Maximum Voltage/ Maximum Speed device. MaximumVoltage/Maximum Speed is set indirectly through the default: 4.0 V/40 execution of this calibration procedure. min: 0.0 V/0 % max: 10.0 V/100 % This item indicates the voltage step to be used in the calibration. Refer to the Voltage Step/Speed Step beginning of this section for guidelines in setting the voltage step/speed step. default: 0.1 V/1 % min: 0.0 V/0 % max: 0.5 V/5 % This item indicates the maximum pressure that can be used when dispensing Maximum Pressure* material. This item is set on the SETUP Equipment screen. default: 2300 psi min: 0 psi max: 6000 psi This item indicates the material pressure the last time material was dispensed. Last Pressure* default: N/A min: 0 psi max: N/A
* Displayed if material pressure is monitored. Use Procedure 12-6 to perform maximum (meter)/maximum meter speed calibration.
- 800 -
analog
out
12.DISPENSE TOOL
B-82594EN-4/01
Procedure 12-6 Performing Maximum Analog Out (Meter)/Maximum Meter Speed Calibration
Before Running theCalibration • • • • • •
A home program has been defined. (Subsection 12.4.2.2) A purge program has been defined. (Subsection 12.4.2.2) Material pressure calibration is COMPLETE, if material pressure is monitored. All dispenser I/O has been properly defined. (Subsection 12.2.7) The Robot motion test cycle parameter is set to ENABLE. (Subsection 12.6.3.1) For Integral Servo Dispenser equipmentsystems only, the ISD meter motion test cycle parameter is set to ENABLE. (Subsection 12.6.3.1)
Steps 1 2 3 4 5
Press MENUS. Select SETUP. Press F1, [TYPE]. Select Shot Meter. Move the cursor to Max analog out (meter)/Max meter speed.
NOTE The screens in this procedure are for DispenseTool systems in which material pressure is monitored. For DispenseTool systems in which material pressure is not monitored, the items pertaining to pressure will not be displayed. 6
Press F2, DETAIL. You will see a screen similar to the following.
NOTE If you are using an ISD system, you will see "Max Meter Speed Calibration" instead of "Maximum Analog Out (meter) Calibration." SETUP Sealing E1 Dispensing Equipment Maximum Analog Out (meter) Calibration Calibration status: INCOMPLETE 1 Home program: [ MOV_HOME ] 2 Purge program: [ MOV_PURG ] Maximum voltage: 4.00 V 3 Voltage step: 0.00 V Maximum pressure: 2300 psi Last pressure: 2000 psi
- 801 -
12.DISPENSE TOOL
B-82594EN-4/01
7 8
9 10 11
To display help information , press NEXT, >, and then press F1, HELP. When you are finished displaying help information, press PREV. Specify the name of the home program and the name of the purge program as follows: a. Move the cursor to Home program or Purge program. b. Press F4, [CHOICE]. c. Move the cursor to the program name you want and press ENTER. Select Voltage step and enter a value between 0.0 and 0.5 volts. The voltage step cannot be zero. Press F3, START, to start the calibration. If the robot is not at the home position , you are prompted to move the robot to the home position, as shown in the following screen. Robot will move to HOME pos. OK to continue? YES NO
a. b.
12
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. c. Set the speed override to an appropriate value for the conditions. d. To move the robot , press and hold SHIFT and press F5, MOVE. If the robot is at the home position , you are prompted to move the robot to the purge position, as shown in the following screen. Robot will move to PURGE pos. OK to continue? YES NO
a. b.
13
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. c. Set the speed override to an appropriate value for the conditions. D To move the robot , press and hold SHIFT and press F5, MOVE. e. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch. To start calibration, select YES and press ENTER in the following screen. Robot will NOT move. Shotmeter will be reloaded. Start calibration? YES NO
- 802 -
12.DISPENSE TOOL
B-82594EN-4/01
The shot meter will be reloaded. You will see a screen similar to the following. SETUP Sealing E1 Maximum voltage: Voltage step: Maximum pressure: Last pressure: Select an fkey below.
14
4.00 V 0.03 V 2300 psi 2200 psi
Increase or decrease the maximum voltage by the voltage step. • To increase the maximum voltage, press F1, INCREASE. • To decrease the maximum voltage, press F2, DECREASE.
WARNING If your system does not monitor material pressure, watch the dispensing pressure gauges for overpressures while dispensing; otherwise, you could damage the equipment. 15
Test the increase or decrease by dispensing material at the maximum voltage shown. a. To dispense, continuously press F4, DISPENSE. b. Watch the Last pressure on the screen. As you dispense, this will be continually updated. c. Release F4, DISPENSE. d Repeat Step 14 through Step 15c until the maximum voltage is attained while the last pressure does not exceed the maximum pressure. Use the guidelines in Fig. 12.2.6.4 to test and tune the voltage step.
Fig. 12.2.6.4 Voltage Step Adjustment Guidelines
- 803 -
12.DISPENSE TOOL
B-82594EN-4/01
16
Press F5, CONTINUE. You will see a screen similar to the following. SETUP Sealing E1 New maximum voltage: Old maximum voltage: Maximum pressure: Last pressure: Enable new value?
17
18
4.03 V 4.00 V 2300 psi 2200 psi
Decide whether the Last pressure is as close as you want it to be to the Maximum pressure: • If the Last pressure is as close as you want it to be to the Maximum pressure, press F2, YES to update the maximum voltage. Maximum voltage will be updated and calibration status set to COMPLETE. You might want to repeat this calibration with a smaller voltage step for a more precise maximum voltage. • If you do not want to enable the new Maximum voltage, press F4, NO. Repeat the calibration until you are satisfied with the results. If the robot is not at the home position , you are prompted to move the robot to the home position, as shown in the following screen. Robot will move to HOME pos. OK to continue? YES NO
a b c d e
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. Set the speed override to an appropriate value for the conditions. To move the robot , press and hold SHIFT and press F5, MOVE. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch.
12.2.6.5 Material pressure calibration Material pressure calibration calibrates the analog signal of the pressure transducer that is connected to the material supply.
NOTE You must perform material pressure calibration only if your system is configured to monitor material pressure.
- 804 -
12.DISPENSE TOOL
B-82594EN-4/01
Description For systems equipped with pressure monitoring capabilities, a pressure transducer, which is located on the material supply line, provides a "Material Pressure" analog output signal to the robot controller.The level of this signal is proportional to the current material supply pressure. The purpose of material pressure calibration is to establish the scaling parameters that DispenseTool needs to convert this signal into pressure units. Material pressure calibration involves cutting off the material supply and dispensing until the supply line pressure is zero. This is followed by opening the supply valve and allowing the material supply pressure to rise to its normal level. The material pressure gauge is monitored and you enter the material pressure value when prompted. The "Material Pressure" signal is also monitored during this time. The scaling parameters are then computed from these two inputs. Table 12.2.6.5 lists and describes material pressure calibration items.
Item Calibration Status Home Program default: MOV_HOME Purge Program default: MOV_PURG Maximum Pressure default: 2300 psi min: 500 psi max: 3000 psi Minimum Pressure default: 500 psi min: 500 psi max: 3000 psi Count Offset default: 0 min: 0 max: 8192 Pressure per Count default: 0.0000 psi min: -9.9999 psi max: +9.9999 psi
Table 12.2.6.5 Material Pressure Calibration Items Description This item indicates whether the material pressure calibration has been completed successfully. This item indicates the program used to move the robot to the home position. You can specify the name of the home program. This item indicates the program used to move the robot to the purge position. You can specify the name of the purge program. This item sets the maximum pressure of the material allowed. This item is set on the main SETUP Equipment screen.
This item sets the minimum pressure of the material allowed. This item is set on the main SETUP Equipment screen.
This item indicates the bias computed by the controller for the analog signal. Before calibration, this is zero. If there is no bias, Count Offset remains zero; otherwise, it is set to a value when calibration has been completed. This item indicates the amount of material pressure, in psi, used with each analog input count. Pressure per Count can be positive or negative, depending upon the I/O used and the input polarity.
Use Procedure 12-7 to perform material pressure calibration.
- 805 -
12.DISPENSE TOOL
B-82594EN-4/01
Procedure 12-7 Performing Material Pressure Calibration NOTE If you have dual equipment, you must perform material pressure calibration for each one.
Before Running the Calibration • • • •
A home program has been defined. (Subsection 12.4.2.2) A purge program has been defined. (Subsection 12.4.2.2) All dispenser I/O has been properly defined. (Subsection 12.2.7) The Robot motion test cycle parameter is set to ENABLE. (Refer to Section 12.6, "Testing a Program and Running Production" for more information.)
1 2 3 4 5 6
Press MENUS. Select SETUP. Press F1, [TYPE]. Select Dispenser. Move the cursor to Material pressure. Press F2, DETAIL. You will see a screen similar to the following.
Steps
NOTE The number of the currently selected equipment is displayed in the middle of the title line on every screen. The currently selected equipment for the screen in this procedure is equipment 1, E1. SETUP Sealing E1 Dispensing Equipment Material Pressure Calibration 1 Home program: [ MOV_HOME ] 2 Purge program: [ MOV_PURG ] Maximum pressure: 2300 psi Minimum pressure: 500 psi Count offset: 0 Pressure per count: 0.00 psi
7 8
9
To display help information , press NEXT, >, and then press F1, HELP. When you are finished displaying help information, press PREV. Specify the name of the home program and the name of the purge program as follows: a. Move the cursor to Home program or Purge program. b. Press F4, [CHOICE]. c. Move the cursor to the program name you want and press ENTER. Press F3, START, to start calibration.
- 806 -
12.DISPENSE TOOL
B-82594EN-4/01
10
If the robot is not at the home position, you are prompted to move the robot to the home position, as shown in the following screen. Robot will move to HOME pos. OK to continue? YES NO
a b c d 11
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. Set the speed override to an appropriate value for the conditions. To move the robot, press and hold SHIFT and press F5, MOVE.
If the robot is at the home position, you are prompted to move the robot to the purge position, as shown in the following screen. Robot will move to PURGE pos. OK to continue? YES NO
a b
12
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. c Set the speed override to an appropriate value for the conditions. d To move the robot, press and hold SHIFT and press F5, MOVE. e Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch. To start calibration, close the supply valve, select YES, and press ENTER, from the following screen. CLOSE supply valve NOW! Robot will NOT move. Material will be dispensed. Start calibration? YES NO
The gun is turned on and begins to purge.
NOTE While dispensing, press F3, QUIT, at any time to stop material flow and abort calibration.
- 807 -
12.DISPENSE TOOL
B-82594EN-4/01
13
Watch the material pressure gauge.When it reaches zero , press F5, CONTINUE, from the following screen. Press CONTINUE when gauge is at zero. QUIT CONTINUE
14
The analog zero pressure input is recorded and the gun is turned OFF. To continue calibration , open the supply valve, select YES, and press ENTER, from the following screen. OPEN supply valve NOW! Robot will NOT move. NO material will be dispensed. Continue calibration? YES NO
NOTE While dispensing, press F3, QUIT, at any time to abort calibration. 15
Watch the material pressure gauge.When the pressure stabilizes , press F5, CONTINUE, from the following screen. Press CONTINUE when pressure stabilizes. QUIT CONTINUE
You will see a screen similar to the following. SETUP Sealing E1 Dispensing Equipment Material Pressure Calibration Calibration status: INCOMPLETE Home program: MOV_HOME Purge program: MOV_PURG Maximum pressure: 2300 psi Minimum pressure: 500 psi Count offset: 0 Pressure per count: 50.0 psi 1 Pressure gauge value: 120.0 psi Enter pressure gauge value.
16
Type the pressure you read on the material pressure gauge and press ENTER.
- 808 -
12.DISPENSE TOOL
B-82594EN-4/01
17
Press F5, CONTINUE. The new pressure per count scaling factor is calculated. The new count offset and pressure per count scaling factor are updated to the screen. You will see a screen similar to the following. SETUP Sealing E1 New count offset: 8192 Old count offset: 8191 New pressure per count: -.0014 psi Old pressure per count: -.0014 psi Enable new values?
18
19
Decide whether the count offset and pressure per count scaling factors are acceptable. • If they are acceptable , press F4, YES. The scaling factors are updated and the calibration status will be set to COMPLETE. • If they are not acceptable , press F5, NO. Repeat the calibration procedure until you are satisfied with the results. If the robot is not at the home position, you are prompted to move the robot to the home position, as shown in the following screen. Robot will move to HOME pos. OK to continue? YES NO
a b c d e
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. Set the speed override to an appropriate value for the conditions. To move the robot, press and hold SHIFT and press F5, MOVE. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch.
12.2.6.6 Two point (2PNT) flow rate calibration The Two Point Flow Rate calibration sequence provides a way to obtain both scale factors and biases for each flow type. This calibration method is usually used to set the scale factor and bias so that the TCP speed change will be more accurately reflected in the flow rate calculation. The 2PNT calibration is meaningful only to the following four flow types: • • • •
Bead width with TCP speed predicted Bead width with programmed speed predicted Volume with TCP speed predicted Volume with programmed speed predicted - 809 -
12.DISPENSE TOOL
B-82594EN-4/01
Calibration Sequence The 2PNT flow rate control calibration will lead you through a sequence of operations that will set up a scale factor and bias for the current flow rate type. This calibration runs a sample program (MOV_2PNT, by default) and asks you to measure and enter the actual sealant dispensed. The robot uses this information to calculate the scale factor and bias for the flow rate type. Table 12.2.6.6 lists and describes each flow rate control calibration item. Item Calibration Status
Seal Schedule in MOV_2PNT value: 30 Flow Rate Type
Flow Model Desired Flow Rate
Nominal TCP Speed default: 500 mm/s Secondary TCP Speed default: 200 mm/s Sample Program default: MOV_2PNT
Home Program default: MOV_HOME
Table 12.2.6.6 PNTFlow Rate Control Calibration Items (Cont’d) Description This item displays the calibration completion status for the selected flow rate type. DEFAULT indicates that calibration has not been performed for the selected flow rate type and that the scale factor for the selected flow rate type is still 1.0 and the bias is 0.0. COMPLETE indicates that calibration has been performed successfully for the selected flow rate type and that the scale factor for the selected flow rate type probably is not 1.0 and the bias might not be 0.0. his item indicates the sealing schedule that must be used in the current sample program, which is MOV_2PNT in this case. The information in this sealing schedule will be used to calculate the scale factor and bias for the flow rate type in the specified schedule. This item indicates the flow rate type that will be used in this calibration. You must set this to the flow rate type you are using in the calibration. Editing this item is the same as editing Flow rate type in the specified sealing schedule, which is sealing schedule 30 by default. This item specifies the kind of flow model applied on the current schedule. Linear and Square flow models are available. This item indicates the target flow rate that will be used for this calibration. Set this to the flow rate that will be used most often in your process. Editing this item is the same as editing Flow rate type in the specified sealing schedule, which is sealing schedule 30 by default. This item is the robot TCP speed nominally used for dispensing. The sample program, MOV_2PNT, will use this speed to dispense a sample seam. You will measure its bead width and input it as the first point data for calibration. This item is the lower robot TCP speed which might be used for dispensing. MOV_2PNT will use this speed to dispense a secondary sample seam. You will measure its bead width and input it as the secondary point data for the calibration. This item indicates the program that will be run as part of this calibration. The sample program should dispense two simple seams at two different speeds so that you can measure the different dispensing rates manually and enter the results into the robot. The sample program must use only SS[30] (where 30 is the number defined in the Seal sched used in MOV_2PNT item) to start sealing. No other SS should be used in this program. A default MOV_2PNT program is provided that includes the appropriate instructions. To use the default program, touch up the positions. Refer to Chapter 14 PLANNING AND CREATING A PROGRAM for information on how to create a sample program. This item indicates the name of a program that moves the robot to the home position. When you perform this calibration, you have the option of running this program before and after you run the sample program, to ensure that the robot starts and ends the calibration at the home position. Refer to Section for information on how to create a home program.
- 810 -
12.DISPENSE TOOL
B-82594EN-4/01
Calibration Procedure Use Procedure 12-8 to perform 2PNT flow rate control calibration.
Procedure 12-8 Performing 2PNT Flow Rate Control Calibration NOTE 1 If a 2PNT calibration is enabled, you should perform this calibration for the flow rate type you want to use on this robot. 2 If you also have multiple equipment, you must perform the 2PNT flow rate control calibration for each one.
Before Running theCalibration • • • •
• •
A home program has been defined. (Subsection 12.4.2.2) A seal schedule SS[30] has been defined. (Subsection 12.2.3) A sample program has been defined. It must dispense two simple, measurable beads using SS[30]. Subsection 12.4.2.2) All dispenser I/O has been properly defined. (Subsection 12.2.7) he Robot motion test cycle parameter is set to ENABLE. (Refer to Section 12.6, "Testing a Program and Running Production" for more information.) The WET RUN test cycle parameter is ENABLED. (Refer to Section 12.6, "Testing a Program and Running Production" for more information.) The "Two_Point Calibration" feature is enabled on the Controlled start menu.
Steps 1 2 3 4 5 6
Press MENUS. Select SETUP. Press F1, [TYPE]. Select the equipment you want to calibrate. Move the cursor to Flow rate control. Press F2, DETAIL. You will see a screen similar to the following.
NOTE The number of the currently selected equipment is displayed in the middle of the title line on every screen. The currently selected equipment for the screen in this procedure is equipment 1, E1.
- 811 -
12.DISPENSE TOOL
B-82594EN-4/01
SETUP Equipment E1 Dispensing Equipment Flow Rate Calibration Calibration status: DEFAULT Seal sched in MOV_SEAM: 30 1 Flow rate type: TCPP Bead Width 2 Desired flow rate: 0.0 mm 3 Nominal TCP speed: 500 mm/s 4 Secondary TCP speed: 200 mm/s 5 Sample program: [MOV_2PNT] 6 Home program: [MOV_HOME] TCPP BW scale factor: 1.000 TCPP BW bias: 0.000 Enter the first measured bead width (mm):
7 8
To display help information , press NEXT, >, and then press F1, HELP. When you are finished displaying help information, press PREV. Specify the flow rate type as follows: a Move the cursor to Flow rate type. b Press F4, [CHOICE]. c Move the cursor to the flow rate type you want and press ENTER.
NOTE Only the TCPP or PROG related flow types are valid for this calibration. 9 10 11 12
13 14 15
Move the cursor to Desired flow rate, type the desired flow rate, and press ENTER. Move the cursor to Nominal TCP speed, type the speed value, and press ENTER. Move the cursor to Secondary TCP speed, type the speed value, and press ENTER. Specify the name of the sample program and the name of the home program as follows: a Move the cursor to Sample program or Home program. b Press F4, [CHOICE]. c Move the cursor to the program name you want and press ENTER. Make sure all items on this screen are correct and that you have satisfied all of the conditions listed in the "Before Running the Calibration Section" at the beginning of this procedure. When you are ready to start the calibration , press F3, START. If the robot is not at the home position, you are prompted to move the robot to the home position, as shown in the following screen. Robot will move to HOME pos. OK to continue? YES NO
a
Select YES and press ENTER. - 812 -
12.DISPENSE TOOL
B-82594EN-4/01
b
16
Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. c Adjust the speed override to an appropriate value for the conditions. d To move the robot , press and hold SHIFT and press F5, MOVE. e Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch. To move the robot along the sample seam defined by the program MOV_2PNT, Robot will move along the sample program. Material will be dispensed. Start calibration? YES NO
a b c
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. Adjust the speed override to 100%.
NOTE Make sure the speed override is set to 100%. Although you do not have to do this to continue, best results are obtained when running the sample seam at 100% of the programmed speed. d e
To move the robot , press and hold SHIFT and press F5, MOVE. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch. The robot will move through the positions in the sample program, turning the gun on and off when the SS[30] and SE instructions are executed. After the program has finished executing, you must measure the two flow rates dispensed and enter them when prompted. You will see a screen similar to the following.
SETUP Equipment E1 Dispensing Equipment Flow Rate Calibration Calibration status: DEFAULT Seal sched in MOV_SEAM: 30 1 Flow rate type: TCPP Bead Width 2 Desired flow rate: 0.0 mm 3 Flow model: LINEAR 4 Nominal TCP speed: 500 mm/s 5 Secondary TCP speed: 200 mm/s 6 Sample program: [MOV_2PNT] 7 Home program: [MOV_HOME] TCPP BW scale factor: 1.000 TCPP BW bias: 0.000
- 813 -
12.DISPENSE TOOL
B-82594EN-4/01
NOTE If your flow rate type is one of the volume flow rates (TCPP volume, or PROG volume), you will be prompted for both seam volume and seam length. 17 18
Measure the first bead width, type it in millimeters, and press ENTER. The measured bead width can be zero. Measure the second bead width, type it in millimeters, and press ENTER.
NOTE When the MOV_2PNT program has completed, the calibration menu will ask for the actual measured bead width of both seams. Measure them in an area at least 25mm off the starting point of the seam, where the bead width has stabilized, and enter the data in the correct order. Each seam must be more than 35mm long. 19
If the measured bead width is zero, decide whether to increment the local scale factor, as shown on the following screen. Measured bead width was zero. Check dispensing equipment. OK to increment local scale factor by 1.0? YES NO
•
20
To increment the local scale factor, select YES and press ENTER. • To keep the local scale factor the same, select NO and press ENTER. After entering the information at the end of the calibration, the new scale factor and bias will be calculated and you will be prompted to approve them. If you enable the new scale factor and bias, these values will be used in calculating the 2PNT flow rate for the currently selected flow rate type. If the robot is not at the home position, you are prompted to move the robot to the home position, as shown in the following screen. Robot will move to HOME pos. OK to continue? YES NO
a b
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. - 814 -
12.DISPENSE TOOL
B-82594EN-4/01
c d e
12.2.7
Adjust the speed override to an appropriate value for the conditions. To move the robot , press and hold SHIFT and press F5, MOVE. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch.
Setting Up Equipment I/O You must set up I/O for Gear Meter dispensing equipment. Inputs are listed in Table 12.2.7 (a). Outputs are listed in Table 12.2.7 (b). Note For safety reasons, the default I/O port index value is set to zero. Be sure to set the indexes to the appropriate values before using the system. You can set up and configure dispenser I/O from the I/O Sealing screen.
Item Dispenser ready Digital input
In-process Digital input
Volume OK Digital input
Major fault Digital input
Minor fault Digital input
Automatic mode Digital input Manual mode Digital input Depressurized Digital input Drum empty Digital input
Table 12.2.7 (a) Dispenser Inputs Description This signal indicates that the dispenser is functioning properly with no faults that prevent a normal dispense cycle (for example, the signal might indicate that all mechanical and physical devices are active and ready to dispense). This signal requires the dispenser to be in the automatic mode and at the proper temperature if applicable. This signal indicates that the dispense system has received a valid style in the dispensing process. This is the period of time between the “style strobe“ and “dispense complete“ signals from the robot. During this time, all dispense monitoring functions will be able to operate. This signal indicates that the volume dispensed for the given style was completed within the predefined limits. When valid, this signal is sent within 50 ms of receiving the "dispense complete" signal from the robot. This signal can be asserted in conjunction with a minor fault. If this signal is asserted, the part and job will be released. This signal indicates that an error has occurred within the dispensing equipment. This error will halt robot motion and require manual intervention. At the dispenser user interface panel, determination of a major and minor fault will be programmable. This signal will be sent within 50 ms of a fault occurrence. The "major fault" signal will be monitored continuously by the robot. This signal indicates that an error has occurred. These errors cause an alert, but they do not stop the processing of the current or next job. At the dispenser user interface panel, determination of a major and minor fault will be programmable. Minor faults will be tracked by the dispenser, and they might result in a major fault after a specified number of occurrences. This signal will be sent within 50 ms of a fault occurrence. The robot will check only minor faults after the "dispense complete" signal has been asserted. This signal indicates that the dispenser is in the automatic mode. This mode is set manually at the dispenser. This signal indicates that the dispenser is in the automatic mode. This mode is set manually at the dispenser. This signal indicates that the dispense equipment has achieved a de-pressurized state as determined by a pressure-sensing device. As the pressure exceeds the de-pressurized value, this signal will drop low. This signal indicates that one or both material supply drums are empty. In a single material supply pump system, a "drum empty" signal is followed by a "major fault signal. In a dual material supply pump system with cross over, a "drum empty" signal alone is used if only one drum is empty. However, if both drums are empty, a "drum empty" signal is followed by a "major fault" signal.
- 815 -
12.DISPENSE TOOL
B-82594EN-4/01
Item Flow meas. bypas Digital input Vol. Dispensed Group input Dispense fault data Group input Rmt strt in proc Digital input (for option Remote Start) Bubble detected Digital input (for option Bubble Detect) Meter full Digital input (for type Shot Meter) Meter empty Digital input (for type Shot Meter)
Meter near empty Digital input (for Shot Meter) Mtr pressurized Digital input (for type Shot Meter) Prim. chk passed Digital input (for type Urethane Glass System) Prim. Chk failed Digital input (for type Urethane Glass System) Felt advanced Digital input (for type Clear and Black) Change brush Digital input (for type Clear and Black) Purge request Digital input (for option Auto Purge) Purge in process Digital input
Description This signal indicates that the dispense controller is operating without flow measurement capability. If this input is ON, the states of input signals Dispenser Ready, Major Fault, and Volume OK are ignored. This signal shows 12 bits of data representing the total volume dispensed for the style that is processed. This signal shows 8 bits of data representing the fault status of the dispensingsystem. This signal indicates that the remote start has been initiated by the dispense controller. This signal will remain asserted until the dispense equipment is capable of dispensing. The remote start process will include achieving the proper temperature set point, if applicable. This signal indicates that the dispense controller has detected a bubble (material gap) in the bead while dispensing.
This signal indicates that the shotmeter is full. The signal drops low as the shotmeter piston clears the sensor. This signal indicates that the shotmeter is empty or nearly empty as identified by a sensor. (The positioning of the sensor for this signal is adjustable.) This signal can be used in systems that perform multiple styles within a single refill or a single style that requires a greater volume than available from a single shot. This signal will remain asserted until the piston’s sensor is above the previously set position. This signal indicates that the shotmeter is nearly empty as identified by a sensor. This signal will remain asserted until the piston’s sensor is above the previously set position. This signal indicates that the shotmeter is at the specified pressure. The pressure is specified by using the "pre-pressurize shotmeter" signal and an analog input voltage that is proportional to the desired pressure. This signal drops when the dispensing is initiated by the robot. This signal indicates that the primer check passed.
This signal indicates that the primer check failed.
This signal indicates that the indexing of the felt is complete.
This signal indicates that the robot has been initiated to change the primer brsh.
This signal is from the dispenser and requests a purge due to dispense inactivity (based on a user-definable time). If the robot is not at the purge position, the robot will request the move from the PLC using the appropriate style and option bits. The purge and home positions can be the same. (for option Auto Purge) This signal is from the dispenser and indicates that the purge operation is in process. This signal will reset after the purge operation is complete. The "purge in process" signal should be sent within 50 msec of the "OK to purge" signal.
- 816 -
12.DISPENSE TOOL
B-82594EN-4/01
Item Open gun Digital output Flow command Analog output Bead shaping cmd Analog output * (for option Atom Air) Style Bits Group output Style strobe Digital output Fault reset
Dispenser Fault
Dispenser Alert
Dispense complete Digital output
Remote start Digital output (for option Remote Start) Prepressurize Mtr Digital output (for type Shot Meter) Reload meter Digital output (for type Shot Meter)
Depressurize Digital output (for type Shot Meter)
Wait Primer Data Digital output (for type Urethane Glass System)
Table 12.2.7 (b) Dispenser Outputs Description This signal, when asserted, tells the dispenser to turn on guns one through five.Any combination of the guns can be "on" at any given time. This analog signal, 0 to 10 V, is comprised of 12 bits that controls the dispense flow rate. This analog signal, 0 to 10 V, is comprised of 12 bits that controls the bead shaping of the dispensed material. This is a five-bit group (binary number) output signal that is used to relay the style information to the dispenser. This signal indicates that the style bits are set, per body style, in order for the dispenser to read them. This output remains ON until volume and fault information is read at the end of the dispense cycle. This output signal goes to the dispenser to reset the fault at the dispenser. Fault reset output is automatically asserted just before sending the style strobe is sent to the dispenser, or just before resuming a paused program. This output signal is always updated to reflect the status of "Major fault" input from the dispenser. This signal can be used by the PLC to monitor the status of the dispenser. This output signal is always updated to reflect the status of "Minor fault" input from the dispenser. This signal can be used by the PLC to monitor the status of the dispenser. This signal is asserted when the dispense cycle is complete. This signal will initiate the dispenser to perform the volume calculations for the current job. Based on the volume dispensed, the "volume OK" signal with or without a minor fault can be asserted. Moreover, a major fault will be asserted based upon the volume dispensed. The "dispense complete" signal shall be pulsed for 50 ms. This signal will be sent from the robot to the dispenser regardless of the result of the previous cycle. The "dispense complete" signal will also be sent as a precautionary measure from the robot to the dispenser when the robot is first turned on. This signal restarts the dispense system from a de-pressurized state. After the de-pressurization, the dispenser will be restored to its previous mode. However,this mode restoration will be possible only if no other manual functions have been selected to change the mode. This signal is used to pre-set the pressure of a shotmeter after a refill. This signal will be preceded by the analog "material flow command" signal. Both signals will drop low when the "meter pressurized" signal is received from the dispenser. This signal is used to prompt a shotmeter to reload or refill. The shotmeter will only refill while the signal is high in order to allow partial refills. This signal will drop low after a preset time following a partial refill or when the "meter full" signal is received from the dispenser. The dispense controller will de-assert the "dispense ready" signal while the reload operation is in progress. If the reload operation is not done properly or a fault occurs during the operation, the dispenser will assert the "major fault" signal. This signal is used to relieve pressure from the shotmeter. This signal can be used in conjunction with the analog "material flow command" signal to reduce the pressure to a specific value. Without an analog signal, the pressure will be reduced to a user-predefined value. This signal will remain low until the "de-pressuriz ed" signal is set by the dispense equipment. This signal informs the dispense controller and PLC that the robot is waiting for a primer check passed of failed input signals before processing with the Urethane operation.
- 817 -
12.DISPENSE TOOL
B-82594EN-4/01
Item
Description
Clear complete: Digital output (for type Urethane Glass System) Black complete: Digital output (for type Urethane Glass System) Urethane complete: Digital output (for type Urethane Glass System) Advance felt Digital output (for type Clear and Black) Brush change complete Digital output OK to purge Digital output (for option Auto Purge) Channel 2 analog **
This signal indicates that the robot has complete the clear primer application.
This signal indicates that the robot has completed the black primer application.
This signal indicates that the robot has completed the urethane application.
This signal informs the dispense controller and PLC to perform an index of the felt.
(for type Clear and Black) This signal indicates that the brush change has been successfully completed. This signal indicates to the dispenser that it is OK to purge. This signal can be received from either the robot or a mechanical device that indicates the robot is at the purge position. The dispenser will drop the "dispense ready" signal during the purge process. This is an output signal that provides secondary TCPP-controlled analog output.
* Displayed if beadshaping is used. ** Displayed if Channel 2 Analog is enabled. You can set up and configure dispenser I/O from the I/O Sealing DETAIL screen.
Item Digital Inputs/Outputs Rack Number
Slot Number
Starting Point Comment
Table 12.2.7 (c) I/O Sealing DETAIL Screen Items Description This item indicates the range of digital inputs and outputs. This item is the physical location on which the I/O board or module is mounted. To change the rack number value, 1. Move the cursor to the Rack Number field. 2. Type the new value. 3. Press ENTER. This item is the space on the rack where the I/O module is connected. To change the slot number value, 1. Move the cursor to the Slot Number field. 2. Type the new value. 3. Press ENTER. This item is the port number within the sequence of ports on the board or module. This item is a text field into which you can type a descriptive comment. To type a comment, 1. Move your cursor to the appropriate line. 2. Press ENTER. 3. Type the comment. 4. Press ENTER.
- 818 -
12.DISPENSE TOOL
B-82594EN-4/01
Item Polarity
Complementary
Description This item is indicates whether signals are of NORMAL or INVERSE polarity. To set the polarity, 1. Move the cursor to the Polarity field. 2. Press F4, INVERSE, or F5, NORMAL. This item indicates whether signals are controlled as complementary pairs. To set complementary pairs, 1. Move the cursor to the Complementary field. 2. Press F4, TRUE, or F5, FALSE.
The timing diagram in Fig. 12.2.7 indicates the I/O handshaking between the robot and the dispenser at the beginning of a job (when the StyleID is sent to the dispenser) as well as at the end of the job (when VolumeOK, Major Fault, or Minor Fault are sent to the dispenser).
Fig. 12.2.7 StyleID - In Process - DispenseComplete I/O Handshaking
Setting up Equipment I/O Procedure 12-9 contains information about setting up equipment I/O only. For information about configuring, forcing, verifying, and simulating analog, digital, and group signals, refer to Chapter 3, “SETTING UP THE HANDLING SYSTEM” and Chapter 6, “EXECUTING A PROGRAM”.
- 819 -
12.DISPENSE TOOL
B-82594EN-4/01
NOTE 1 If you have multiple equipment, you must set up equipment I/O for each one. 2 If you have a multiple gun configuration, you must set up the I/O index for all guns of all equipment. Procedure 12-9 Setting Up Equipment I/O NOTE Refer to Subsection 12.2.7 for details on setting up equipment I/O.
Steps 1 2 3 4
Press MENUS. Select I/O. Press F1, [TYPE]. Select Dispenser. You will see either the input or output screen for the currently selected equipment. You will see a screen similar to the following.
NOTE The number of the currently selected equipment is displayed in the middle of the title line on every screen. The currently selected equipment for the screens in this procedure is equipment 1, E1. I/O Sealing In E1 Dispensing Equipment NAME OUT PT SIM Gear Meter Disp. System 1/11 1 Dispenser ready: DI[¥¥1] U 2 In-process: DI[ 2] U 3 Volume OK: DI[ 3] U 4 Major fault: DI[ 4] U 5 Minor fault: DI[ 5] U 6 Automatic mode: DI[ 6] U 7 Manual mode: DI[ 7] U 8 Depressurized: DI[ 8] U 9 Drum empty: DI[ 9] U 10 Flow meas. bypas: DI[ 10] U 11 Vol. dispensed: GI[ 1] * 12 Disp fault data: GI[¥¥2] * 13 Rmt strt in proc: DI[ 0] * 14 Bubble detected: DI[ 0] * 15 Purge request: DI[ 0] * 16 Purge in process: DI[ 0] *
5
VALUE OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF **** **** *** *** *** ***
To change between the input and outputscreens , press F3, IN/OUT. You will see a screen similar to the following.
- 820 -
12.DISPENSE TOOL
B-82594EN-4/01
I/O Sealing Out E1 Dispensing Equipment NAME OUT PT 1 Open gun 1: DO[ 1] 2 Open gun 2: DO[ 0] 3 Open gun 3: DO[ 0] 4 Flow command: AO[ 1] 5 Style Bits: GO[ 1] 6 Style strobe: DO[ 2] 7 Fault reset: DO[ 3] 8 Dispenser Fault: DO[ 4] 9 Dispenser Alert: DO[ 5] 10 Channel 2 analog: AO[ 0] 11 Atomizing air: AO[ 2]
12.2.8
SIM VALUE U OFF * *** * *** U 0 U 0 U OFF U OFF U OFF U OFF U 0 U 0
Gun Purge You can purge material from the dispensing gun to remove material prior to using new material or prior to gun cleaning.
Item Purge rate Guns used
Table 12.2.8 MNFCTN: PURGE Screen Items Descripton This item is the flow rate during the purge process. This item allows you to select the guns to be used during purging. This item is displayed only if the number of guns selected (at CTRL start) is greater than 1
Use Procedure 12-10 to purge the gun.
Procedure 12-10 Purging the Gun
Conditions •
The SEAL ENBL LED is on. (Refer to Chapter 17 STATUS DISPLAYS AND INDICATORS for more information.)
1 2 3
Press MAN FCTNS. Press F1, [TYPE]. Select Purge. You will see a screen similar to the following.
Steps
NOTE The number of the currently selected equipment is displayed in the middle of the title line on every screen. The currently selected equipment for the screens in this procedure is equipment 1, E1. MANFCTN: PURGE E1 Sealing Equipment 1/2 To purge: Press SHIFT and F2 (PURGE) To stop purging: Press F3 (STOP) Set to WET run and enable TP
- 821 -
12.DISPENSE TOOL
B-82594EN-4/01
1 Purge rate: 2 Guns used:
4 5
6 7
8 9 10 11
12.2.9
0.0 V 1-----
To display help information , press NEXT, >, and then press F1, HELP. When you are finished displaying help information, press PREV. To select the equipment number , a Check the currently selected equipment number. The equipment number is displayed to the right of the screen name as E# , where # is the equipment number. If the number displayed is the equipment number you want, go to Step 6 . b Press NEXT, >. c Press F3, EQUIP. d Type the number of the equipment and press ENTER. To set the purge rate, move the cursor to Purge rate, enter the purge rate voltage and press ENTER. To select which guns will be used during the purge, a Move the cursor to Guns used. b Move the cursor to the position that corresponds to the gun number. c Press the function key that corresponds to the value you want: • To select a gun to be used during the purge, press F4, #, where # corresponds to the number of the gun. • To specify that a gun will not be used during the purge, press F5, - . Place a container under the dispensing tool to catch the dispensed material. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. To purge, press and hold SHIFT and press F2, PURGE. To stop purging, press F3, STOP.
Channel 2 Analog Control Setup The dispensing process might require a secondary analog signal which could be used by Fan Air to control the bead shape or other items. This signal is called the Channel 2 Analog signal. The portion of this signal that provides the Channel 2 signal at the correct value and at the proper time is called the Channel 2 (Ch2) control. This section contains the following information about Channel 2 control: • Concepts • Calibration • Timing
- 822 -
12.DISPENSE TOOL
B-82594EN-4/01
12.2.9.1 Concepts This section contains a description of the concepts involved in Channel 2 control: • Speed compensation • Channel 2 type • Channel 2 calculation
Speed Compensation The rate at which material flows from the nozzle is usually proportional to robot speed. In general, • When the robot is moving slowly, the flow rate should be low. • When the robot is moving quickly, the flow rate should be high. DispenseTool uses three methods to compensate for robot speed while dispensing material: • Tool center point speed prediction (TCPP) • Programmed speed prediction (PROG) • No robot speed compensation (CONST) Tool center point speed prediction is the most accurate speed compensation method. This method is recommended for all applications in which it is critical that the flow rate be proportional to the robot speed. In TCP speed prediction, the robot looks ahead an amount of time equal to the EQUIPMENT ANT-TIME (specified in the current sealing schedule) to check what the robot speed will be. DispenseTool then adjusts the analog flow command signal to be proportional to what the robot speed will be after the EQUIPMENT ANT-TIME has elapsed. Programmed speed prediction is similar to TCP speed prediction in operation, but is partially accurate. In programmed speed prediction, the theoretical robot speed - the speed programmed in the PROCESS teach pendant program - is used to adjust the analog flow command signal. Programmed speed prediction is accurate when the robot is not accelerating, decelerating, going around corners, changing direction, or changing orientation. Theno robot speed compensation method uses neither TCP nor programmed speed prediction. This is appropriate only for the very few applications in which the analog signal does not have to be proportional to the robot speed. Table 12.2.9.1 (a) lists each method and when to use it. Refer to the sections that follow for a description of each speed compensation method.
- 823 -
12.DISPENSE TOOL
Method
B-82594EN-4/01
Table 12.2.9.1 (a) Speed Compensation Methods Is it Proportional to Is it Accurate? Robot Speed?
Use this Method When...
Tool center point speed prediction (TCPP) Programmed speed prediction (PROG)
Yes
Yes, most accurate of the three methods.
It is important for the flow rate to be proportional to the robot speed.
Yes
Only when the robot is not accelerating, decelerating, going around corners, changing direction, or changing orientation.
No robot speed compensation (CONST)
No.
Only when the robot is not accelerating, decelerating, going around corners, changing direction, or changing orientation. Yes.
It is not important for the flow rate to be proportional to the robot speed.
NOTE The proper selection and usage of speed compensation methods depends upon the application process.
Channel 2 Type Channel 2 type defines how the Channel 2 controlled variable will be measured. DispenseTool offers the following Channel 2 types: • Bead width - measured in millimeters • Percentage - of flow rate range • Volume - measured in cc/meter • Voltage - measured in a direct voltage to be applied to the analog output signal that controls the flow rate • Pressure - measured in PSI or BAR Table 12.2.9.1 (b) lists the speed compensation methods that can be used for each flow type. Table 12.2.9.1 (b) Speed Compensation Methods for Each Flow Type Flow Type Speed Compensation Method Bead width (mm)
Percentage (%))
Volume (cc/m)
Voltage (v)
Pressure (PSI) Pressure (BAR)
TCP speed prediction Programmed speed prediction No speed compensation TCP speed prediction Programmed speed prediction No speed compensation TCP speed prediction Programmed speed prediction No speed compensation TCP speed prediction Programmed speed prediction No speed compensation No speed compensation No speed compensation
You set the flow types in each Seal Schedule. Refer to Subsection 12.2.3.
- 824 -
12.DISPENSE TOOL
B-82594EN-4/01
Channel 2 Analog Calculation(Traditional Method) The Channel 2 output is calculated based on the kind of speed compensation that is used. There is a separate Channel 2 calculation for Channel 2 types that use TCP speed prediction, programmed speed prediction, and no speed compensation. The equations for each kind of speed compensation are described as follows. Table 12.2.9.1 (c) contains a description of each item used in these equations. Any Channel 2 type that uses TCP speed prediction uses the equation in Fig. 12.2.9.1 (a) to determine the Channel 2 output.
Fig. 12.2.9.1 (a) Channel 2 Equation with TCP Speed Prediction
Any Channel 2 type that usesprogrammed speedprediction uses the equation in Fig. 12.2.9.1 (b) to determine the Channel 2 output.
Fig. 12.2.9.1 (b) Channel 2 Equation with Programmed Speed Prediction
Any Channel 2 type that uses no speed compensation uses the equation in Fig. 12.2.9.1 (c) to determine the Channel 2 output.
Fig. 12.2.9.1 (c) Channel 2 Equation with No Speed Compensation
NOTE To convert volts to ticks (which appear on I/O menus), multiply volts by 200.0.
- 825 -
12.DISPENSE TOOL
B-82594EN-4/01
Table 12.2.9.1 (c) Items used in Channel 2 Output Calculation Equations (Traditional Method) Item Description Ch2_Amount_in_Seal_Schedule
Scale_Factor_for_this_Ch2_Type
Ch2_Correction_Factor_in_Seal_Schedule
Tool_Center_Point_Predicted_Speed
Predicted_Programmed_Speed
Ch2_Bias_for_this_Equipment
This item obtains the desired Channel 2 amount in each sealing schedule. The units used correspond to the Channel 2 type you have selected in that schedule. This item is the scaling factor that is set up for each Channel 2 type during the Channel 2 control calibration procedure. There is a separate scale factor kept for each Channel 2 type. This factor is designed to convert the Channel 2 amount specified in each sealing schedule to a more useful internal designation for Channel 2 output. This item is the Channel 2 Correction Factor that appears in each Seal Schedule. Adjust this value when you want to change the analog flow command used when one Seal Schedule is active, but do not want to change the Channel 2 item on that schedule. This value is usually kept between 0.5 and 2.0. his item is determined by looking at what the robot speed will be fter the the Equipment Delay has elapsed. The Equipment Delay is specified in each Seal Schedule. This value is very accurate and under normal circumstances, the best choice for the application. The only time this information is not accurate is when the TCP speed prediction system goes into error mode, such as from a "Speed Limit" error. his item is the programmed speed (speed specified in your teach pendant program) that will predict the Equipment Delay. This value is not accurate when the robot is accelerating, decelerating, going around corners, changing direction, or changing orientation. TCP speed prediction is usually a better solution. This item is the Channel 2 Bias item that appears as a system variable in volts. This item is always added to the flow rate analog output. This item is 0.0 by default, and the normal range of values is between0.0 and 3.0.
Channel 2 Calculation: 2PNT (Two Point Calibrated Calculation Method) Similar to flow rate, the 2PNT (two point) Channel 2 Analog is calculated based on the two point calibration. The 2PNT equations for each kind of speed compensation are described as follows. Table 12.2.9.1 (d) contains a description of each item used in these equations. Any 2PNT Channel 2 type that uses TCP speed prediction uses the equation in Fig. 12.2.9.1 (d) to determine the Channel 2 output.
Fig. 12.2.9.1 (d) 2PNT Channel 2 Equation with TCP Speed Prediction
Any Channel 2 type that uses programmed speed prediction uses the equation in Fig. 12.2.9.1 (e) to determine the Channel 2 output. - 826 -
12.DISPENSE TOOL
B-82594EN-4/01
Fig. 12.2.9.1 (e) 2PNT Channel 2 Flow Rate Equation with Programmed Speed Prediction
NOTE 1 To convert volts to ticks (which appear on I/O menus), multiply volts by 200.0. 2 If you select this method, you must enable this in the CTRL start configuration menu, and perform the 2PNT calibration. Refer to Subsection 12.2.6.6. Table 12.2.9.1 (d) Items used in Channel 2 Output Calculation Equations (2PNT Calibrated Method) Item Description Ch2_Amount_in_Seal_Schedule
Scale_Factor_for_this_Ch2_Type
Ch2_Correction_Factor_in_Seal_Schedule
Tool_Center_Point_Predicted_Speed
Predicted_Programmed_Speed
Ch2_Bias_for_this_Equipment
2PNT_Bias_Ch2
This item obtains the desired Channel 2 amount in each sealing schedule. The units used correspond to the Channel 2 type you have selected in that schedule. This item is the scaling factor that is set up for each Channel 2 type during the Channel 2 control calibration procedure. There is a separate scale factor kept for each Channel 2 type. This factor is designed to convert the Channel 2 amount specified in each sealing schedule to a more useful internal designation for Channel 2 output. This item is the Channel 2 Correction Factor that appears in each Seal Schedule. Adjust this value when you want to change the analog flow command used when one Seal Schedule is active, but do not want to change the Channel 2 item on that schedule. This value is usually kept between 0.5 and 2.0. This item is determined by looking at what the robot speed will be after the the Equipment Delay has elapsed. The Equipment Delay is specified in each Seal Schedule. This value is very accurate and under normal circumstances, the best choice for the application. The only time this information is not accurate is when the TCP speed prediction system goes into error mode, such as from a "Speed Limit" error. This item is the programmed speed (speed specified in your teach pendant program) that will predict the Equipment Delay. This value is not accurate when the robot is accelerating, decelerating, going around corners, changing direction, or changing orientation. TCP speed prediction is usually a better solution. This item is the Channel 2 Bias item that appears as a system variable in volts. This item is always added to the flow rate analog output. This item is 0.0 by default, and the normal range of values is between0.0 and 3.0. This item is a voltage bias obtained through 2PNT calibration. If the calibration is complete, the 2PNT_bias_Ch2 will be automatically added to the calculation equation.
- 827 -
12.DISPENSE TOOL
B-82594EN-4/01
12.2.9.2 Setup and calibration The Channel 2 control calibration sequence provides a way for the robot to translate the Channel 2 amount you specify in each sealing schedule (units of mm, %, cc/m, volts, PSI, or bar) into volts that are output to the dispensing controller. As explained in Subsection 12.2.9, the robot translates the Channel 2 amount specified in the sealing schedule into volts by multiplying the Channel 2 amount you specify by the scale factor for that Channel 2 type.
Scale Factors There are fourteen scale factors, one for each of the following possible Channel 2 types: • Bead width with TCP speed predicted • Bead width with programmed speed predicted • Bead width with no speed compensation • Percentage with no speed compensation • Volume with TCP speed predicted • Volume with programmed speed predicted • Volume with no speed compensation • Volts with no speed compensation • Pressure (PSI) with no speed compensation • Pressure (bar) with no speed compensation • Volts with TCPP speed predicted • Percentage with TCPP speed predicted • Volts with PROG speed predicted • Percentage with PROG speed predicted All of the scale factors have a default value of 1.0 when robot software is loaded. The default value of 1.0, however, is not typical for most Channel 2 equipment. Therefore, you must perform a Channel 2 control calibration sequence for each Channel 2 type you plan to use on the robot if you want the Channel 2 amount specified in each sealing schedule to be accurately reflected by the dispensing equipment.
Calibration Sequence The Channel 2 control calibration will lead you through a sequence of operations that will set up a scale factor for the current Channel 2 type. This calibration runs a sample program (MOV_SEAM, by default) and asks you to measure and enter the actual Channel 2 output. The robot uses this information to calculate the scale factor for the Channel 2 type. Table 12.2.9.2 lists and describes each Channel 2 control calibration item.
- 828 -
12.DISPENSE TOOL
B-82594EN-4/01
Item DESCRIPTION
Seal Schedule in MOV_SEAM value: 30 Ch2 Type
Desired Ch2 Amount
Sample Program default: MOV_SEAM
Home Program default: MOV_HOME
Table 12.2.9.Channel 2 Analog Control Calibration Items Description This item displays the calibration completion status for the selected Channel 2 type. • DEFAULT indicates that calibration has not been performed for the selected Channel 2 type and that the scale factor for the selected Channel 2 type is still 1.0. • COMPLETE indicates that calibration has been performed successfully for the selected Channel 2 type and that the scale factor for the selected Channel 2 type probably is not 1.0. This item indicates the sealing schedule that must be used in the current sample program, which is MOV_SEAM in this case. The information in this sealing schedule will be used to calculate the scale factor for the Channel 2 type in the specified schedule. This item indicates the Channel 2 type that will be used in this calibration. You must set this to the Channel 2 type you are using in the calibration. Editing this item is the same as editing Channel 2 type in the specified sealing schedule, which is sealing schedule 30 by default. This item indicates the target Channel 2 that will be used for this calibration. Set this to the Channel 2 amount that will be used most often in your process. Editing this item is the same as editing Channel 2 type in the specified sealing schedule, which is sealing schedule 30 by default. This item indicates the program that will be run as part of this calibration. The sample program should produce a sample Channel 2 output at a steady speed so that you can measure the sample output manually and enter the results into the robot. The sample program must use only SS[30] (where 30 is the number defined in the Seal sched used in MOV_SEAM item) to start sealing. No other SS should be used in this program. A default MOV_SEAM program is provided that includes the appropriate instructions. To use the default program, touch up the positions. This item indicates the name of a program that moves the robot to the home position. When you perform this calibration, you have the option of running this program before and after you run the sample program, to ensure that the robot starts and ends the calibration at the home position.
Calibration Procedure Use Procedure 12-11 to perform channel 2 control calibration.
Procedure 12-11 Performing Channel 2 Control Calibration NOTE 1 The number of the currently selected equipment is displayed in the middle of the title line on every screen. The currently selected equipment for the screen in this procedure is equipment 1, E1. 2 If you have multiple equipment, you must perform flow rate control calibration for each one.
Before Running the Calibration • • •
A home program has been defined. (Subsection 12.4.2.2) A seal schedule SS[30] has been defined. (Subsection 12.2.3) A sample program has been defined. It must dispense a simple, measurable bead using SS[30]. (Subsection 12.5.3.2) • All dispenser I/O has been properly defined. (Subsection 12.2.7) • The Robot motion test cycle parameter is set to ENABLE. (Subsection 12.6.3.1) • The WET RUN test cycle parameter is ENABLED. - 829 -
12.DISPENSE TOOL
B-82594EN-4/01
(Subsection 12.6.3.2)
Steps 1 2 3 4 5 6
Press MENUS. Select SETUP. Press F1, [TYPE]. Select the equipment you want to calibrate. Move the cursor to Channel 2 Analog. Press F2, DETAIL. You will see a screen similar to the following.
NOTE The number of the currently selected equipment is displayed in the middle of the title line on every screen. The currently selected equipment for the screen in this procedure is equipment 1, E1. SETUP Equipment E1 Dispensing Equipment Flow Rate Calibration Calibration status: DEFAULT Seal sched in MOV_SEAM: 30 1 Ch2 type: TCPP Bead Width 2 Desired Ch2 amount: 0.0 mm 3 Sample program: [MOV_SEAM] 4 Home program: [MOV_HOME] TCPP BW scale factor: 1.000
7 8
9 10
11 12 13
To display help information , press NEXT, >, and then press F1, HELP. When you are finished displaying help information, press PREV. Specify the flow rate type as follows: a Move the cursor to Ch2 type. b Press F4, [CHOICE]. c Move the cursor to the flow rate type you want and press ENTER. Move the cursor to Desired flow rate, type the desired flow rate, and press ENTER. Specify the name of the sample program and the name of the home program as follows: a Move the cursor to Sample program or Home program. b Press F4, [CHOICE]. c Move the cursor to the program name you want and press ENTER. Make sure all items on this screen are correct and that you have satisfied all of the conditions listed in the "Before Running the Calibration Section" at the beginning of this procedure. When you are ready to start the calibration , press F3, START. If the robot is not at the home position, you are prompted to move the robot to the home position, as shown in the following screen. - 830 -
12.DISPENSE TOOL
B-82594EN-4/01
Robot will move to HOME pos. OK to continue? YES NO
a b
14
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. c Adjust the speed override to an appropriate value for the conditions. d To move the robot , press and hold SHIFT and press F5, MOVE. e Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch. To move the robot along the sample seam defined by the program MOV_SEAM, Robot will move along the sample program. Material will be dispensed. Start calibration? YES NO
a b c
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. Adjust the speed override to 100%.
NOTE Make sure the speed override is set to 100%. Although you do not have to do this to continue, best results are obtained when running the sample seam at 100% of the programmed speed. d e
To move the robot , press and hold SHIFT and press F5, MOVE. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch. The robot will move through the positions in the sample program, turning the gun ON and OFF when the SS[30] and SE instructions are executed. After the program has finished executing, you must measure the flow rate dispensed and enter it when prompted. You will see a screen similar to the following.
- 831 -
12.DISPENSE TOOL
B-82594EN-4/01
SETUP Equipment E1 Dispensing Equipment Flow Rate Calibration Calibration status: COMPLETE Seal sched in MOV_SEAM: 30 Desired Ch2 rate: 5.0 mm Sample program: [MOV_SEAM] Home program: [MOV_HOME] TCPP BW scale factor: 1.00 Enter measured bead width (mm):
NOTE If your flow rate type is one of the volume flow rates (TCPP volume, PROG volume, or CONST volume), you will be prompted for both seam volume and seam length. 15 Measure the bead width, type it in millimeters, and press ENTER. The measured bead width can be zero. 16 If the measured bead width is zero, decide whether to increment the local scale factor on the following screen. Measured bead width was zero. Check dispensing equipment. OK to increment local scale factor by 1.0? YES NO
•
17
To increment the local scale factor, select YES and press ENTER. • To keep the local scale factor the same, select NO and press ENTER. After entering the information at the end of the calibration, the new scale factor will be calculated and you will be prompted to approve the new scale factor. If you enable the new scale factor, this value will be used in calculating the flow rate for the currently selected flow rate type. If the robot is not at the home position, you are prompted to move the robot to the home position, as shown in the following screen. Robot will move to HOME pos. OK to continue? YES NO
a b c
Select YES and press ENTER. Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. Adjust the speed override to an appropriate value for the conditions. - 832 -
12.DISPENSE TOOL
B-82594EN-4/01
d e
To move the robot , press and hold SHIFT and press F5, MOVE. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch.
12.2.9.3 Timing diagram The timing diagrams in this section show the timing for the relationship between Flow rate output and the Channel 2 output.
NOTE The system variables $SLSETUP[1].$a2_ss_ofst and $SLSETUP[1].$a2_se_ofst can be used to adjust the ON/OFF time of Channel 2 Analog.
Fig. 12.2.9.3 Generic Dispense Process Signal Timing Protocols
12.2.10
Nonlinear Flow Model DispenseTool can use the Square Flow type of nonlinear flow model. The square flow model uses the square function to calculate the flow rate output based on the following formula: AOUT = sf * mf * cf * (bw2 )+ bf - 833 -
12.DISPENSE TOOL
B-82594EN-4/01
where: AOUT - analog output sf - linear scale factor mf - material factor cf - correction factor bw - desired bead width bf - linear flow rate bias
NOTE The flow model item appears in each sealing schedule with a default value set to LINEAR. If you change this value to SQUARE FLOW, the DispenseTool software automatically calculates the flow rate output based on the formula above. Refer to Subsection 12.2.3 , "Setting Up Schedules," for more information.
12.2.11
Error Status Summary This section describes the status of the dispensing equipment when it is checked for incorrect status.
NOTE These descriptions are for a single equipment system only. If you are using a multiple equipment system, and the equipment which is not currently sealing causes the error, the robot will not be paused. The following conventions are used in this section: • • •
• •
I/O signal names are shown in all capital letters. In Fig. 12.2.11, DISPENSER E-STOP is an I/O signal name. Condition statements begin with the word "If." In Fig. 12.2.11, the condition statements are labeled. The step indented below a condition statement is executed if the condition statement is TRUE. In Fig. 12.2.11, for the first condition statement, the two lines that follow it will be executed if the condition statement is TRUE. If more than one step or series of condition statements is indented below a condition statement, the entire group of steps and conditions is marked with a bracket, as shown in Fig. 12.2.11. E%d represents the equipment number displayed through the DispenseTool core software. E%s represents the equipment number displayed through a KAREL program. If you have only one equipment, E%d or E%s will be E1.
- 834 -
12.DISPENSE TOOL
B-82594EN-4/01
Fig. 12.2.11 Example Signal Status
12.2.11.1 Group 1 This section shows the status of signals monitored for the following kinds of Group 1 equipment: • Shot Meter • Gear Meter • Variable Orifice • Pressure Regulator • Urethane Glass • Clear Black Sequence of Signals Monitored at All Times During Program Execution This section shows the status of signals that are monitored at all times during program execution.
Fig. 12.2.11.1 (a) Sequence of Signals Monitored at All Times
Sequence of Signals Monitored When the Controller is On This section shows the status of signals that are monitored when the controller is on.
- 835 -
12.DISPENSE TOOL
B-82594EN-4/01
Fig. 12.2.11.1 (b) Sequence of Signals Monitored When the Controller is On
Sequence of Signals Monitored When a JOB is Started This section shows the status of signals that are monitored when a JOB is started.
Fig. 12.2.11.1 (c) Sequence of Signals Monitored When a JOB is Started
Sequence of Signals Monitored When a JOB is Ended This section shows the status of signals that are monitored when a JOB is ended.
Fig. 12.2.11.1 (d) Sequence of Signals Monitored When a JOB is Ended
- 836 -
12.DISPENSE TOOL
B-82594EN-4/01
Sequence of Signals Monitored During SS[] and SE[] This section shows the status of signals that are monitored during SS[] and SE[].
Fig. 12.2.11.1 (e) Sequence of Signals Monitored During SS[] and SE[]
- 837 -
12.DISPENSE TOOL
B-82594EN-4/01
12.3
SETTING UP THE CELL
12.3.1
DispenseTool Cell Communication Setup Production operation is defined as running a dispensing job at speed while all production conditions are enabled. Before you production, you must set up the method for communicating information required to run production between the robot and controller. This is called cell communication setup .
full run the cell
The Cell Communication SETUP screen provides a way of setting up the general features of the cell interface. Most items on this screen require their own I/O signals. Only the signals required for the current Cell Communication SETUP screen will appear on the Cell I/O screen. This means that if there is a change in the Cell Communication SETUP screen there will also probably be a change in the Cell I/O screen.
CAUTION You must perform a Cold start after making any change to the Cell Communication SETUP screen or Cell I/O screen in order for those changes to take effect. Refer to Chapter . Table 12.3.1 lists and describes the Cell Communication SETUP screen items. Table 12.3.1 Cell Communication SETUP Items Cell communication setup item Robot State Reporting default: DISABLE
Hold Cycle Complete High default: DISABLE
Description If this is ENABLED, Robot State Reporting will cause the following digital output signals to appear on the Cell Output screen: • POWER ON Robot has successfully turned on • ROBOT READY Robot is ready for the next job • CLEAR OF TRANSFER Set ON by the CLEAR OF TRANSFER macro • NO FAULTS IN JOB There were no problems in this sealing job • HEARTBEAT Alternates between ON and OFF every 896 ms while the system is running • PROCESS DATA CTRL Control codes for process data • PROCESS DATA Processes input data If this is ENABLED, the CYCLE COMPLETE signal will stay ON from the end of one job until the start of the next one. If DISABLED, the CYCLE COMPLETE signal will be pulsed for the length of the Pulse Signal Width item on the Cell Communication SETUP screen.
- 838 -
12.DISPENSE TOOL
B-82594EN-4/01
Cell communication setup item Test Run Fault Handling default: ENABLE
TP Fault Recovery default: ENABLE
PLC Fault Recovery default: DISABLE
PLC Fault Reporting default: DISABLE
Degrade/Backup Groups default: DISABLE
Number of User DINs default: 0 min: 0 max: 10 Number of User DOUTs default: 0 min: 0 max: 10
Description If this is ENABLED, the DispenseTool enhanced error handler will be active during testing as well as production runs. The error handler could, if the appropriate options are enabled, do the following during a SOP or teach pendant initiated execution: • Report all errors which occur to the cell controller. • Force the TP fault recovery screen to activate if the program is paused. • Allow the cell controller fault recovery to be active if the robot remote lamp is ON. production runs. If DISABLED, the DispenseTool enhanced error handling mechanism and fault recovery screens will be active during If this is ENABLED, the robot will display the Fault Recovery Menu on the teach pendant screen when the robot encounters an error severe enough to stop production. You will then be able to select the desired fault recovery option from the teach pendant keypad to resume or abort production. If this is DISABLED, you will still be able to reach the Recovery screen through the ALARMS screen. When this is ENABLED, the following signals will appear on the Cell I/O screen: Cell Output screen: • WAITING FOR PLC The robot is waiting for the PLC to respond • PROGRAM ABORTED The program has been aborted • BOOTH RESET REQUEST Robot requests that the entire cell (booth) be reset(normally done to clear cell E-Stops) Cell Input screen: • CONTINUE WET Robot should continue with dispensing material • CONTINUE DRY Robot should continue without dispensing material • ABORT JOB Robot should abort this job The robot uses these I/O signals to allow the cell controller to lead the robot through fault recovery remotely, independent of the teach pendant. It is possible to have both teach pendant and cell controller fault recovery ENABLED, in which case the robot will accept fault recovery instructions from either source. When this is ENABLED, the following signals will appear on the Cell I/O screen: Cell Input Screen: • FAULT ACK STROBE Pulsed by the cell controller to acknowledge that a fault has been received These signals are used to report all errors to the cell controller in the order in which they occur. This causes the BACKUP STYLE SELECT group input and (if the Acknowledge Style Data item in the Cell Communication Setup screen is set to TRUE) the BACKUP STYLE ACK group output to appear on the Cell I/O screens. DispenseTool will take no action based upon these signals, but will echo the data from BACKUP STYLE SELECT onto BACKUP STYLE ACK after the STYLE SELECT group is read, at the start of style handshaking. This allows you to indicate how many user inputs, for use in teach pendant or KAREL programs, should appear in the Cell Input screen.
This allows you to indicate how many user outputs, for use in teach pendant or KAREL programs, should appear in the Cell Output screen.
- 839 -
12.DISPENSE TOOL
B-82594EN-4/01
Use Procedure 12-12 to set up general cell communication information.
Procedure 12-12 Cell Communication Setup
Steps 1 2 3 4
Press MENUS. Select SETUP. Press F1, [TYPE]. Select Cell. See the following screen for an example of the default cell communications setup. SETUP E1 Cell Communication 1 Robot state reporting: DISABLE 2 Hold cycle comp. high: DISABLE 3 Test run fault handling: ENABLE 4 TP fault recovery: ENABLE 5 PLC fault recovery: DISABLE 6 PLC fault reporting: DISABLE 7 Degrade/backup groups: DISABLE 8 Number of user DINs: 0 9 Number of user DOUTs: 0 Please cold start after setting data.
5 6
To display help information, press NEXT, >, and then press F1, HELP. When you are finished displaying help information, press PREV. Select each item and set it as desired.
CAUTION You must perform a Cold start after making any change to the SETUP Cell Communication screen or Cell I/O screen in order for those changes to take effect. 7
12.3.2
When you are finished setting items, Cold start the controller. Refer to Subsection B.1.4 for more information.。
DispenseTool Cell Interface I/O Signals
12.3.2.1 Overview This section describes the cell I/O used by DispenseTool. The recommended I/O configuration uses program number select , or PNS, with acknowledge disabled and no job queue. Other communication formats can be selected using the RSR/PNS Cell Setup screen. Refer to Subsection 12.3.1 for more information on changing communication formats.
- 840 -
12.DISPENSE TOOL
B-82594EN-4/01
I/O Setup Sequence The steps involved in setting up cell I/O are 1 2
3 4 5
6
Carefully determine which handshaking protocol is to be used for this application. The handshaking protocols available are RSR and PNS. Refer to Subsection 12.3.1 . Using Table 12.3.2.2 and Table 12.3.2.3, determine which signals are necessary for the application. Remember to include fault reporting and recovery signals if they are used for this application. Map these signals to digital inputs and outputs. The individual UOP signals must be mapped consecutively in the order they are given in Table 12.3.2.2 and Table 12.3.2.3. Consult your FANUC Robotics representative to verify that your cell I/O map is correct. Configure communication handshaking in the Cell Setup screen. When you have finished, Cold start the controller. Refer to Chapter for information on performing a Cold start of the controller. Set up the cell I/O points.
NOTE You must perform a Cold start on the controller after any changes are made to the cell communication configuration menu, UOPs, groups, or digital I/O. Cell I/O consists of UOP signals, group signals, and digital signals. You must define the rack, slot, and start point of each signal you use. Table 12.3.2.2 lists the cell input signals. Table 12.3.2.3 lists the cell output signals. In these tables, a "*" that precedes a signal name indicates that the signal is asserted low. The first eight inputs and the first eight outputs shown in Table 12.3.2.2 and Table 12.3.2.3 are the User Operator Panel (UOP) I/O signals. These signals are always grouped together in the digital I/O system, but they can be assigned to whatever I/O location is required. The remaining I/O signals can be assigned individually to anywhere in the I/O system. The sizes of the I/O groups listed in the tables are user-configurable. Cell I/O consists of UOP signals, group signals, and digital signals. You must define the rack, slot, and start point of each signal you use.
- 841 -
12.DISPENSE TOOL
B-82594EN-4/01
12.3.2.2 DispenseTool cell interface input signals Input Signal *IMSTP UOP Input #1 Always active
Table 12.3.2.2 Cell Input Signals Description *IMSTP is the immediate stop software signal. *IMSTP is a normally OFF signal held ON. When it is set to OFF, it • Pauses a program if one is running • Immediately stops the robot and applies robot brakes • Shuts off power to the servos. This signal is always active.
System Variables N/A
WARNING *IMSTP is a software controlled input and cannot be used for safety purposes. Use *IMSTP with EMG1, EMG2, and EMGCOM to use this signal with a hardware controlled emergency stop. Refer to the maintenance manual for connection information of EMG1, EMG2, and EMGCOM. *HOLD UOP Input #2 Always active
* SFSPD UOP Input #3 Always active
*HOLD is the external hold signal. *HOLD is a normally OFF signal, held ON. When it is set to OFF, it will do the following: • Pause program execution • Slow motion to a controlled stop and hold • Optional Brake on Hold shuts off servo power after the robot stops *SFSPD is the safety speed input signal. This signal is usually connected to the safety fence. *SFSPD is a normally OFF signal held ON. When it is set to OFF it will do the following: • Pause program execution • Reduce the speed override value to that defined in a system variable. This value cannot be increased while *SFSPD is OFF. • Not allow a REMOTE start condition. Start inputs from UOP or PLC are disabled when *SFSPD is set to OFF and only the teach pendant has motion control with the speed clamped.
- 842 -
N/A
N/A
12.DISPENSE TOOL
B-82594EN-4/01
Input Signal CSTOPI UOP Input #4 Always active
Description CSTOPI is the cycle stop input. The function of this signal depends on the system variable $SHELL_CFG.$USE_ABORT. If the system variable $SHELL_CFG.$USE_ABORT is set to FALSE , the CSTOPI input clears the queue of jobs to be executed.
System Variables N/A
WARNING When $SHELL_CFG.USE_ABORT is false, CSTOPI does not stop automatic program execution
FAULT RESET UOP Input #5 Always active
CYCLE START UOP Input #6 Active when the robot is in a remote condition and the robot is not running a job (CMDENBL = ON)
HOME UOP Input #7 Active when the robot is in a remote condition and is not running a job
*ENBL UOP Input #8 Always active
If the system variable $SHELL_CFG.$USE_ABORT is set to TRUE , the CSTOPI input • Clears the queue of jobs to be executed • Immediately aborts the currently executing or paused program This signal will also cancel the current job, if the robot is waiting for error recovery instructions from the cell controller. FAULT RESET is the external fault reset signal. When this signal is received the following will happen: • Error status, signified by the FAULT (UOP output 6) output being high, is cleared. • Servo power is turned on • The paused program will not be resumed CYCLE START has two functions: to start the next job, or to continue the current one. The CYCLE START input must always be triggered to start the next PNS job. If the Job Queue is ENABLED, a job must first be placed into the queue with the PNS digital inputs and outputs. If the Job Queue is disabled, the CYCLE START input will cause the robot to read the STYLE SELECT group input and run the next job. The CYCLE START input is used for style initiation when the robot is in PNS mode but can be used only in error recovery if the robot is in RSR mode. If the current job is paused and PLC error recovery is enabled, this input will try to make the job continue in the current WET/DRY state. If the current job has been stopped and the program defined in $ERROR_PROG run, the $RESUME_PROG (if one is defined for this job) can be executed by pulsing this input. When this signal is received the robot executes the program "MOV_HOME," which will contain the return path. This input will only run MOV_HOME if a job is not already RUNNING or PAUSED. If the current job is PAUSED, this input will execute the current ERROR_PROG, if one has been defined for this job. ENBL is the enable input. This signal must be ON for the cell controller to have motion control. When ENBL is ON and the REMOTE switch on the operator panel is in the REMOTE position, the robot is in remote operating (cell controller) condition.
- 843 -
N/A
N/A
N/A
N/A
12.DISPENSE TOOL Input Signal STYLE SELECT‡ Group Input
BACKUP STYLE SELECT* Group Input
WET/DRY MODE‡ Digital Input
ERROR ACK STROBE‡ Digital Input CONTINUE WET‡ Digital Input
CONTINUE DRY‡ Digital Input
CANCEL THIS JOB‡ Digital Input
ZONE n IS CLEAR‡ Digital Input
B-82594EN-4/01
Description This input determines which style is to be used. This is a group of inputs which is necessary for both RSR and PNS communications so that the robot can be told which style program needs to be executed next. This group can be of any size desired, but it is normally between four and eight input lines. The standard DispenseTool cell interface takes no action based upon the contents of this group. If both the BACKUP STYLE SELECT group input and the BACKUP STYLE ACK group output have been correctly defined and set up, the contents of the BACKUP STYLE SELECT will be echoed onto the BACKUP STYLE ACK group during style handshaking, at the same time the STYLE SELECT group input is echoed onto the STYLE ACK group output. These signals only appear if the Degrade/Backup groups are enabled in the Cell Communication Setup screen. This input is checked every time a job number is read on the STYLE SELECT input group. If this signal is LOW at that time, the robot will be placed into DRY RUN mode when the job is executed. If this signal is HIGH, the robot will be placed in WET run. If a Job Queue is used, the state of this signal will be recorded with each Job Queue entry. This input, if correctly defined, can be used by the cell controller to acknowledge faults. $ER_OUT_PNT.$in_num If the current fault is recoverable, this input can be strobed by the cell controller to request that the robot continue the job in WET mode (with dispensing material enabled). This item appears on the Cell I/O screen if PLC Error Recovery is ENABLED. This input causes the robot to continue the job in DRY mode (without dispensing material) if possible. This item appears on the Cell I/O screen if PLC Error Recovery is ENABLED. This input should be pulsed by the cell controller to request that the current job be aborted. Note: Be careful not to abort a job in the middle of a restrictive work environment (such as a car body), as it will be difficult to return to the HOME position. The robot will stop wherever it is and inform the cell controller that the cycle is complete. This item appears on the Cell I/O screen if PLC Error Recovery is ENABLED. Up to five inputs can be used for interference zone handshaking. The ZONE n IS CLEAR input is used in the interference zone macro instructions to allow the cell controller to inform the robot when it is cleared to enter the interference zone. This output is normally LOW, in the "not clear" state.
- 844 -
System Variables $CELL_SETUP.$gi_stysel_t $CELL_SETUP.$gi_stysel_I
$SLCELLIO[1].$gi_bckup_int $SLCELLIO[1].$gi_bckup_ini
$SLCELLIO[1].$di_seal_ont $SLCELLIO[1].$di_seal_oni
$ER_OUT_PNT.$in_num
$SLCELLIO[1].$di_cont_wett $SLCELLIO[1].$di_cont_weti
$SLCELLIO[1].$di_cont_dryt $SLCELLIO[1].$di_cont_dryi
$SLCELLIO[1].$di_cancelt $SLCELLIO[1].$di_canceli
$IZONEIO.$di_zn n 1cl_t $IZONEIO.$di_zn n cl_i
12.DISPENSE TOOL
B-82594EN-4/01
Input Signal USER INPUT n ‡ Digital Input
Option bit A Option bit B Option bit C Decision code
Path seg continue
Description
System Variables
The number of user inputs to appear in the CELL I/O screen (up to five) is set up in the CELL SETUP screen. These inputs are intended for use in user teach pendant or KAREL programs and are in the CELL I/O screen for the convenience of setting and monitoring. The index numbers of these inputs, set in the CELL I/O screen, can be accessed in the system variables $SLCELLIO[x].di_usr_defxl, where x is the index number of the input, 1-9, and A. These inputs are used to specify specific options to go along with the selected style program. They do not affect which program is run, but can be used within a style program to control optional features or actions. This is a group input that can be read by the program as a numeric value to be used for making some type of decision or as some other type of internal value. This input is set by the PLC in response to the robot "path segment request" output
$SLCELLIO[1].$di_usr_def n t $SLCELLIO[1].$di_usr_def n i
‡
$cell_setup.$di_optna_I $cell_setup.$di_optnb_I $cell_setup.$di_optnc_i $cell_setup.$di_decsn_i
$cell_setup.$di_pthcnt_i
Set these signals using the Cell I/O screen. Refer to Procedure 12-13
12.3.2.3 DispenseTool cell interface output signals Output Signal CMDENBL UOP Output #1
SYSRDY UOP Output #2 PAUSED UOP Output #4 HELD UOP Output #5 FAULT UOP Output #6
Table 12.3.2.3 Cell Output Signals Description CMDENBL is the command enable output. This output will be ON if the robot is in the REMOTE condition (as indicated by the REMOTE light on the operator panel) and no faults exist (the teach pendant FAULT LED is OFF). For the robot to be in the REMOTE condition, all of the following conditions must be true: • The REMOTE/LOCAL keyswitch on the operator panel is in the REMOTE position. • UOP input #1 (IMSTP), UOP input #2 (HOLD), UOP input #3 (SAFETY FENCE), and UOP input #8 (ENBL) are all ON. • The robot is in AUTOMATIC mode. This means that the AUTO/BYPASS input must be ON. This will set the system variable $RMT_MASTER to 0. • The teach pendant is disabled. SYSRDY is the system ready output. This output indicates that servos are turned on. PAUSED is the paused program output. This output turns on when the current job program is paused. HELD is the hold output. This output turns on while the robot standard operator’s panel HOLD button is being pressed, or the UOP *HOLD input is OFF. FAULT is the error output. This output turns on when a job is in a severe error condition and is waiting for an outside response to an error.
- 845 -
System Variables N/A
N/A N/A N/A
N/A
12.DISPENSE TOOL Output Signal ATPERCH UOP Output #7
TPENBL UOP Output #8 BACKUP STYLE ACK‡ Group Output
IN CYCLE‡ Digital Output CYCLE COMPLETE‡ Digital Output
WET/DRY MODE‡ Digital Output
At HOME POSITION Digital Output
AT PURGE POSITION ‡ Digital Output
AT REPAIR POSITION ‡ Digital Output
POWER ON ‡ Digital Output
B-82594EN-4/01
Description ATPERCH is the at perch output. This output turns on when the robot reaches the predefined perch HOME position as defined as the last position in the MOV_HOME program. TPENBL is the teach pendant enable output. This output turns on when the teach pendant is on. The standard DispenseTool cell interface takes no action based upon the contents of this group. If both the BACKUP STYLE SELECT group input and the BACKUP STYLE ACK group output have been correctly defined and set up, the contents of the BACKUP STYLE SELECT will be echoed onto the BACKUP STYLE ACK group during style handshaking, at the same time the STYLE SELECT group input is echoed onto the STYLE ACK group output. This signal is on at all times from the start of a job until the job completes or is aborted. This signal goes high each time a job completes or is aborted. This signal is always pulled low when the next job begins. If the option, "Hold cycle complete high," is enabled, this signal will stay on from the completion of one job to the start of the next. Otherwise, the length of time the signal is ON is specified by the menu item in the Cell Communication Setup screen. Refer to Subsection 12.3.1 . This signal reflects the current DRY RUN status of the robot. This output will be ON if the robot is currently in WET RUN, OFF if in DRY RUN. This signal is updated every 250 milliseconds. This signal functions in the same way as the UOP AT PERCH output. This is a redundant signal, but is useful in installations that want to connect this output to a stack light or other display local to the robot. This signal is turned ON when the robot stops moving at or very near the HOME position (defined as the last position in the MOV_HOME teach pendant program) and turns OFF when the robot is moving or stops away from the HOME position. This input is used to tell the cell controller or system operator when the robot is at the defined PURGE position. The PURGE position is defined as the last position recorded in the program, MOV_PURG. This position is only updated upon Cold start. This input is used to notify the system operator that the robot is currently at the defined REPAIR position. The REPAIR position is defined as the last position in the program, MOV_REPR. This position is only updated upon a Cold start. This output only appears on the Cell I/O screen if the option, "Robot state reporting," has been enabled on the Cell Setup screen. This output is turned ON when the controller has successfully turned on and DispenseTool has started running and is never turned off.
- 846 -
System Variables N/A
N/A $SLCELLIO[1].$go_bckp_ac kt $SLCELLIO[1].$go_bckp_ac ki
$CELL_SETUP.$do_incycl_t $CELL_SETUP.$do_incycl_i $SLCELLIO[1].do_cyc_comp t $SLCELLIO[1].do_cyc_compi
$SLCELLIO[1].$do_seal_enb t $SLCELLIO[1].$do_seal_enb i $SLCELLIO[1].$do_at_homet $SLCELLIO[1].$do_at_homei
$SLCELLIO[1].$do_at_purgt $SLCELLIO[1].$do_at_purgi
$SLCELLIO[1].$do_at_svpos t $SLCELLIO[1].$do_at_svpos i $SLCELLIO[1].$do_power_o nt $SLCELLIO[1].$do_power_o ni
12.DISPENSE TOOL
B-82594EN-4/01
Output Signal ROBOT READY ‡ Digital Output
CLEAR OF TRANSFER ‡ Digital Output
PROCESS COMPLETE ‡ Digital Output
HEARTBEAT ‡ Digital Output
PROCESS DATA CONTROL CODE ‡ Group Output
PROCESS DATA ‡ Group Output
EQUIPMENT NUMBER Group Output
Description
System Variables
This output only appears on the Cell I/O screen if the option, "Robot state reporting," has been enabled in the Cell Setup screen. This output is high only when all of the following conditions are TRUE: • The cell controller has control of the robot (the operator panel REMOTE LED is ON). • A JOB is NOT running. • The robot is NOT in single step mode. • No faults currently exist and the robot is not in fault recovery mode. • The servo drives are turned on. • A HOME position has been set up and the robot is currently at the HOME position. (Refer to Subsection 12.4.2.2 .) This output is intended for use in determining when the robot is ready to start the next JOB. This output is updated every 3.5 seconds. This output only appears on the Cell I/O screen if the option, "Robot state reporting," has been enabled in the Cell Setup screen. This signal is intended to be used as an indication that the robot has moved far enough away from the transfer line that the workpiece can be indexed. This output is set to ON by the DispenseTool macro CLEAR OF TRANSFER, which is called in a user teach pendant program. It is automatically set to OFF when the next JOB begins. This output only appears on the Cell I/O screen if the option, "Robot state reporting," has been enabled on the Cell Setup screen. This signal is set to OFF only at the start of a JOB. This signal is set to ON at the end of a JOB only if the JOB completed without aborting early and no sealing was interrupted or skipped due to being in DRY RUN mode. This signal alternates between the ON and OFF state approximately every 640 milliseconds (ms). The signal is intended to verify the link between the robot and the cell controller, since a remote I/O link will keep the last state if the robot is turned off. It is recommended that the cell controller E-stop the robot and transfer lines if the signal does not change at least every 1000ms. This group is intended to hold a code that describes the contents of the PROCESS DATA group output. The codes in the PROCESS DATA CONTROL CODE group might indicate such items as material volume dispensed, gun on time, and the current cycle time. This output is reserved for use in site-specific customizations and will appear only if the Robot state reporting option has been enabled on the Cell SETUP screen. This group output is intended to hold actual process data that can be transmitted at the end of each JOB. This output will only appear if the Robot state reporting option has been enabled on the Cell SETUP screen. This group output is intended to be used to tell the cell controller which dispensing equipment is currently active. This signal has not yet been implemented.
$SLCELLIO[1].$do_robt_rdyt $SLCELLIO[1].$do_robt_rdyi
- 847 -
$SLCELLIO[1].$do_clr_xfert $SLCELLIO[1].$do_clr_xferi
$SLCELLIO[1].$do_no_errort $SLCELLIO[1].$do_no_errori
$SLCELLIO[1].$do_heartbea t $SLCELLIO[1].$do_heartbeai
$SLCELLIO[1].$go_proc_cod t $SLCELLIO[1].$go_proc_cod i
$SLCELLIO[1].$go_proc_datt $SLCELLIO[1].$go_proc_doti
$SLCELLIO[1].$go_eq_numt $SLCELLIO[1].$go_eq_numi
12.DISPENSE TOOL Output Signal WAITING FOR PLC RESPONSE ‡ Digital Output PROGRAM ABORTED ‡ Digital Output
PLC RESET REQUEST ‡ Digital Output
CLEAR OF ZONE n ‡ Digital Output
USER OUTPUT ‡ Digital Output
Style Strobe Style Request/Echo
Option request A Option request Option request C
Decision code req
B-82594EN-4/01
Description
System Variables
This output informs the cell controller that the robot is currently waiting for a continue or cancel signal from the cell controller. This signal only appears on the Cell I/O screen if PLC Fault Recovery has been ENABLED. This output will be turned ON if the teach pendant program was aborted before reaching the end of the program. This is usually caused by a fatal error or by selecting the ABORT (ALL) item on the FCTN menu of the teach pendant. This signal only appears on the Cell I/O screen if PLC Fault Recovery has been ENABLED. PLC RESET REQUEST informs the cell controller that one of the robot’s RESET buttons has been pressed, and that the cell controller should reset the errors of all robots on the line. This signal only appears on the Cell I/O screen if PLC Fault Reporting has been ENABLED. This output is always pulsed whenever any robot reset button is pressed. There are up to six outputs that can be used for interference zone handshaking. After the number of interference zones has been set up, the correct number of outputs will appear in the Cell I/O screen. The CLEAR OF ZONE n output is used to inform the cell controller that the robot is not currently in the zone specified by n . This signal is normally HIGH and should only become LOW if the robot asks the cell controller for permission to enter a zone, or is already in that zone. The number of user outputs to appear in the Cell I/O screen, up to ten, is set up in the Cell Setup screen. These outputs are intended for use in user teach pendant or KAREL programs and are in the Cell I/O screen for the convenience of setting and monitoring. The index numbers of these outputs, set in the CELL I/O screen, can be accessed in the system variables $SLCELLIO[x].do_usr_defxo, where x is the index number of the output, 1-9, and A. This output is used to tell the PLC when to read the ’Style Request/Echo’ output. This output indicates to the robot which group output is used to tell the PLC what index into the style table was received These outputs are used for two purposes:a) During the running of a style program, they are set to echo the values of the corresponding option input bits as read when the program was initiated. When the program ends, the outputs are reset. b) When a manual style request is made, these are set to the user-specified values that should then be returned on the option bit inputs when the PLC issues the program request. This output group is set to a user-specified value when a manual style request is made. The value should then be returned on the decision code input group by the PLC when it issues the program request.
$SLCELLIO[1].$do_wait_plct $SLCELLIO[1].$do_wait_plci
- 848 -
$SLCELLIO[1].$do_mot_nrec t $SLCELLIO[1].$do_mot_nrec i
$SLCELLIO[1].$do_booth_rrt $SLCELLIO[1].$do_booth_rri
$IZONEIO.$do_zn n cl_t $IZONEIO.$do_zn n cl_i
$SLCELLIO[1].$do_usr_def n t $SLCELLIO[1].$do_usr_def n i
$cell_setup.$do_stystr_i $cell_setup.$go_stysel_i
$cell_setup.$do_optna_I $cell_setup.$do_optnb_I $cell_setup.$do_optnb_I
$cell_setup.$go_decsn_i
12.DISPENSE TOOL
B-82594EN-4/01
Output Signal Path segment Path segment req cont
Task OK Manual style req
Refpos1[n] n = 1 to 10 Refpos2[ n ] n = 1 to 10 Refpos3[ n ] n = 1 to 10
Description This group output is set by a program to indicate the next path segment that it is going to enter. After setting the path segment group output, the program sets this output and then waits for the "path segment continue" input before proceeding to the next path segment. NOTE Path segment control is an optional feature that can be used by a program and PLC that support it. This output is set by a style program to indicate that it is successfully running. When issuing a manual style request, the shell program first sets the style request, option bits, and decision code request outputs, and then sets this output to indicate to the PLC that a manual style is being requested. This output indicates which output is used to indicate when the robot arm is at motion group 1’s reference position n if the reference position is enabled. This output indicates which output is used to indicate when the robot arm is at motion group 2’s reference position n if the reference position is enabled. This output indicates which output is used to indicate when the robot arm is at motion group 3’s reference position n if the reference position is enabled.
System Variables $cell_setup.$go_pthseg_I $cell_setup.$do_pthreq_I
$cell_setup.$do_taskok_I $cell_setup.$do_mansty_I
$refpos1[ n ].$dout_indx n = 1 to 10 $refpos2[ n ].$dout_indx n = 1 to 10 $refpos3[ n ].$dout_indx n = 1 to 10
‡Set these signals using the Cell I/O screen. Refer to Procedure 12-13
12.3.2.4 Setting up DispenseTool cell interface I/O signals Use Procedure 12-13 to set specific cell input and output signals. Refer to Chapter 3, “SETTING UP THE HANDLING SYSTEM” for information on configuring UOP, digital, and group I/O.
Procedure 12-13 Setting Cell I/O
Steps 1 2 3 4
Press MENUS. Select I/O. Press F1, [TYPE]. Select Cell. You will see either the input or output screen. You will see a screen similar to the following.
- 849 -
12.DISPENSE TOOL
B-82594EN-4/01
I/O Cell Inputs NAME 1 Start: 2 PROD Start: 3 Style Select: 4 Option bit A 5 Option bit B 6 Option bit C 7 Decision code: 8 Tryout mode: 9 Path seg continue: 10 Zone 1 is clear: 11 Zone 2 is clear: 12 Zone 3 is clear: 13 Zone 4 is clear: 14 Zone 5 is clear: 15 Zone 6 is clear: 16 Backup style sel.: 17 Wet/dry mode: 18 Error ack strobe: 19 Continue wet: 20 Continue wet: 21 Cancel this job: 22 User input 1: 31 User input 10:
5 6 7 8
12.3.3
IN PT SIM UI[ 6] U UI[18] U GI[ 0] U DI[ 0] U DI[ 0] U DI[ 0] U GI[ 0] U DI[ 0] U DI[ 0] U DI[ 0] U DI[ 0] U DI[ 0] U DI[ 0] U DI[ 0] U DI[ 0] U GI[ 0] U DI[ 0] U DI[ 0] U DI[ 0] U DI[ 0] U DI[ 0] U DI[ 0] U DI[ 0] U
STATUS *** *** ***** *** *** *** ***** *** *** *** *** *** *** *** *** ***** *** *** *** *** *** *** ***
To change between the input and output screens, press F3, IN/OUT. To display more detailed information about the I/O signal, press F2, DETAIL. Select each item and set as desired. When you are finished setting items, Cold start the controller. Refer to Subsection B.1.4 for more information.
Interference Zone Setup
12.3.3.1 Interference zone setup overview An interference zone is an area that falls within the work envelope of a robot, in which there is the potential for the robot motion to coincide with the motion of another robot or machine, and for acollision to occur. Before you use interference zones, you must set up the appropriate cell setup items and cell I/O signals to define the interference zones. You control robot movement in and out of interference zones using interference zone macro command instructions . You use these instructions in a teach pendant program. Interference zone macro command instructions are described in Subsection 12.3.3.3 . Fig. 12.3.3.1 shows an example of interference zones.
- 850 -
12.DISPENSE TOOL
B-82594EN-4/01
Fig. 12.3.3.1 Interference Zones
Setting up interference zones requires setup of the cell controller and the controller.
12.3.3.2 Cell controller setup You must program the cell controller to arbitrate interference zone entry and exiting according to the following rules: • Separate discrete lines must connect the cell controller to each robot. • The cell controller must handle each request for entry into an interference zone individually. The cell controller must be the device that decides which robot is allowed to enter the interference zone and must give permission to that robot only. The cell controller must follow the timing diagram shown in Fig. 12.3.3.2.
Fig. 12.3.3.2 Cell Controller Timing for Interference Zones
The timing sequence is as follows:
Time 0 The cell controller sets all ZONE n CLEAR digital inputs to OFF, signaling to all robots that they do not have permission to enter any interference zones.
- 851 -
12.DISPENSE TOOL
B-82594EN-4/01
Time 1 All teach pendant programs must set all CLEAR OF ZONE n digital outputs to ON at the beginning of the cycle (assuming the robot IS clear of all zones). Do this using the SAFE ZONE macro command instruction.
Time 2 The robot requests entry into the interference zone by setting one of the CLEAR OF ZONE n digital outputs to OFF. The robot must then wait, without entering the interference zone, for the corresponding ZONE IS n CLEAR digital input to go ON. This can be done automatically by calling the ENTER ZONE macro command instruction from within the job.
Time 3 The cell controller gives permission to only one robot to enter the interference zone by setting the ZONE n IS CLEAR digital input to ON. The ENTER ZONE macro command instruction then returns control to the job and the robot is allowed to enter the interference zone and continue the job.
Time 4 After leaving the interference zone, the robot signals it is out of the zone by turning on the CLEAR OF ZONE digital output. This is done in the job by calling the EXIT ZONE macro command instruction. The cell controller acknowledges by setting the ZONE IS CLEAR digital input to OFF. Refer to Subsection 12.3.3.3 for more information on the interference zone macro command instructions.
12.3.3.3 Teach pendant program example Fig. 12.3.3.3 contains an example of a teach pendant program that uses interference zones. JOB0001 1/9 1: SAFE ZONE 2: CALL PROC0001 3: CALL PROC0002 4: ENTER ZONE (1) 5: CALL PROC0003 6: EXIT ZONE (1) 7: CALL PROC0004 8: END JOB [End] Fig. 12.3.3.3 Interference Zones Used in a Teach Pendant Program
- 852 -
12.DISPENSE TOOL
B-82594EN-4/01
First, the program verifies that the robot is not claiming any interference zones, by calling the SAFE ZONE macro command instruction. JOB0001 then calls processes PROC0001 and PROC0002 to accomplish part of this dispensing job. In order to perform the third process, PROC0003, the robot must enter an interference zone, so it requests permission to do so by using the ENTER ZONE 1 macro command instruction. After the cell controller has given permission to enter the interference zone, the ENTER ZONE 1 macro command will return control to JOB0001 and PROC0003 will be executed. Since PROC0003 causes the robot to exit the interference zone at its completion, the EXIT ZONE 1 macro command is used to inform the cell controller that the robot no longer requires that all other robots stay out of the zone. PROC0004 will then be executed and JOB0001 will complete using the END JOB macro command, which will move the robot to the HOME position. The HOME position should be away from any interference zones. Refer to Section 9.1 for more information on macro command instruct ions.
12.3.3.4 Macro commands You control robot movement in and out of interference zones using interference zone macro commands . There are three interference zone macro commands: • ENTER ZONE (n) • EXIT ZONE (n) • SAFE ZONE
ENTER ZONE (n) ENTER ZONE (n) signals that the robot is about to enter the interference zone specified by n . n can be a number from 1 to 5. The robot will not proceed into the interference zone until the cell controller issues the INTERFERENCE ZONE n CLEAR signal.
EXIT ZONE (n) EXIT ZONE (n) signals that the robot has left the interference zone specified by n . n can be a number from 1 to 5. This macro issues the output CLEAR OF INTERFERENCE ZONE n .
- 853 -
12.DISPENSE TOOL
B-82594EN-4/01
SAFE ZONE When the robot is not in any interference zone it is in a safe zone . A safe zone is a way of communicating that the robot has exited all interference zones. For example, if the program takes the robot into two overlapping interference zones and then exits both into a safe zone, the SAFE ZONE macro command can be used to communicate that the robot has cleared both zones. This macro issues all CLEAR OF INTERFERENCE ZONE digital outputs. This macro is called when the robot controller is turned on, and the robot is at the home position.
Defining a Zone You must define the physical space of the zone. The zone should include all possible locations of collisions and a buffer. In the program, before the point where the robot enters the zone, insert the ENTER ZONE macro command. After the robot leaves the zone, insert the EXIT ZONE or SAFE ZONE macro command in the program.
12.3.4
DispenseTool Cell Controller Error Recovery If the PLC Fault Recovery item in the Cell Communication Setup screen is ENABLED, the cell controller is permitted to transmit fault recovery options to the robot. Cell controller error recovery is available even if TP Fault Recovery is ENABLED, allowing fault recovery options to be received from both the teach pendant and external sources. The robot uses eight additional signals to communicate with the cell controller for this purpose. Some have UOP equivalents. Refer to Table 12.3.4.
Signal CONTINUE WET Digital Input SOP CYCLE START/ UOP CYCLE START UOP Input #6
CONTINUE DRY Digital Input CANCEL JOB Digital Input
UOP CSTOP UOP Input #4
Table 12.3.4 I/O Signals for Cell Controller Error Recovery Description If the current fault can be recovered, this input can be strobed by the cell controller to request that the robot continue the job in WET mode (with material enabled). If the current job can be continued, the appropriate input (UOP if in REMOTE mode, SOP if in LOCAL mode) will continue the current job, in the current WET/DRY state. It is not recommended that the UOP CYCLE START be used for this purpose, since jobs are also initiated with this input. If the ERROR_PROG has been executed already and a RESUME_PROG is defined, the input will cause the robot to execute the program defined in RESUME_PROG and continue the job. This input causes the robot to continue the job in DRY mode (without material) if possible. This input should be pulsed by the cell controller to request that the current job be canceled. Note: Be careful not to abort a job in the middle of a restrictive work environment (such as a car body), as it will be difficult to get back to the HOME position, since the robot will stop wherever it is when this signal is received. This input has the same function as the CANCEL JOB digital input except that it will also clear the contents of the job queue at the same time it cancels the current job. In most systems, this can be used as a replacement for the CANCEL JOB input, since it is part of the minimum I/O configuration.
- 854 -
12.DISPENSE TOOL
B-82594EN-4/01
Signal UOP HOME UOP Input #7 WAITING FOR PLC Digital Output PROGRAM ABORTED Digital Output
BOOTH RESET REQUEST Digital Output
Description This input can be strobed to request that the robot execute the program defined in ERROR_PROG (if defined). This signal is turned ON when the robot is waiting for a recovery option from the cell controller. The WAITING FOR PLC output will be ON for as long as the robot is waiting for the fault recovery inputs from the cell controller. This output will be turned ON if the teach pendant program was aborted before reaching the end of the program. This is usually caused by a fatal error or by selecting the ABORT (ALL) item on the FCTN menu of the teach pendant. This signal only appears on the Cell I/O screen if PLC Fault Recovery has been ENABLED. This signal is pulsed for 100 ms every time the SOP or teach pendant RESET button is pressed, at any time. This signal is intended to be used by the cell controller of complex workcells, in which several robots might need to be reset to resume production after an emergency stop or other fault.
In the timing diagram shown in Fig. 12.3.4, it is assumed that the job has stopped when the cell controller lowered the UOP IMSTP input. Any PLC error reporting has already taken place. The cell controller operator is now aware of the problem and will take the necessary steps to correct it.
- 855 -
12.DISPENSE TOOL
B-82594EN-4/01
Fig. 12.3.4 Cell Controller Error Recovery Timing Diagram
This timing diagram is described as follows:
Time 1 The job has already stopped. All PLC error reporting has been completed.
Time 2 The cell controller operator corrects the cause of the error by setting the UOP IMSTP input to ON. This removes the fault. The operator then triggers the UOP RESET input. This causes the robot to bring the servomotors back up and the UOP FAULT output to go OFF.
- 856 -
12.DISPENSE TOOL
B-82594EN-4/01
Time 3 The robot, seeing the UOP RESET, resets the robot’s fault status and responds with a BOOTH RESET REQUEST output, asking the cell controller to reset the rest of the robots in the workcell. The UOP CMDENBL and UOP SYSRDY signals turn ON at this time, indicating that the robot can continue.
Time 4 Now that the cause of the error has been removed, the robot begins fault recovery procedures by signaling that it is waiting for a cell controller response with the WAITING FOR PLC output.
Time 5 The cell controller operator sees that the robot is waiting for input on one of the three recovery inputs (CONTINUE WET, CONTINUE DRY, or CANCEL JOB) and proceeds to pulse the CONTINUE WET input, requesting that the robot continue the current job in the WET RUN mode.
Time 6 The robot responds to the CONTINUE WET input by turning the WAITING FOR PLC output OFF and setting the WET/DRY output to ON (WET).
Time 7 The robot then continues the JOB where it left off, which turns the UOP PAUSED output OFF and the UOP PROGRAM RUNNING output ON.
- 857 -
12.DISPENSE TOOL
B-82594EN-4/01
12.4
PLANNING AND CREATING A PROGRAM
12.4.1
Planning a Program
12.4.1.1 Application program guidelines for DispenseTool Use the following guidelines when you teach an application program: • Use the proper schedule for each position; consult application process specification information for your application. • Minimize changes in wrist orientation. • Use joint motion type and fine termination type in motion instructions that move to dispensing positions. • Use linear motion and continuous termination type whenever the gun is turned on. • Consider the rotations of the wrist so that after rotating it in one direction it is rotated back in the other direction. Try not to rotate the wrist constantly, but plan rotation so you can gradually rotate the wrist over a number of seams. • Make sure the positions in the program are recorded so that the dispensing cables do not bind when the minor axes move. • Use the fewest number of GUNON/GUNOFF (SS[]/SE) positions as possible. • Finish each program with the applicator turned off. • Slower speeds yield higher bead quality. • Check the error log after test runs. Certain motion warnings, such as "MOTN-056 Speed Limits Used," are not displayed on the teach pendant error line, but might still affect dispensing quality. Avoid these errors. • Any "speed limit" error or change in the override speed will cause the TCPP (tool center point speed prediction) to enter the TCPP error mode, during which time the speed compensation quality might be poor. The error, "TCPP-018 Begin error mode at line:nn," or "TCPP-019 Speed ovrd mode at line:nn" will be displayed when this happens.
12.4.1.2 Guidelines for using sub type program There are two points to be aware of: • Your main program should be of the Job sub type. • The dispensing program should be a sub-program of the Process sub type, which can be called from the main program. When you create a program, please specify the program sub-type as Process. After you do this, youwill be required to display the Process header page where you can then specify the equipment number. After the equipment number is properly set, the system will automatically select the correct equipment when the sub-program is called.
- 858 -
12.DISPENSE TOOL
B-82594EN-4/01
For SpotTool+ only, you can use main programs of type “NONE,” which calls JOB type programs, which in turn calls PROCESS type programs. This allows you to call different application programs from one main program.This feature is enabled or disabled by the system variable $slgnstup[1].usenone4main.
12.4.2
Writing and Modifying a Program
12.4.2.1 Creating and writing a new DispenseTool program Procedure 12-14 Creating and Writing a New Program NOTE If you want to edit a program with the teach pendant off, this is called Background Program Editing.
Conditions • All personnel and unnecessary equipment are out of the workcell.
Steps 1
2
Set the User frame number: a Press MENUS. b Select SETUP. c Press F1, [TYPE]. d Select Frames. e If user frames are not displayed press F3, [OTHER], and select User Frame. If F3, [OTHER], is not displayed, press PREV. f To select the user frame to use, press F5, SETIND, type the number of the user frame you want, and press ENTER. This sets the active user frame ($MNUFRAMNUM[1]) to the number of the frame you specify. Name the program: a Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. b Press SELECT. c If F2, CREATE, is not displayed, press NEXT, >. d Press F2, CREATE. You will see a screen similar to the following. 1 Words 2 Upper Case 3 Lower Case 4 Options -- Insert -Select --- Create Teach Pendant Program --Program Name [ ] -- End -Enter program name
- 859 -
12.DISPENSE TOOL
B-82594EN-4/01
e f
Move the cursor to a method of naming the program. The function key labels will change depending on the naming method you choose. Type the program name: • Move the cursor to select a method of naming the program.
NOTE As you move the cursor through the list of naming methods, the labels on the function keys will change. •
Press the function keys whose labels correspond to the name you want to give to the program. These labels vary depending on the naming method you chose in Step 2e . For example, if you chose Upper Case, press a function key corresponding to the first letter. Press that key until the letter you want is displayed in the program name field. Press the right arrow key to move the cursor to the next space. Continue until the entire program name is displayed.
NOTE To delete a character to the left of the cursor, press BACK SPACE. •
When you are finished, press ENTER. You will see a screen similar to the following.
1 Words 2 Upper Case 3 Lower Case 4 Options Select --- Create Teach Pendant Program --Program Name [TEST111 ] -- End -Select function
3
To view and modify program header information: a Press F2, DETAIL. You will see a screen similar to the following.
- 860 -
12.DISPENSE TOOL
B-82594EN-4/01
NOTE 1 Your program name will vary, depending on what application you are using and what method you used for creating the program name. 2 When using SpotTool+ with dispense plug-in and multi-group motion all programs that use motion while dispensing are required to use group mask [1,*,*,*,*]. 3 For system level macro programs, the group mask cannot be changed. Refer to Section 9.1 for more information on macro commands. Program Detail Creation Date: Modification Date: Copy Source: Positions: 10 Size: 1; Program Name: 2; Sub Type: 3; Comment: 4; Group Mask: 5; Write protect: 6; Ignore pause:
02-Jan-xxxx 02-Jan-xxxx [ ] 312 Byte [ RSR1000 ] [ JOB ] [ ] [1,*,*,*,*] [ON ] [OFF ]
b
4
Review the settings on the screen. • If you like the settings that are displayed on the screen and want to skip setting program header information and begin editing the program. press F1, END, and skip to Defining Default Motion Instructions in this procedure. • If you want to change the settings, continue with Step 4. To change the program: a Move the cursor to the program name and press ENTER. b Move the cursor to select a method of naming the program. c Press the function keys whose labels correspond to the name you want to give to the program. These labels vary depending on the naming method you chose in Step 4b To delete a character, move the cursor to the right of the character and press BACK SPACE. d When you are finished, press ENTER.
NOTE You cannot modify details if the program is set up as a system level macro. These macros are identified with the letter "s" at the far right side of the macro setup screen. 5
To change the sub type: a Move the cursor to the sub type and press F4, [CHOICE]. You will see a screen similar to the following. - 861 -
12.DISPENSE TOOL
B-82594EN-4/01
Sub Type 1 None 2 Job 3 Process 4 Macro
5 Cond 6 7 8
b Select a sub type and press ENTER. To type a comment: a Move the cursor to Comment and press ENTER. b Select a method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press ENTER. For example, if you chose Upper Case, press a function key corresponding to the first letter. Press that key until the letter you want is displayed in the comment field. Press the right arrow key to move the cursor to the next space. Continue until the entire comment is displayed. To delete a character to the left of the cursor, press BACK SPACE. To set write protection: a Move the cursor toWrite protect. b If you want to turn write protection on, press F4, ON. c If you want to turn write protection off, press F5, OFF.
6
7
NOTE Write protection must be set to OFF to create a program. 8
9 10
To set ignore pause: a Move the cursor to Ignore pause. Refer to Subsection 4.1.6 for information on ignore pause. b If you want to turn on ignore pause, press F4, ON. c If you want to turn off ignore pause, press F5, OFF. To set stack size: a Move the cursor to Stack size. b Enter the new Stack size. To display the DispenseTool header information press F3, NEXT (or F2, PREV). See the following screen as an example of non-tracking process program header information. Sealing Application Process 1/3 Program: PROC0001 [ ] Cycle time: ****** s Last cycle time: ****** s Gun on time: ****** s Last gun on time: ****** s 1 Default user frame: 1 2 Default tool frame: 1 3 Equipment number: 1
See the following screen as an example of tracking process program header information. - 862 -
12.DISPENSE TOOL
B-82594EN-4/01
Sealing Application Process 1/3 Program: PROC0001 [ ] Cycle time: ****** s Last cycle time: ****** s Gun on time: ****** s 1 Default tool frame: 1 2 Equipment number: 1 3 Line track schedule num: 0 4 Line track boundary num: 0 5 Continue track at prog end: TRUE
See the following screen as an example of a job header information. Sealing Application Job 1/1 Program: PROC0001 [ ] Cycle time: ****** s Last cycle time: ****** s Gun on time: ****** s Last gun on time: ****** s Material volume: ****** cc Last mat. volume: ****** cc 1 Part ID: 0
11
If you are setting up a tracking program, set the line tracking frame number to a value between 1 and 6. Frame number 1 is the default frame.
NOTE A line tracking frame number of 0 indicates a non-tracking path. 12
13
If you are setting up a tracking program, set the continue track at program end to TRUE or FALSE. • To have the robot continue to track after the program has finished, press F4, TRUE. • To have the robot stop tracking when the program finishes, press F5, FALSE. If you are setting up a tracking program, the Line track boundary num indicates the current boundary in the line tracking schedule. The current boundary value is automatically updated when you execute a program. • If Selected Boundary is set to zero (which is the default), the boundary value will not be updated when the program is executed.
- 863 -
12.DISPENSE TOOL
B-82594EN-4/01
•
If Selected Boundary is greater than zero, the boundary value will be automatically updated. When the program finishes, the current selected boundary value in the line tracking schedule will be reset. For example, if the current value of $LNSCH[1].$sel_bound = 1, and a line tracking program is executed with Selected Boundary = 6, $LNSCH[1].$sel_bound will be set to 6. When the program is finished, the current boundary will be set back to 1.
NOTE If the system variable $LNCFG.$rstr_bnds = FALSE, the boundary will not be restored when the program finishes. 14 15 16
If you are setting up a tracking program, you will be prompted to synchronize the conveyor. To return to the DETAIL screen or display more header information, press F3, NEXT, (or F2, PREV) until F1, END is displayed. When you have finished entering program information, press F1, END. The teach pendant editor screen will be displayed.
NOTE Whenever you want to return to the first SELECT menu, press PREV until it is displayed. 17 18
Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch. To define default motion instructions: a Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON. b Press F1, POINT. You will see a list of default motion instructions similar to the following. 1: 2: 3: 4:
L L L J
P[] P[] P[] P[]
250mm/sec CNT100 500mm/sec CNT100 1000mm/sec CNT100 100% FINE
NOTE If the instructions listed are the ones you want to use, do not modify them. Go to Defining Default Application Instructions. c d
To modify the default motion instructions, press F1, ED_DEF. Move the cursor to a component in the default instruction you want to modify. - 864 -
12.DISPENSE TOOL
B-82594EN-4/01
e
19 20
Use the appropriate arrow and function keys to modify the component and press ENTER. If the [CHOICE] function key is displayed, press F4 to display a list of values for the selected component. For example, to change the speed value, move the cursor to 100%. Type a new value and press ENTER. The new value will be displayed. Each time you add this instruction to the program the new value will be used. f Repeat Step 18d through Step 18e for each default instruction that you want to define. g When you are finished defining default motion instructions, move the cursor to the instruction you want to be the current default instruction and press F5, DONE. h To save the modified default motion instructions, refer to Section 8.4 , "Backing Up Files." i To load default motion instruction files, refer to Section 8.5 , "Loading Files." Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch. To define default application instructions: a Continuously press the DEADMAN switch and turn the teach pendant ON/OFF switch to ON.
NOTE Seal start (SS_PT) and Seal End (SE_PT) instructions can be used only in a process program. b
SS 1: 2: 3: 4:
Display the default instructions you want to modify: • For seal start (SS), press F2, SS_PT. • For seal end (SE), press F3, SE_PT. You will see a list of default seal start or seal end instructions similar to the following. Default L P[ ] 250mm/sec CNT100 SS[1] L P[ ] 500mm/sec CNT100 SS[1] L P[ ] 750mm/sec CNT100 SS[1] L P[ ] 1000mm/sec CNT100 SS[1]
NOTE If the instructions listed are the ones you want to use, do not modify them. c d
Start modifying the default instructions: • For seal start (SS), press F2, ED_DEF. • For seal end (SE), press F3, ED_DEF. Move the cursor to a component in the default instruction you want to modify.
- 865 -
12.DISPENSE TOOL
B-82594EN-4/01
e
21 22
Use the appropriate keys and function keys to modify the component and press ENTER. If the [CHOICE] function key is displayed, press F4 to display a list of values for the selected component. For example to change the speed, move the cursor to 500. Type a new value and press ENTER. The new value will be displayed. Each time you add this instruction to the program the new value will be used. f Repeat Step 20d through Step 20e for each instruction that you want to define. When you are finished setting up default dispensing instructions, move the cursor to the instruction you want to be the current default instruction and press F5, DONE. To record a position using the current default motion instruction: a Jog the robot to the location in the workcell where you want to record the motion instruction. b Press and hold in the SHIFT key and press F1, POINT. The instruction will be added to the program automatically.
NOTE The @ indicator will be displayed on the screen at the current line in the program indicating that the robot is at the current position. 23
To record the position using one of the other three default motion positions: a Jog the robot to the location in the workcell where you want to record the motion instruction. b Press F1, POINT. c Move the cursor to a new default position. d Press ENTER and the position is recorded. This then becomes the current default position.
NOTE The @ indicator will be displayed on the screen at the current line in the program indicating that the robot is at the current position. 24
To record the position and the default seal start (SS) or seal end (SE) instruction: • For a seal start (SS) instruction, press SHIFT and F2, SS_PT. To record the position using one of the other three default seal start (SS) instructions , press F2, SS_PT. Use the cursor to select a new seal start (SS) instruction. This then becomes the current default seal start (SS) instruction.
- 866 -
12.DISPENSE TOOL
B-82594EN-4/01
•
For a seal end (SE) instruction, press SHIFT and F3, SE_PT. To record the position using one of the other three default seal end (SE) instructions , press F3, SE_PT. Use the cursor to select a new seal end (SE) instruction. This then becomes the current default seal end (SE) instruction.
NOTE The @ indicator will be displayed on the screen at the current line in the program indicating that the robot is at the current position. 25
26
To add other instructions: a Press F4, [INST]. b Select the kind of instruction you want and select the appropriate items on the screen to build the instruction. Refer to Chapter 15 PROGRAM ELEMENTS for details about each instruction. When you are finished, turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch.
NOTE If the system variable $BACKGROUND is FALSE, the teach pendant must remain on during programming. If you want to turn the teach pendant off, you must edit the program in the background.
12.4.2.2 Defining predefined positions in DispenseTool programs You must define the predefined positions in programs specified for them. These programs begin with the letters, "MOV_." DispenseTool uses the following predefined position programs: • • • •
MOV_HOME - moves the robot to the home position MOV_REPR - moves the robot to the service, or repair, position MOV_PURG - moves the robot to the purge position MOV_SEAM - moves the robot along a sample dispensing seam
You must define MOV_HOME, MOV_PURG, and MOV_SEAM before you can calibrate the dispensing equipment. You can define MOV_REPR if you want to use this position in your dispensing application. At power up, the system examines these programs and the last defined position data becomes the predefined position. Use Procedure 12-15 to define predefined positions in programs.
- 867 -
12.DISPENSE TOOL
B-82594EN-4/01
NOTE DispenseTool uses the last position in MOV_HOME as Ref[1] position. Refer to Seciton 3.10 for more information about Reference position. Procedure 12-15 Defining Predefined Positions in DispenseTool Programs
Conditions • All personnel and unnecessary equipment are out of the workcell.
Steps 1 2 3 4 5
Press SELECT. Select the predefined program name you want to use. For example, if you want to teach the home position, select the program name MOV_HOME. When you are finished selecting the program name, press ENTER. Press SELECT and press NEXT, >. To display program header information, press F2, DETAIL. You will see a screen similar to the following.
Program Detail Creation date: Modification Date: Copy source: Positions: FALSE 1 Program Name 2 Sub Type: 3 Comment: 4 Group Mask: 5 Write protect: 6 Ignore Pause:
6
1/6 01-Jan-xxxx 01-Jan-xxxx [ ] Size 17 Byte [ MOV_HOME] [Process ] [ ] [1,*,*,*,* ] [ OFF ] [ OFF ]
To select a sub type: a Move the cursor to Sub Type and press F4, [CHOICE]. Refer to Chapter 15 PROGRAM ELEMENTS for information on sub types. You will see a screen similar to the following.
Sub Type 1 None 2 Job 3 Process 4 Macro
b
Select the sub type and press ENTER.
- 868 -
12.DISPENSE TOOL
B-82594EN-4/01
7
To type a comment: a Move the cursor to Comment and press ENTER. b Select a method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press ENTER. e For example, if you chose Upper Case, press a function key corresponding to the first letter. Press that key until the letter you want is displayed in the comment field. Press the right arrow key to move the cursor to the next space. Continue until the entire comment is displayed. To delete a character to the left of the cursor, press BACK SPACE.
NOTE DispenseTool supports one motion group only. Group mask must be set to [1,*,*,*,*] or [*,*,*,*,*]. 8
To set the group mask (or motion group):
NOTE 1 When using SpotTool+ with dispense plug-in and multi-group motion all programs that use motion while dispensing are required to use group mask [1,*,*,*,*]. 2 For system level macro programs, the group mask cannot be changed. Refer to Section 9.1 for more information on macro commands. a
b c
Move the cursor to the group you want to enable or disable. You can use multiple groups in a single program, but only two groups can perform Cartesian motion within a single program. The first position in the group mask corresponds to the first group. Only group 1 is supported. If you want to enable a group, press F4, 1. If you want to disable a group, press F5, *. If you disable all groups, you cannot add motion instructions to your program.
NOTE After the group mask has been set, and motion instructions have been added to the program, the group mask cannot be changed for that program. 9
To set write protection: a Move the cursor to Write protect. Refer to Chapter 15 PROGRAM ELEMENTS for information on write protect. b If you want to turn write protection on, press F4, ON. c If you want to turn write protection off, press F4, OFF.
- 869 -
12.DISPENSE TOOL
B-82594EN-4/01
10
11
To set ignore pause: a Move the cursor to Ignore pause. Refer to Chapter 15 PROGRAM ELEMENTS for information on ignore pause. b If you want to turn on ignore pause, press F4, ON. c If you want to turn off ignore pause, press F4, OFF. To display the DispenseTool header information press F3, NEXT (or F2, PREV) . See the following screen as an example of process program header information.。
Sealing Application Process Program: PROC0001 [ ] Cycle time: ****** Last cycle time: ****** Gun on time: ****** Last gun on time: ****** 1 Default user frame: 1 2 Default tool frame: 1 3 Equipment number: 1
12
s s s s
To return to the DETAIL screen or display more header information, press F3, NEXT, (or F2, PREV) until F1, END is displayed.
NOTE If, at any time, you want to return to the first SELECT menu, press PREV until this menu is displayed. 13 14
When you have finished entering program information, press F1, END. The teach pendant editor screen will be displayed. Add motion instructions to the program to move the robot to the desired position. Keep motion speed slow to ensure the safety of personnel and equipment any time the position is reached.
- 870 -
12.DISPENSE TOOL
B-82594EN-4/01
12.5
PROGRAM ELEMENTS
12.5.1
Overview A program element is a component of a program. A teach pendant program is a series of program elements selected and organized to perform an application. For dispensing systems and PaintTool systems, there are two kinds of programs: process programs and job programs. A process program directs the robot to perform a specific task. A job program contains several processes. Fig. 12.5.1 shows some of the program elements of a typical palletizing program.
Fig. 12.5.1 Program Example
- 871 -
12.DISPENSE TOOL
B-82594EN-4/01
A program consists of the following program elements: • Program header information, which can include information such as program name, comment, group mask, program type, application mask, write protection setting, cycle time, gun on time, and material volume • In PaintTool or DispenseTool, a process program contains UTOOL and FRAME number entries, tracking schedule, and boundary field when using the Line/Rail Tracking option • Line numbers, assigned to each program instruction • Motion instructions, which include commands that tell the robot where and how to move • Program instructions for logic, I/O, data handling, program control, advanced functions, and so forth. • Remarks to annotate the program. • Program end marker, indicating that there are no more instructions in the program.
12.5.2
Program Header Information
12.5.2.1 Overview Program header information is specific information that identifies and classifies the program. Table 12.5.2.1 (a) lists SELECT screen items and operations. Table 12.5.2.1 (b) lists the SELECT DETAIL screen items and operations. The items displayed on your screen will vary.
Item No. Program name Attribute field CREATE DELETE MONITOR ATTR COPY DETAIL LOAD SAVE AS PRINT
Table 12.5.2.1 (a) Select Screen Items and Operations Description This item is the line number. This item is the name of the program. This item is a descriptive field for each program. This field can be any of the following: Comment, Protection, Last Modified, Size, or Copy Source. Press this key to display the Create Teach Pendant Program screen from which you can create a new program listing. When you create a new program, it will be added to the Program name listing. Press this key to delete a program. Press this key to monitor a program that is currently running. Press this key to select the appropriate attribute to display. Press this key to display the Copy Teach Pendant Program screen from which you can copy one file to another. Press this key to key to display the Program DETAIL screen. Press this key to display the Load Teach Pendant Program screen from which you can load the selected program. Press this key to save the selected program. You can specify the device to which the program is saved. You can also specify a new name if you want to save the file with a different name. Press this key to display the Print Teach Pendant Program screen from which you can select a program to print to the selected device.
- 872 -
12.DISPENSE TOOL
B-82594EN-4/01
Item Creation Date Modification Date Copy Source Positions Size Program name Sub Type
Comment Group Mask Write protect Ignore pause
Stack Size
Cycle Time
Last Cycle Time Gun On Time Last Gun On Time
Material Volume Last Material Volume
Table 12.5.2.1 (b) Program DETAIL Screen Items and Operations Available in Available in job job programs Description or process only programs only This item is the date on which the program name was created. This item is the date when the file was last displayed in the editor. This item is the name of the file from which the file was copied. This item indicates whether the program contains recorded robot positions. This item is the size of the program in bytes. This item is the name of the program. This item is the kind of program you want to write. This value can be one of the following: None, Macro, or Cond (Condition Handler). This item is a description field for the selected program. This item identifies the group of axes, or motion group, that the program controls. This item identifies whether the program can be modified. This item indicates whether the program will continue to run when an error occurs, a command is issued, or the teach pendant is enabled. When a program is executed, a stack of 300 long words (1200 bytes) is allocated unless you specify a stack size. The stack is allocated from available user RAM. The minimum and default stack size is 300. The maximum stack size is 4000. This item displays the cycle time for the most recent execution of the currently selected job or process. This item displays the cycle time for the second most recent execution of the currently selected job or process. This item displays the total amount of time the gun was on for the most recent execution of the currently selected job or process. This item displays the total amount of time the gun was on for the second most recent execution of the currently selected job or process. This item displays the volume of the material dispensed in the most recent execution of the currently selected job or process. This item displays the volume of the material dispensed in the second most recent execution of the currently selected job or process.
- 873 -
Yes Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes
Yes
***
*
*, **
*
*
*
Available in process programs only
12.DISPENSE TOOL
B-82594EN-4/01
Available in job or process programs only
Item
Description
Default User Frame Default Tool Frame Part ID
This item displays the name of the user frame to be used by the process program. This item displays the name of the tool frame to be used by the process program. This item displays the number of the job being executed. This item allows you to specify up to two homogeneous dispensing equipments controlled by one robot controller. This item displays the current line tracking schedule.
Equipment Number Line Track Schedule Number Line Track Boundary Number Application Mask Program Type PREV NEXT 1 * ON/OFF
Available in job programs only
*, ** *, ** X *
****
This item displays the current line tracking boundary set. This item displays the currently set application in systems with more than one application available. The p rogram type indicates the kind of Multi-Arm p rogram being u sed. This should always be set to Normal Program. Press this key to return to the previous screen. Press this key to display application-specific program detail information. Press this key to add a motion group to your program. Press this key to disable a motion group for your program. Press these keys to set the appropriate items to ON or OFF.
*
Available in process programs only
****
***
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
These items are shown only for Dispensing systems with multiple equipment, to allow you to set the equipment number for your program. ** For PaintTool, this applies to process programs only. *** This applies to DispenseTool and SpotTool+ only. **** This applies to DispenseTool and PaintTool only.
- 874 -
12.DISPENSE TOOL
B-82594EN-4/01
Program header information is displayed only the first time you create a program. If you want to view this information again, you must display it by choosing the SELECT menu and pressing the DETAIL key. See the following screen for an example. Program detail Creation Date: 03-FEB-xxxx Modification Date: 03-FEB-xxxx Copy Source: [ ] Positions: FALSE Size 17 Byte 1 Program name [ PROG742 ] 2 Sub Type: [ None ] 3 Comment: [ ] 4 Group Mask: [1,*,*,*,* ] 5 Write protect: [ OFF ] 6 Ignore pause: [ OFF ] 7 Stack size: [ 300 ] Fig. 12.5.2.1 Program Header Information
The following sections contain details on each kind of program header information.
12.5.2.2 Sub type Sub type identifies the kind of program you want to write. These are: • • • • •
None Macro Cond Job * Process
*
Process and Job sub types are available on SpotTool+ software only if multiple equipment is defined for the Dispense application.
Table 12.5.2.2 summarizes the program instructions that can be used in a DispenseTool program that is either a job, process, none, or macro sub type. Table 12.5.2.2 Job and Process Program Instruction Summary for DispenseTool Available when Sub Type Available when Sub Type Available when Sub Type Program Instruction = Job = Process = None or Macro Dispensing Motion Offset Register Position register I/O Wait Miscellaneous Macro
X X X X X X X
X X X X X X X X X
- 875 -
X X X X X X X X X
12.DISPENSE TOOL Program Instruction JUMP and IF/SELECT CALL Skip Multiple Control Program Control Position Register Look-Ahead Condition Monitor Payload
B-82594EN-4/01
Available when Sub Type = Job
Available when Sub Type = Process
Available when Sub Type = None or Macro
X X X X X X
X
X X
X
X
X X X X X X X X
None If you select none, the program will be created as a .TP program, which can include any instructions in your teach pendant program.
Macro A macro program created as a .MR program can contain any instruction and function as a normal .TP program. However, only macro programs can be set up to be xecuted in a variety of ways including from operator panel buttons, teach pendant keys, and the Manual Functions menu. They can also be assigned a name in the macro table and be called with this name in a macro program. Macro programs can also be called by a program when the MACRO instruction is used. Refer to the "Utilities" chapter of this manual for more information.
Cond A "ch" program has a Cond (Condition Handler) sub type. Refer to the "Utilities" chapter of this manual for more information on the condition monitor function.
Job A job is a program that includes one or more processes. When you run production, you run the job that corresponds to the task you want to perform. This job contains program calls to each of the processes that will be performed during production.
NOTE In PaintTool, when you write a job program, you can include only the following kinds of program instructions: • • • •
CALL program Conditional branching (IF and SELECT) I/O and register instructions Program end
Typically, a job program is used as the main program. The job program then calls the process program(s) to do the application processing. For any dispensers, you must use job and process programs in this manner because the job and process header contains some information that is necessary to run the program properly. - 876 -
12.DISPENSE TOOL
B-82594EN-4/01
Process A process is a program that directs the robot to perform a specific task. In PaintTool, you can include any program instructions except branching instructions in a process program. Eight predefined process programs are created for you in PaintTool: • • • • • • • •
Home Gun Clean In (CLNIN) Gun Clean Out (CLNOUT) Bypass Purge Zero Special1 Special2
These programs are created for you so that you can move to the positions you define in these programs using the Move Menu. Refer to the “Planning and Creating a Program” chapter for details on how to define and use predefined positions.
12.5.2.3 Cycle Time Cycle time displays the cycle time for the most recent execution of the currently selected job or process. This information is displayed on the job or process program DETAIL screen. This information is also displayed on the STATUS Seal Data screen if the Job/Process feature is enabled. If you are running SpotTool+ and the application mask is set to Spot weld and you want to see the cycle time value for the welding process that has just been run, you can press NEXT two times from the Program DETAIL screen. The cycle time value only updates if the welding process has been completed from UOPIN, SOP, or DIN - it will not update if you press SHIFT FWD from the teach pendant. The value will not update if this screen is displayed with the welding process that is currently running. It is not necessary to display the cycle time screen when creating a program; the program header will be modified when the program completes (or the first time the screen is displayed), if you did not display the header when you first created the program. Refer to in Chapter for information on displaying the cycle time on the Program DETAIL screen.。
- 877 -
12.DISPENSE TOOL
B-82594EN-4/01
12.5.2.4 Last cycle time Last cycle time displays the cycle time for the second most recent execution of the currently selected job or process. This information is displayed on the job and process program DETAIL screen. This information is also displayed on the STATUS Seal Data screen if the Job/Process feature is enabled.
12.5.2.5 Gun on time Gun on time displays the total amount of time the gun was on for the most recent execution of the currently selected job or process. This information is displayed on the job and process program DETAIL screen. This information is also displayed on the STATUS Seal Data screen if the Job/Process feature is enabled.。
12.5.2.6 Last gun on time Last gun on time displays the total amount of time the gun was on for the second most recent execution of the currently selected job or process. This information is displayed on the job and process program DETAIL screen. This information is also displayed on the STATUS Seal Data screen if the Job/Process feature is enabled.
12.5.2.7 Material volume Material volume is the volume of the material dispensed in the most recent execution of the currently selected job. This information is displayed on the job program DETAIL screen. This information is also displayed on the STATUS Seal Data screen if the Job/Process feature is enabled.
12.5.2.8 Last material volume Last material volume is the volume of the material dispensed in the second most recent execution of the currently selected job. This information is displayed on the job program DETAIL screen. This information is also displayed on the STATUS Seal Data screen if the Job/Process feature is enabled.
12.5.2.9 Default user frame Thedefault user frame is the name of the user frame to be used by the process program. This information is displayed on the process program DETAIL screen if the Job/Process feature is enabled. This item is not used if the tracking option is installed.
- 878 -
12.DISPENSE TOOL
B-82594EN-4/01
12.5.2.10 Default tool frame The default tool frame is the name of the tool frame to be used by the process program. Refer to the "General Setup" chapter of the FANUC Robotics SYSTEM R-30iA Controller Application-Specific Setup and Operations Manual for more information about the available tool frames. This information is displayed on the process program DETAIL screen if the Job/Process feature is enabled.
12.5.2.11 Equipment number Equipment number allows you to specify up to five homogeneous dispensing equipments controlled by one robot controller.
12.5.3
Dispensing Instructions
12.5.3.1 Overview Dispensing instructions tell the robot when to dispense material. There are two kinds of dispensing instructions: • •
Dispense start instructions Dispense end instructions
These instructions can be used only in a process program. Dependent and Independent Dispensing Instructions Dispense instructions are either dependent or independent. Dependent dispensing instructions include the dispense start and dispense end instructions. These instructions are motion options attached to a motion instruction. The following is an example of using dependent dispensing instructions: 5: J P[2] 500mm/sec CNT100 SS[1] 6: J P[3] 500mm/sec CNT100 SE
Independent dis pensing instructions include the dispense start and dispense end instructions. These instructions appear on a separate line and are not associated with any motion instruction. The following is an example of using independent dispensing instructions:。 10: SS[1] 11: SE
- 879 -
12.DISPENSE TOOL
B-82594EN-4/01
12.5.3.2 Dispense (seal) start instructions Thedispense (seal) start instruction tells the robot to begin dispensing material. The dependent and independent dispense start instructions are the same. SS[x] The SS[x] instruction initiates the dispensing of material using the specified dispensing schedule. See Fig. 12.5.3.2 for the dependent dispense start motion option or the independent dispense start instruction.
Fig. 12.5.3.2 Dispense Start SS[x]
12.5.3.3 Dispense (seal) end instructions Thedispense (seal) end instruction tells the robot to stop dispensing material. SE The SE instruction finishes the dispensing of material using the specified dispensing schedule. See Fig. 12.5.3.3 for the independent dispense end instruction.
Fig. 12.5.3.3 Independent Dispense End SE
12.5.4
Program Control Instructions
12.5.4.1 Error program instruction for DispenseTool ERROR_PROG = program The error program instruction defines the program name that will be stored in the system variable $ERROR_PROG. The error program is intended to rovide the robot with instructions to move the dispensing gun away from the workpiece and to a service area when an error occurs. When the robot reaches the service area, the dispensing gun can be inspected and maintenance performed. You must create the error program you want to execute when there is an error. See Fig. 12.5.4.1.
- 880 -
12.DISPENSE TOOL
B-82594EN-4/01
Fig. 12.5.4.1 Error Program
The ERROR_PROG can be any program, job, process or macro.
CAUTION Do not use any SS[ ] or SE[ ] instruction in an ERROR_PROG, otherwise, unexpected events will occur.
12.5.4.2 Resume program instruction for DispenseTool RESUME_PROG = program The resume program instruction defines the program name that will be stored in the system variable $RESUME_PROG. The resume program is intended to move the dispensing gun from the service area (the last position in the ERROR_PROG) to the general area where the error occurred. See Fig. 12.5.4.2.
NOTE This program instruction is not the same as the Fast Fault Recovery resume program function.
Fig. 12.5.4.2 RESUME_PROG = program
The RESUME_PROG can be any program, job, process or macro.
CAUTION Do not use any SS[ ] or SE[ ] instruction in a RESUME_PROG, otherwise, unexpected events will occur.
- 881 -
12.DISPENSE TOOL
B-82594EN-4/01
12.6
TESTING A PROGRAM AND RUNNING PRODUCTION
12.6.1
OVERVIEW This section provides an overview of testing a program and running production.
Testing Operations During test operations you should • Run a program by Stepping through each line of the program Continuously running the program for a single cycle Enabling and disabling robot motion and the pelletizing, spot welding, arc welding, painting, or dispensing process during testing to verify each instruction of the program • Monitor your program • Adjust program information without stopping the program or production, if desired. • Manually controlling wire feed and weld enable (ArcTool only) • Performing test arc welds (ArcTool only) • Performing test spot welds (SpotTool+ only)
Production Operations During production operations you should • Run a thoroughly tested program continuously and repeatedly with all production conditions enabled • Perform maintenance procedures when necessary • Perform automatic purge (DispenseTool only) • Perform error recovery procedures when necessary • Execute multiple programs
NOTE During testing and running production, you must know how to stop the program if there is a safety problem or adjustment to make, and know how to restart the program.
- 882 -
12.DISPENSE TOOL
B-82594EN-4/01
12.6.2
Program Pause and Recovery
12.6.2.1 ERROR_PROG and RESUME_PROG DispenseTool provides the ability to execute a specific program (ERROR_PROG) when an error ccurs, and then to execute another program (RESUME_PROG) when the error has been corrected to continue the job. ERROR_PROG is intended to provide the robot with instructions to move the dispensing gun away from the workpiece and to a service area when an error occurs. When the robot reaches the service area, the dispensing gun can be inspected and maintenance performed. You must create the ERROR_PROG program and then define the name of the ERROR_PROG using the ERROR_PROG instruction in your job program. RESUME_PROG is intended to move the dispensing gun from the service area (the last position in the error program) to the general area where the error occurred. You must create the RESUME_PROG program and then define the name of the RESUME_PROG program using the RESUME_PROG instruction in your job program.
NOTE If you are using line tracking, • The conveyor might not stop immediately when an error occurs. In such cases, jog the robot to the position at which you want the robot to resume the job before you run the ERROR_PROG. After the RESUME_PROG is run, the robot will return to the position where the ERROR_PROG was invoked, and then resume the job from that position. • Be sure to keep the conveyor stopped while you are running the ERROR_PROG and RESUME_PROG. Example ERROR_PROG and RESUME_PROG are most useful when dispensing material inside an enclosed area, such as an automobile body. In this case, manually jogging the robot away from the area when an error occurs would be difficult. See Fig. 12.6.2.1 (a) for an example using ERROR_PROG and RESUME_PROG.
- 883 -
12.DISPENSE TOOL
B-82594EN-4/01
Fig. 12.6.2.1 (a) ERROR_PROG and RESUME_PROG Example
The numbered items in Fig. 12.6.2.1 (a) are described as follows: [1] 1 2 3 4 5 6 7
The robot is paused at this position due to an error. The robot begins running ERROR_PROG. ERROR_PROG moves the robot past any obstructions and out of the work area. The robot arrives at the service area, where tooling can be inspected. The operator can then choose to run RESUME_PROG. RESUME_PROG is run and moves the robot from the service area, past any obstructions, and back into the work area. RESUME_PROG completes execution, moving the robot near the position where the error occurred. The robot moves to the exact position where the error occurred and continues the job in the selected WET/DRY status.
Execution Logic The robot uses the logic shown in Fig. 12.6.2.1 (b) when a job is being executed using ERROR_PROG and RESUME_PROG.
- 884 -
12.DISPENSE TOOL
B-82594EN-4/01
Fig. 12.6.2.1 (b) ERROR_PROG and RESUME_PROG Execution Logic
ERROR_PROG To use an ERROR_PROG, you must: • Create the ERROR_PROG program • Include an ERROR_PROG instruction in your job program to specify the name of the ERROR_PROG program When setting up an ERROR_PROG program, remember that an ERROR_PROG program is valid from the time the error program instruction is included in the job until the job completes. Because the job can be paused or aborted at any time with an error, the ERROR_PROG program must be executable at every point in which the robot travels after the error program instruction is included in the job or process program. If the path traveled by the job and its processes is contoured or obstructed, the ERROR_PROG program will have to be changed several times during the job. Fig. 12.6.2.1 (c) shows an example of a complex job, in which a new ERROR_PROG program and RESUME_PROG program is defined for each process.
- 885 -
12.DISPENSE TOOL
B-82594EN-4/01
1: ERROR_PROG = ERR_PRG1 2: RESUME_PROG = RES_PRG1 3: CALL PROC0021 4: ERROR_PROG = ERR_PRG2 5: RESUME_PROG = RES_PRG2 6: CALL PROC0022 7: ERROR_PROG = ERR_PRG3 8: RESUME_PROG = RES_PRG3 9: CALL PROC0023 10: END JOB Fig. 12.6.2.1 (c) Example Program, ERROR_PROG and RESUME_PROG
The ERROR_PROG can be any program, job, process or macro.
CAUTION Do not use any SS[ ] or SE[ ] instruction in an ERROR_PROG; otherwise, unexpected events will occur.
RESUME_PROG To use a RESUME_PROG, you must: • Create the RESUME_PROG • Include a RESUME_PROG instruction in your job program to specify the name of the RESUME_PROG A RESUME_PROG must be defined to move the robot from the final position of the corresponding The final position of the RESUME_PROG must be located at a position close to the point where the error occurred. The path from this position to where the error occurred must be unobstructed, because the robot will move the TCP to the exact position in which the error occurred. The robot will then continue the job. The RESUME_PROG can be any program, job, process or macro.
CAUTION Do not use any SS[ ] or SE[ ] instruction in a RESUME_PROG; otherwise, unexpected events will occur.
12.6.2.2 DispenseTool fault recovery procedures Fault recovery procedures are available for specific DispenseTool errors. You perform these procedures at the teach pendant or at the cell controller, depending on how your system is set up. If the robot has the Error Recovery and AccuPath options installed and enabled, the system can perform "no gap, no overwrap" recovery when you select the Continue Wet or Fast Fault Recovery operation.
- 886 -
12.DISPENSE TOOL
B-82594EN-4/01
With this operation, if you select Continue Wet, the robot backs up a certain distance prior to the location where dispensing was interrupted and then resumes forward motion. When the robot reaches the location where dispensing was interrupted, the dispensing resumes without creating a gap or overwrap. No adjustment is required. Setting $slsetup.[eq_n].enb_autoffst to FALSE will disable this feature. If $slsetup[eq_n].enb_autoffst is FALSE, then the back distance is specified in $slsched(eq_n)[sch_n].rsm_offset. If $slsetup[eq_n].enb_autoffst is FALSE and $slsched(eq_n)[sch_n].rsm_offset is 0.0, then the back distance is specified in $slsetup[eq_n].rsm_offset. Use Procedure 12-16 to perform recovery procedures from the teach pendant. Refer to Section for fault recovery procedures you perform at the cell controller.
Procedure 12-16 Performing Recovery Procedures from the Teach Pendant
Conditions • •
The teach pendant is disabled. The robot has been reset. (The Fault light on the teach pendant is off.)
1
Look at the teach pendant screen for the Fault Recovery screen. • If the Teach Pendant Error Recovery item in the Cell Communication Setup screen is ENABLED, the Fault Recovery screens will appear when the following conditions are true: The robot is running a job while in AUTOMATIC mode (the job was initiated by the PLC). n error occurs that either pauses or aborts the current job. (Setting the appropriate ACTION in the fault table can force this.) The Fault Recovery screens can also appear when the following conditions are true: The "Test Run Fault Handling" item on the SETUP Cell screen is ENABLED. A pause error is posted (the appropriate ACTION in the fault table can force this). • If the Teach Pendant Error Recovery item in the Cell communication Screen is DISABLED, you can display the Fault Recovery screen manually by performing the following steps: Press ALARMS. Press F1, [TYPE]. Select Recovery. Check whether the robot is waiting for a user recovery option. • If the robot is not waiting for a user recovery option, the following screen will be displayed.
Steps
2
- 887 -
12.DISPENSE TOOL
B-82594EN-4/01
JOB0001 LINE 1 RUNNING FAULT RECOVERY E1 No fault recovery options exist at this time
•
If the robot is waiting for a user recovery option, a screen similar to the following will be displayed.
PROG-047 TP is disabled while running JOB0001 LINE1 RUNNING FAULT RECOVERY E1 ERROR: A fatal error has occurred. ACTION: Look up the error in Appendix A of your Dispensetool manual and correct the cause of this error, then press [CHOICE].
3
To use the Fast Fault Recovery option to recover from a fault, press F4, [CHOICE]. You will see a screen similar to the following. PROG-047 TP is disabled while running JOB0001 LINE1 RUNNING FAULT RECOVERY E1 1 CANCEL 5 FAST FAULT 2 ERR_PROG 6 DISABLE FAULT 3 CONT WET 7 4 CONT DRY 8 FAULT RECOVERY ERROR: A fatal error has occurred. ACTION: Look up the error in Appendix A of your Dispensetool manual and correct the cause of this error, then press [CHOICE].
NOTE 1 If the Fast Fault Recovery option is installed, the Fast Fault option will be displayed. 2 For those errors that can be disabled for 20 job cycles, the Disable Fault option will be displayed. The Fast Fault Recovery option is available if the: • Error recovery option is loaded. • Error recovery option is configured so that the Error Recovery Function is ENABLED and Fast Exit/Entry feature is ENABLED. • The Error was not of the ABORT type. DISABLE FAULT is available if the: • Error can be disabled for 20 job cycles (currently only 11006 - Hand Broken) • The table (10 available slots) is not full. • Entry is not already in the table or is in the table but has exceeded the 20 job cycles. - 888 -
12.DISPENSE TOOL
B-82594EN-4/01
• 4
$disb_fault.$enable=TRUE
To execute the Fast Fault Recovery option, select FAST FAULT.
NOTE To display all currently available options, press F4, [CHOICE]. If you can recover from the error (it is not an ABORT error), you can select WET or DRY. If an error program has been defined since the beginning of this job, you can select ERR_PROG. You can cancel the job by selecting CANCEL. •
To continue in WET mode, press F4, [CHOICE], and select CONT WET. This option will appear only if the job has been paused on a PAUSE error or an error that has been set up in the fault table with a PAUSE action code. Selecting this option will cause the job to continue from where it left off, with the robot in WET mode.
NOTE If the robot is between SS[] and SE[] nodes (currently dispensing) and the SS[] command was executed while in DRY mode (the robot entered the sealing segment in DRY mode, so it did not start dispensing), selecting Resume WET will not take effect until the next SS[] is reached. •
•
To continue in DRY mode, press F4, [CHOICE], and select CONT DRY. This option will only appear if the job has been paused on an error with PAUSE severity or an error that has been set up in the fault table with a PAUSE action code. Selecting this option will continue the job from where it left off, with the robot in DRY mode. To execute the current program defined in ERROR_PROG, press F4, [CHOICE], and select ERR_PROG. This option will be available only if an ERROR_PROG has been defined since the current job started. The robot will record its current location and begin executing the program name that was most recently assigned to ERROR_PROG. When the program has finished executing, the following screen will be displayed.
APSH-036 User JOB has been paused JOB0001 LINE 1 PAUSED FAULT RECOVERY E1 ACTION: The ERROR_PROG program has finished successfully. Selecting WET or DRY here will run the RESUME_PROG program and then resume the job in WET or DRY mode as
- 889 -
12.DISPENSE TOOL
B-82594EN-4/01
selected. Make the choice using the CHOICE key below.
CAUTION If the cause of the fault is the robot crashing into an object, do not select Run $RESUME_PROG. Running $RESUME_PROG will return the robot to the exact position of the crash. Instead, move the robot away from the object and press RESET. •
•
If no RESUME_PROG has been defined for this job or process, press F4, [CHOICE]. The option of executing RESUME_PROG will not be available and you will have to cancel the program. CANCEL will always appear. If the job has already been aborted, this might be the only option available. When you select CANCEL, the job will be aborted and the robot will remain at the current position. If a RESUME_PROG has been defined for this job or process, press the appropriate wet or dry function key: To resume in WET mode, press F4, [CHOICE], and select CONT WET. To resume in DRY mode, press F4, [CHOICE], and select CONT DRY. The robot will enter the selected WET or DRY mode and will execute the most recently defined RESUME_PROG, whether it was set in a job or process. A RESUME_PROG is intended to bring the robot back into the work area, close to the position where it was when the error occurred. A new RESUME_PROG should be defined and specified every time the last one defined is no longer valid. Refer to Subsection 12.6.2.1 for more information about RESUME_PROG. After the RESUME_PROG has completed execution, the robot will move to the position it recorded in Step 2 , which will be exactly where the job stopped when the error occurred. After the robot reaches the exact position where the error occurred, the robot will continue the job in the selected WET or DRY mode. To cancel the current job, press F4, [CHOICE], and select CANCEL. This option is always available. It allows you to cancel the current job, leaving the robot at its current position.
- 890 -
12.DISPENSE TOOL
B-82594EN-4/01
12.6.3
Test Cycle
12.6.3.1 Test cycle setup Setting up the test cycle allows you to control the conditions for test running a program. These conditions are in effect any time a program is run until you change the conditions. You can set the test cycle conditions listed and described in Table 12.6.3.1. Use Procedure 12-17 to set up test cycle conditions.
Test Cycle Condition Group
Robot Lock
Dry Run
Cartesian Dry Run Speed Joint Dry Run Speed
Jog Dry Run Speed
Digital/Analog I/O
Table 12.6.3.1 Test Cycle Conditions Description This item specifies the motion group number of the program for which the test cycle conditions are being set. (Does not apply to SpotTool+.) Robot Lock This item determines whether the robot will move during the test cycle. If set to OFF, the robot will move. If set to ON, the brakes are set, servo power is turned off, and the robot will not move. (Does not apply to SpotTool+.) This item determines whether the robot will move during the test cycle. If set to OFF, the robot will move. If set to ON, the brakes are set, servo power is turned off, and the robot will not move. (Does not apply to SpotTool+.) This item determines whether the EOAT will function during the test cycle. If set to OFF , the EOAT will function. If set to ON, the EOAT will not function. (Does not apply to SpotTool+.) Cartesian Dry Run Speed This item determines the speed at which the robot will move during program execution when using Cartesian motion (linear or circular moves) when dry run is set to ON. (Does not apply to SpotTool+.) This item determines the speed at which the robot will move during program execution when using Cartesian motion (linear or circular moves) when dry run is set to ON. (Does not apply to SpotTool+.) This item determines the speed at which the robot will move during program execution when using joint motion when dry run is set to ON. A joint dry run speed of 100 will test run the program at 100% of the programmed speed. (Does not apply to SpotTool+.) This item determines the speed at which the robot will jog when dry run is set to ON. A jog dry run speed of 100% indicates that any jogging done during dry run test cycle will be at the normal jog speed. A jog dry run speed of less than 100% indicates that any jogging done during dry run test cycle will be reduced by that percentage. The jog dry run speed is independent of the Cartesian dry run speed and the Joint dry run speed. (Does not apply to SpotTool+.) This item determines whether digital/analog input and output signals will turn on and off during the test cycle. If set to ENABLED, the input and output signals will turn on and off. If set to DISABLED, the input and output signals will not function. (Does not apply to SpotTool+.)
- 891 -
12.DISPENSE TOOL
B-82594EN-4/01
Test Cycle Condition Step Statement Type
Step Path Node
Robot Motion — (SpotTool+ and DispenseTool only)
ISD Meter Motion — Applies to DispenseTool only (for ISD systems only)
ISD Bypass — DispenseTool only (for ISD systems only)
Description This item allows you to select at which statements the robot will pause between steps. There are the following statement types: • TPP LINE OR KAREL STATEMENT The program pauses when the execution of each program is completed. The program pauses after executing each step in a routine. (applies to all applications except ArcTool, SpotTool+ and DispenseTool) • MOTION The program pauses when the execution of each motion statement is completed. (applies to all applications except SpotTool+ and DispenseTool) • ROUTINE The program pauses after each statement is executed. However, when executing a routine, the program pauses only after every motion statement and when returning from the routine. (applies to all applications except SpotTool+ and DispenseTool) • STATEMENT The program pauses when the execution of each program statement is completed. The program pauses after executing each step in a routine. (applies only to SpotTool+ and DispenseTool) • TP & MOTION The program pauses when the execution of a teach pendant statement or when a KAREL motion statement is completed. (applies only to SpotTool+ and DispenseTool) This item specifies whether to pause the program after each path node during a KAREL MOTION ALONG statement. When set to ON, the program will pause after each path node. When set to OFF, each path will be executed as one continuous step. (Does not apply to SpotTool+.) Determines whether the robot will move during the test cycle. • When set to DISABLED, the robot will perform all motion normally and can be stopped by any emergency stop fault. • When set to ENABLED, the robot will simulate performing all motion commands (automatic and jogging) internally, but will not move the robot or supply power to the servo amplifiers. The robot is not affected by any emergency stop faults in this mode. This item determines whether the meter will move during operation. • When set to ENABLE, the meter will move, and the material will be dispensed. All dispenser-related errors will be detected. • When set to DISABLE, the meter will simulate performing its motion (dispensing, repositioning) internally, but will not move the meter or supply power to the servo amplifiers. The meter is not affected by any EMERGENCY STOP faults while in this mode. In normal mode (not in Bypass mode) the gun will not open for SS/SE instructions. In Bypass mode, however, the gun will open so that the material dispensed using the supply pressure. Refer to the ISD Bypass description below. This item determines whether the meter is bypassed or not. When set to YES, all the meter valves are opened and meter motion will be prohibited. Therefore, the meter is bypassed. In this mode, the material could be dispensed (using the SS/SE instructions) from the material supply pressure. In this mode of operation, calculated volume dispensed is not accurate. This mode could be used to run production in an emergency situation where the dispenser system has severe problems (such as a broken cable, and so forth) by dispensing material from the supply pressure. In this case, you would need to disable the ISD meter motion. All ISD related operations (change dir, reposition, prepressure, and so forth) are ignored. This mode of operation can be used with the ISD meter motion enabled or disabled. When set to NO, the system operates normally.
- 892 -
12.DISPENSE TOOL
B-82594EN-4/01
Procedure 12-17 Setting Up Test Cycle Conditions
Steps 1 2 3 4
Press SELECT. Select the program you want to test and press ENTER. Press MENUS. Select TEST CYCLE. Depending on the application you are using, you will see a screen similar to the following. TEST CYCLE Setup Group 1 1 Robot lock: 2 Dry run: 3 Cart. dry run speed: 4 Joint dry run speed: 5 Jog dry run speed: 6 Digital/Analog I/O: 7 Step statement type: 8 Step path node:
5 6
OFF OFF 300.00mm/s 25.00% 100.00% ENABLE STATEMENT OFF
To display help information , press NEXT,>, and then press F1, HELP. When you are finished displaying help information, press PREV. Set Test Cycle conditions as desired.
NOTE 1 You can change test cycle conditions only if there is not a program running. 2 If you are using ArcTool, and if you disable I/O from the TEST CYCLE SETUP screen, I/O might appear to be simulated when it actually is not. For simulation to occur, you must enable I/O on the TEST CYCLE SETUP screen.
12.6.3.2 Controlling WET/DRY mode manually You can control wet/dry mode manually at any time without using the TEST CYCLE screen. You control WET/DRY mode using the FUNCTIONS menu. Use Procedure 12-18 to control WET/DRY mode manually. You can dispense material in either wet or dry mode. Wet mode means all I/O signals are asserted and the material is actually dispensed. Dry mode means all I/O signals are asserted except the material dispense signal.
- 893 -
12.DISPENSE TOOL
B-82594EN-4/01
Procedure 12-18 Controlling WET/DRY Mode Manually
Steps 1
From any screen, press FCTN. You will see a screen similar to the following. FUNCTIONS 1 ABORT (ALL) 2 SAVE 3 TOGGLE WET/DRY 4 TOGGLE WRIST JOG 5 TOGGLE SUB GROUP 6 TOGGLE REMOTE TCP 7 CHANGE RTCP FRAME 8 9 0 -- NEXT --
2
12.6.4
To change WET to DRY, or DRY to WET, select 9, TOGGLE WET/DRY. • When changing fromWET to DRY, the SEAL ENBL LED on the teach pendant will turn off. • When changing from DRY to WET, the SEAL ENBL LED on the teach pendant will turn ON. The next time you execute a sealing instruction, the dry or wet setting you made will be in effect.
Soft Panel
12.6.4.1 Soft panel overview The soft panel menus are used to perform commonly used functions. Three kinds of Soft Panel menus are available: • • •
Manual style functions—For Style Program Select Mode only Application-specific functions Custom functions-Configurable (this might be displayed and will depend on your configuration)
This section describes how to set up and use these Soft Panel functions.
12.6.4.2 General and application-specific soft panel functions To use the soft panel, you must set the general and application-specific soft panel items to appropriate values. Table 12.6.4.2 describes the soft panel items.
- 894 -
12.DISPENSE TOOL
B-82594EN-4/01
Soft panel item Dispense Controller Mode
Move to Repair from Home Return Home From Repair Move to Purge from Home Return Home From Purge Force Process Complete
Table 12.6.4.2 Soft Panel Description Description Allows you to set the WET/DRY status of the robot controller dispensing functions: • When in WET mode , the controller will send the correct gun open and analog flow commands to the dispensing equipment at the programmed times. • When in DRY mode , the controller will not send any gun open or analog flow control commands to the dispensing equipment. If the robot is at the HOME position, Move to Repair from Home will lead you through the steps necessary to move the robot to the REPAIR position. The program, MOV_REPR.TP, is executed during this procedure. If the robot is at the REPAIR position, the robot will move to HOME by moving backwards through the program, MOV_REPR.TP. In order for this to work effectively, the first position in the MOV_REPR.TP program should be the same as the HOME position. If the robot is at the HOME position, Move to Purge from Home will lead you through the steps necessary to move the robot to the PURGE position. The program, MOV_PURG.TP, is executed during this procedure. If the robot is at the PURGE position, the robot will move to HOME by moving backwards through the program, MOV_PURG.TP. In order for this to work effectively, the first position in the MOV_PURG.TP program should be the same as the HOME position. Force Process Complete will turn on the PROCESS COMPLETE digital output signal. The PROCESS COMPLETE digital output signal will stay ON until the next style is run. Force Process Complete will remain set to ENABLED while the PROCESS COMPLETE digital output is ON. Setting Force Process Complete to DISABLED will turn OFF the PROCESS COMPLETE digital output, if it is ON, and allow DispenseTool to determine whether to turn on the PROCESS COMPLETE signal automatically.
Procedure 12-19 Using the Soft Panel Application Menu
Steps 1 2
Press MENUS. Select SOFT PANEL and F2, [SHOW], and select Application. If you are using SpotTool+, you will see a screen similar to the following. SOFT PANEL 1/6 1 Dispense controller mode: WET 2 Move to repair from home: DISABLED 3 Return home from repair: DISABLED 4 Move to purge from home: DISABLED 5 Return home from purge: DISABLED 6 Force process complete: DISABLED
3
Set Soft Panel conditions as desired.
NOTE Changes can only be made using the menu when the robots are in manual or isolate mode when using Style, or with the TP enabled for RSR/PNS.
- 895 -
12.DISPENSE TOOL
12.6.5
B-82594EN-4/01
Maintenance and Repair You can usemacro commands to appear on the MANUAL FCTNS to perform maintenance and repair procedures. If you are using DispenseTool, you can also use the MANUAL FCTNS screen to execute the predefined programs that direct the robot to move to the home positions, move to the purge position, and move to the service position. You must define these programs before you can execute them from the MANUAL FCTNS screen. Use Procedure 12-20 to perform a manual function.
Procedure 12-20 Using the MANUAL FCTNS Screen
Conditions • •
Macro commands that perform maintenance and repair functions have been set up to appear on the MANUAL FCTNS screen. If you are using DispenseTool, the programs MOV_HOME, MOV_PURG, and MOV_SERV have been defined.
Steps 1 2 3 4
Press MENUS. Select MANUAL FCTNS. Press F1, [TYPE]. Select Macros. You will see a screen similar to the following. Manual Macros Instruction 1 OPEN HAND 2 CLOSE HAND 3 RELAX HAND 4 OPEN HAND 5 CLOSE HAND 6 RELAX HAND 7 GO TO REPAIR
5 6
1 1 1 2 2 2 POS
Move the cursor to the instruction you want to execute. Continuously press and hold in the DEADMAN switch and turn the teach pendant ON/OFF switch to ON.
WARNING In the next step, the robot will move. Make sure that personnel and unnecessary equipment are out of the workcell; otherwise, you could injure personnel or damage equipment. 7
Press and hold the SHIFT key and press F3, EXEC. The F3 key can be released, but the SHIFT key must be held continuously until the instruction has finished executing. - 896 -
12.DISPENSE TOOL
B-82594EN-4/01
12.6.6
Enabling or Disabling Joint Motion Warning If you accidentally use joint motion while dispensing, the quality of your bead might be poor. This feature causes the system to post the "SEAL-245 Joint Motion While Dispensing" warning if joint motion is initiated while the system is dispensing. By default, this feature is disabled. Use Procedure 12-21 to enable or disable the feature.
Procedure 12-21 Enabling or Disabling Joint Motion Warning WARNING System variables control how the robot and controller operate. Do not set system variables unless you are certain of their effect; otherwise, you could injure personnel, damage equipment, or disrupt the normal operation of the robot and controller.
Steps 1 2 3 4
Press MENUS. Select SYSTEM. Press F1, [TYPE]. Select Variables. You will see a screen similar to the following. SYSTEM Variables 1 $ANGTOL 2 $APPLICATION 3 $AP_MAXAX 4 $AP_PLUGGED 5 $AP_TOTALAX 6 $AP_USENUM 7 $ASCII_SAVE 8 $AUTOINIT 9 $BLT 10 $CHECKCONFIG
5 6 7
[3] of STRING [21] 0 2 16777216 [32] of BYTE FALSE 2 0 FALSE
Move the cursor to $slgnstup and press ENTER. Select [1] from the list and press ENTER. Move the cursor to $jntwarn_enb. Press F4, [TRUE] to enable the Joint Motion Warning. Press F5, [FALSE] to disable the Joint Motion Warning. The default value is FALSE.
- 897 -
12.DISPENSE TOOL
B-82594EN-4/01
12.7
STATUS DISPLAYS AND INDICATORS
12.7.1
Status Indicators
12.7.1.1 Teach pendant status indicators Teach pendant status indicators indicate the system condition when you are using the teach pendant to control the system. Fig. 12.7.1.1 (a) and Fig. 12.7.1.1 (b) show the teach pendant status indicators. You might have different indicators depending on the application that you are using. Table Fig. 12.7.1.1 lists and describes each teach pendant status indicator.
Fig. 12.7.1.1 (a) Teach Pendant Status Indicators
Fig. 12.7.1.1 (b) shows the status indicators on the iPendant.
Fig. 12.7.1.1 (b) iPendant Status Indicators
Indicator FAULT HOLD STEP
Table 12.7.1.1 Teach Pendant Status Indicators Description This item indicates that a fault condition has occurred. This item indicates that the robot is in a hold condition. HOLD is not on continuously during a hold condition. This item indicates that the robot is in step mode.
- 898 -
12.DISPENSE TOOL
B-82594EN-4/01
Indicator BUSY RUNNING I/O ENBL PROD MODE
TEST CYCLE JOINT XYZ TOOL GUN ENBL for SpotTool+ WELD ENBL for Spotool+ SEAL ENBL for DispenseTool TEST CYCLE for DispenseTool MAN ENBL for PaintTool WELD ENBL for ArcTool
ARC ESTAB DRY RUN
I/O ENBL for SpotTool+
Description This item indicates that the controller is processing information. This item indicates that a program is being executed. This item indicates that I/O is enabled. This item indicates that the system is in production mode and CYCLE START will start the process. For PalletTool, this item indicates that the system is running in production mode with the Remote/Local item on the System Config screen set to REMOTE. This item indicates that the system is test running a teach pendant or KAREL program with the Remote/Local item on the System Config screen set to LOCAL. This item indicates that the current jog coordinate system is JOINT. This item indicates that the current jog coordinate system is JOG frame, USER frame, or WORLD. This item indicates that the current jog coordinate system is TOOL. This item indicates that the gun will stroke when spot welding commands are executed. This item indicates that welding is enabled, and that spot welds will be performed when SPOT[] commands are executed. This indicates that the system is ready for production and wet run is set to ENABLE. SEAL ENBL indicates that material can and will be dispensed. This item indicates that the system is in test cycle mode. This item indicates that you can perform manual functions. This item indicates that arc welding is enabled. If the arc welding program is not running by remote, this LED is controlled by the teach pendant key WELD ENBL . If the arc weld program is running by remote, this LED can be controlled by a digital input. This item indicates that the robot is welding. This item indicates that the program will execute without welding. If te test cycle dry run conditions has been set to ON, then the DRY RUN LED will be ON. The robot motion speed is controlled by the amount specified in the test cycle screen. This item indicates that I/O is enabled. I/O cannot be disabled.
12.7.1.2 DispenseTool status The DispenseTool status screen displays information about the current job or process. Table 12.7.1.2 lists and describes each DispenseTool status item.
Item Cycle Time units: seconds Last Cycle Time units: seconds Gun On Time units: seconds Last Gun On Time units: seconds Volume Used* units: cc
Table 12.7.1.2 DispenseTool Status Items Description This item displays the duration of the selected job or process. This item displays the duration of the selected job or process, for the last time the job or process was executed. This item displays the amount of time the gun is on for the selected job or process. This item displays the amount of time the gun was on the last time the job or process was executed. This item displays the volume of material used in the selected job.
- 899 -
12.DISPENSE TOOL
B-82594EN-4/01
Item
Description
Last Volume Used* units: cc Gun Efficiency units: Last Gun Efficiency units: % Gun On Screen Gun On (ms) Units: milliseconds
This item displays the volume of material used in the selected job, the last time the job or process was executed. This item is the percentage of time that the gun was on during the JOB. This item is the percentage of time that the gun was on during the previous JOB. This item is the cumulative gun on time for the current job, or the gun on time from when the currently selected program was most recently executed. The gun on time for each equipment is displayed, if multiple equipment is used. This item is updated dynamically as the robot dispenses material. This item is the gun on time from the time before the most recent execution of the currently selected program. The gun on time for each equipment is displayed, if multiple equipment is used. This item is updated dynamically as the robot dispenses material. This item is the number of the dispensing equipment. This item shows the total Gun On Time for all equipment and the total Last Gun On Time for all equipment. This item is updated dynamically as the robot dispenses material.
Last Gun On (ms) Units: milliseconds
Eq. Total Units: milliseconds Volume Volume Units: cc
This item is the total material volume used in the most recent execution of the currently selected program. The Volume value is shifted into the Last Volume column at the start of each job and the Volume value is updated at the end of each job. This item is the total material volume used the time before the most recent execution of the currently selected program. This item is displayed only if a job is currently selected and volume reporting option is used. This item is the number of the dispensing equipment. This item shows the total Volume for all equipment and the total Last Volume for all equipment.
Last Volume Units: cc
Eq. Total Units: cc
*
Displayed only if a JOB is currently selected and volume reporting option is used.
NOTE To enable jobs and processes for standard SpotTool+, set the system variable $JOBPROC_ENB = 1. Use Procedure 12-22 to display DispenseTool status.
Procedure 12-22 Displaying DispenseTool Status
Steps 1 2 3
Press STATUS. Press F1, [TYPE]. Select Seal Data. You will see a screen similar to the following. - 900 -
12.DISPENSE TOOL
B-82594EN-4/01
STATUS Seal Data Cycle time: Last cycle time: Gun on time: Last gun on time: Gun efficiency Last gun efficiency
4 5
58.4 58.6 31.0 30.9 0.0 0.0
s s s s % %
To display help information , press NEXT, >, and then press F1, HELP. When you are finished displaying help information, press PREV. To display the dynamic gun on time for the dispensing equipment you selected, press F2, GUN ON. You will see a screen similar to the following.
STATUS Seal Data: Last two jobs run Gun On (ms) Last Gun On (ms) Eq. 1: 23800 23700 Eq. 2: 4000 4000 Eq. 3: 3200 3200 ----------------Total: 31000 30900
6
To return to the previous screen, press F2, LISTING. To display the volume at the end of the job for the dispensing equipment you selected, press F3, VOLUME. You will see a screen similar to the following. STATUS Seal Data: Last two jobs run Volume (cc) Last Volume (cc) Eq. 1: 100.0 97.0 Eq. 2: 200.0 200.0 Eq. 3: 51.0 51.0 ----------------Total: 351.0 348.0
To return to the previous screen, press F2, LISTING.
12.7.1.3 Application status The Application Status screen displays the teach pendant key and LED indicators used for the urrently selected application. Available applications are enabled at controlled start. The current pplication is selected either using the FCTN menu or from within a teach pendant program. Use Procedure 12-23 to display application status. - 901 -
12.DISPENSE TOOL Table 12.7.1.3 Application Status Screen Items Description
Item USERKEYS LEDS on TP
B-82594EN-4/01
This item lists the use of teach pendant user keys U1 through U7 for the currently selected application. This item lists the use of teach pendant LEDs L1 through L3 for the currently selected application.
Procedure 12-23 Displaying Application Status
Steps 1 2 3
Press STATUS. Press F1, [TYPE]. Select Appl. You will see a screen similar to the following.
NOTE The screen for the currently selected application will be displayed. Appl status DispenseTool USERKEYS LEDS on U1: MANUAL FCTN L1 : U2: SOFT PANEL L2 : U3: TEST CYCLE L3 : U4: HOT EDIT U5: STATUS U6: ALARMS U7 : POSITION
TP SEAL ENBL PROD MODE TEST CYCLE
12.7.1.4 Program status for DispenseTool The program status screen displays the name of the running teach pendant or KAREL program, the running routine if a KAREL program is running, and the running task number and name. Refer to Table 12.7.1.4 for a description of each program status item. Use Procedure 12-24 to display program status information.
Program status item Task number Task name Program Routine
Line number
Table 12.7.1.4 Program Status Items Description This item indicates the number of the default task. You can change the task number to display information about other tasks that are running. This item displays the name of the task that corresponds to the selected task number. This item displays the name of the teach pendant or KAREL program that is being executed by the selected task number. This item displays the name of the current routine, when a KAREL program is selected. If a KAREL program is being executed, the routine name might be different than the program name. This item displays the program line number for the teach pendant or KAREL program that is being executed by the selected task number.
- 902 -
12.DISPENSE TOOL
B-82594EN-4/01
Program status item Status
Description This item displays the activity of the teach pendant or KAREL program that is being executed by the selected task number. Status can be • RUNNING • PAUSED • ABORTED • MOVING (teach pendant programs only) • WAITING (teach pendant programs only) • WAITING FOR DI[n] (teach pendant programs only) • WAITING FOR RI[n] (teach pendant programs only)
Procedure 12-24 Displaying Program Execution History
Steps 1 2 3
Press STATUS. Press F1, [TYPE]. Select Exec-hist. You will see a screen similar to the following. STATUS Program 1 Task number: Task name: Program: Routine: Line number: Status:
4
1 SLSHELL SLSHELL INIT_SHELL 1321 RUNNING
To display information for another tasknumber, select Task number and enter the number of the task you want to view.
- 903 -
12.DISPENSE TOOL
B-82594EN-4/01
12.8
PROGRAM AND FILE MANIPULATION
12.8.1
Manipulating Files
12.8.1.1 Backing up files Application Files When you select "Application," all files listed in the $FILE_APPBCK system variable will be saved. You should not modify this system variable. Table 12.8.1.1 lists and describes the various kinds of application files.
Name *.VR *.PC *.TX FR:*.HTM FR:*.STM FR:*.GIF FR:*.JPG SYSSEAL.SV* SYSSLIO.SV* SYSSLSCH.SV*
Table 12.8.1.1 Application Files Description KAREL variable files KAREL program files Dictionary files HTML web pages on FR: device HTML web pages using iPendant Controls or Server Side Includes on FR: device GIF image files on FR: device JPEG image files on FR: device This file contains sealing setup system variable values for your system. This file contains sealing I/O setup system variable values for your system. (Note: does not include IPS I/O if equipped with IPS dispenser.) This file contains sealing schedule system variable values for your system.
*
These files appear if you are using DispenseTool or SpotTool+ with the Dispense Plug-in.
- 904 -
12.DISPENSE TOOL
B-82594EN-4/01
12.9
ADVANCED FUNCTIONS
12.9.1
Error Recovery (Option)
12.9.1.1 DispenseTool-specific information I/O Handshaking with Dispenser With normal operation, StyleID handshaking takes place at the beginning of a job and DispenseComplete handshaking takes place at the end of a job. With the error recovery feature, the robot system tries to keep the integrity of I/O handshakings with the dispenser as much as possible. If you choose “continue weld/wet” option in the error recovery menu, the robot will execute dispense complete processing at the end of job. If you choose “continue noweld/dry” option, the robot will not send dispense complete at the end of job, but all faults will be ignored. If you choose “fast fault recovery” option, the robot will not perform dispense complete processing when it exits dry, nor will it send the style ID to the dispenser when it re-enters dry, but it will perform dispense complete processing after the application is re-enabled, so that it appears that dispenser is executing just one job. One exception to this is when an error is detected at the dispense complete processing, and you choose the fast fault recovery option. Since the dispense complete processing is already performed, the job will be redone, and therefore, style ID processing will be done again at the beginning of the job, and dispense complete processing at the end of the job.
Fast Fault Recovery Upon Volume Fault If a volume fault is detected during the “dispense complete” processing, the “volume fault” will be posted, and the recovery screen will be displayed with the following recovery options. Except for “Fast Fault Recovery,” choosing other options has the same effect as other faults, but choosing “Fast Fault Recovery” has different effect for “Volume fault” case. • • • •
Continue wet Continue dry Fast Fault Recovery Abort
- 905 -
12.DISPENSE TOOL
B-82594EN-4/01
In the case of selecting “Fast Fault Recovery” for “Volume Fault,” the application is re-enabled upon reentry at the beginning of the TP program that calls the DispenseComplete (EndJob) macro that initiated the “volume fault,” instead of re-enabling the application at the exact location where the fault was detected (which is within the DispenseComplete macro).
NOTE 1 As you can see from the explanation, this mechanism works as intended only if the DispenseComplete macro is called from the process program. If DispenseComplete is called in a wrong place, the timing at which that application is re-enabled might not be correct. For example, if the DispenseComplete macro is placed within the main JOB program after returning from the process program, the application would be re-enabled at the beginning of the main job program, instead of the beginning of the process sub-program. It is also recommended that DispenseComplete should be called at the end of the dispensing process for each dispenser. This will ensure that any completed process will not be reapplied upon re-entry. 2 Upon re-enabling the dispensing application, the robot sends the Style ID to the dispenser (since the robot is re-doing the entire job). This takes place just before executing the first line of the process program. With the above features, the sequence for Fast Fault Recovery becomes the following: 1 First, the user is required to use the JOB type program to specify the PartID, and a PROCESS program must be called to do the dispensing job. Also, the DISPENSE_COMPLETE macro must be called within the PROCESS program. 2 Volume error is detected by the system. “Volume fault” message is posted. At this point, the cursor is at the next line after the DISPENSE_COMPLETE macro. 3 You can select from the error recovery options. Select “Fast Fault Recovery”. 4 The system fast-exits, runs the maint_prog, then fast re-entry. It will go thru the program with DRY mode until it comes to the first line of the PROCESS program for which the volume fault occurred. 5 As soon as the program comes to the first line of the PROCESS program, the system does the StyleID handshaking with the dispenser, and then continues executing the program with WET mode. (Fast Fault Recovery sequence is now over).
- 906 -
12.DISPENSE TOOL
B-82594EN-4/01
Task OK Processing A setup switch controls this feature. If the switch is enabled, DispenseTool will set the Task OK output signal to ON for the following events: • •
Selecting "ContinueWet" Just before the application FastFaultRecovery.
is
re-enabled
during
NOTE Task OK is blindly turned ON for these cases, and therefore, it is the responsibility of the user to verify the quality for these cases.
- 907 -
12.DISPENSE TOOL
B-82594EN-4/01
12.10
NEMO PUMP
12.10.1
Overview You must set up DispenseTool configuration, schedules, and equipment information for the kind of dispensing equipment you are using. This section describes how to set up this information for the NEMO® Pump. NEMO® is a registered trademark of HEISHIN Ltd.. DiepsenseTool manipulates the NEMO Pump as follows, • When the robot starts dispensing, the NEMO Pump rotates at a high rate to increase the material pressure. • When the robot stops dispensing, the NEMO Pump rotates in reverse at a high rate to decrease the material pressure. Fig. 12.10.1 shows an example of NEMO Pump operation.
SS[1]
SE
t
Robot TCP Speed
Prepress rate t
NEMO Pump Speed
Depress rate Prepress time Depress time
Fig. 12.10.1 NEMO Pump operation
12.10.2
Limitations • • • • •
If you want to use the functionalities described in this section, you must install the “NEMO Pump function” software option. You cannot use ISD equipment in the NEMO Pump system. You cannot use IPD equipment in the NEMO Pump system. If you want to use the robot brakes to control the NEMO Pump, you must set the brake number to 2 or larger. One robot can manipulate upto two NEMO Pumps. If the robot manipulates only one NEMO Pump, it will operate as equipment 1. - 908 -
12.DISPENSE TOOL
B-82594EN-4/01
• •
12.10.3
If the robot manipulates two NEMO Pumps, the pump connected to Process axis 1 will operate as equipment 1, and another pump connected to Process axis 2 will operate as equipment 2. While one of the pumps is operating, another cannot operate. If you want to perform dispensing with the NEMO Pump, you must use the sealing schedules 1 to 50. If you want to perform dispensing with the NEMO Pump, you must use a program of the Process sub type. Refer to Section 12.4, “PLANNING AND CREATING A PROGRAM” for information on how to create a program.
Setting Up Process Axes You must set up specific information about the hardware before you can use the NEMO Pump. The “Process axis” is used to control the NEMO Pump.
Procedure 12-25 Setting Up Process Axes
Steps 1 2 3
Perform a controlled start. Refer to Section B.1.3 for information on the controlled start. Press MENUS. Select MAINTENANCE. You will see a screen similar to the following. ROBOT MAINTENANCE CONTROLLED START MENUS Setup Robot System Variables Group Robot Library/Option Ext Axes 1 M-710iC/70 0 0 IS Driver 1 [ TYPE ] ORD NO
4 5
AUTO
MANUAL
Move the cursor to IS Driver Press F4, MANUAL. You will see a screen similar to the following.
Enter the total number of ISDT axes to be installed (max 8):
6
Enter the number of process axes. To use only one NEMO Pump, enter 1. To use two NEMO Pumps, enter 2. You will see a screen similar to the following.
Enter the FSSB number (from 1 to 3) on which ISDT axis 1 is installed:
- 909 -
12.DISPENSE TOOL
B-82594EN-4/01
7
Enter the FSSB number. You will see a screen similar to the following.
Enter the hardware axis number for ISDT axis 1:
Enter the hardware axis number. You will see a screen similar to the following.
NOTE If you want to use two NEMO Pumps, you must set the FSSB number and hardware axis number for each process axis. Table12.10.3 Item
Process Axes Setup Items Description 149. ACbM1 MOTOR SIZE 11. /4000 MOTOR TYPE 10. 20A CURRENT LIMIT FOR AMPLIFIER 10. 20A CURRENT LIMIT FOR MOTOR AMPLIFIER NUMBER 2 AMPLIFIER TYPE 2. A06B-6114 series Alpha I amp. or … GEAR RATIO 1* 2. Change, -> 4000 (rpm) MAX JOINT SPEED SETTING MOTOR DIRECTION 1. TRUE ** 1. Change, -> 10 (ms) EXP_ACCEL TIME LOAD RATIO 5 BRAKE SETTING 2 ***
* GEAR RATIO must be set to 1. ** MOTOR DIRECTION must be set to 1:TRUE. *** If you want to use the robot brakes to control the NEMO Pump, you must set BREAKE SETTING to 2 or larger.
- 910 -
12.DISPENSE TOOL
B-82594EN-4/01
12.10.4
Setting Up DispenseTool Configuration You must set up DispenseTool configuration before you can use the NEMO Pump. Table 12.10.4 lists and describes each configuration item.
Item Number of Equipments default: 1 range: 1 to 5 Equipment type: default: Var[iable] Orifice
Table 12.10.4 DispenseTool Configuration Setup Items Description This item defines the maximum number of equipments to be set up and controlled by DispenseTool. This item defines the type of equipment you are using. NOTE If you want to use only one NEMO Pump, you must set $SLUSRCST[1].USECUSTOM to TRUE. If you want to use two NEMO Pumps, you must set both $SLUSRCST[1].USECUSTOM and $SLUSRCST[2].USECUSTOM to TRUE.
Procedure 12-26 Setting Up DispenseTool Configuration
Steps 1
Perform a controlled start. Refer to Section B.1.3 for information on the controlled start. The DispenseTool Application Configuration Setup screen is displayed. You will see a screen similar to the following. Seal Config CONTROLLED START MENUS DispenseTool Application Configuration 1 F Number: F00000 2 Number of equipments: 1 3 Number of guns: 1 4 Equipment type: Variable Orifice 5 Beadshaping air: DISABLE 6 Remote start: DISABLE 7 Automatic purge: DISABLE 8 Bubble detect: DISABLE 9 Linear 2P calibration: DISABLE 10 Channel 2 analog output: DISABLE 11 AccuSeal advanced feature: DISABLE
- 911 -
12.DISPENSE TOOL
B-82594EN-4/01
2
If you want to change the number of equipment, move the cursor to Number of equipments and type in the appropriate value. You will see a prompt box similar to the following. You have changed the number of equipment. Press YES to confirm your change and wait for new sysvar reallocation. YES NO
NOTE You can configure multiple equipment of different types if you type a value larger than 1. 3 4
If you are sure that you want to change the number of equipments, select YES and press ENTER. To select a specific piece of equipment, press F3, EQUIP, and type the number of the piece of equipment. You will see a screen similar to the following. Seal Config CONTROLLED START MENUS E2 DispenseTool Application Configuration 1 F Number: F00000 2 Number of equipments: 1 3 Number of guns: 1 4 Equipment type: Variable Orifice 5 Beadshaping air: DISABLE 6 Remote start: DISABLE 7 Automatic purge: DISABLE 8 Bubble detect: DISABLE 9 Linear 2P calibration: DISABLE 10 Channel 2 analog output: DISABLE 11 AccuSeal advanced feature: DISABLE
5
6 7 8
9
Move the cursor to the appropriate item and set it as desired. • To use only one NEMO Pump, set Equipment type of E1 to Variable Orifice. • To use two NEMO Pumps, set both Equipment types of E1 and E2 to Variable Orifice. Press MENUS. Select VARIABLES. The system variables screen is displayed. To use only one NEMO Pumps, set $SLUSRCST[1].USECUSTOM to TRUE. To use two NEMO Pumps, set both $SLUSRCST[1].USECUSTOM and $SLUSRCST[2].USECUSTOM to TRUE. When you are finished setting the DispenseTool configuration items, perform a cold start. Refer to Subsection B.1.4 for information on the cold start.
- 912 -
12.DISPENSE TOOL
B-82594EN-4/01
12.10.5
Setting Up NEMO Pump Information Fig. 12.10.5 shows a flow chart of setting up the NEMO Pump.
(1) Flow rate control calibration
Refer to Subsection 12.2.6.2.
(2) Maximum analog out (meter)/maximum meter speed calibration
Refer to Subsection 12.2.6.4.
(3) Setting up NEMO Pump information
Refer to Subsection 12.10.5.
(4) Setting up NEMO Pump schedules
Refer to Subsection 12.10.6.
Refer to Subsection 12.2.3, 12.2.4.
(5) Setting up schedules
Fig. 12.10.5 Flow chart of setting up NEMO Pump
NOTE The timing of the NEMO Pump motion is to be adjusted by using Equip. ant-time, SS time offset and SE time offset. Refer to Subsection 12.2.4 (PROCESS TIMING PROTOCOLS) for information on the effects. You must set up specfific information about the NEMO Pump before you can use it. Table 12.10.5 lists and describes each NEMO Pump setup item.
Item NEMO Pump motion*
Prepress rate (%) default: 0.0 min: 0.0 max: 100.0
Table 12.10.5 NEMO Pump Setup Items Description ENABLE- The NEMO Pump will move during execution of dispensing instructions, SS, SE, or purging. DISABLE- The NEMO Pump will not move. This item specifies the NEMO Pump speed during prepressure motion. This value is a percentage of the maximum motor speed.
- 913 -
12.DISPENSE TOOL
B-82594EN-4/01
Item Depress rate (%) default: 0.0 min: 0.0 max: 100.0 Volume per rev. (cc/rev) default: 0.0 min: 0.0 max: 99999.999 Gear ratio default: 0.0 min: 0.0 max: 99999.999
Description This item specifies the NEMO Pump speed during depressure motion. This value is a percentage of the maximum motor speed.
This item specifies the volume per one NEMO Pump revolution. This value is used to calculate the volume of dispensed material.
This item specifies the NEMO Pump revolution per motor revolution. This value is used to calculate the volume of dispensed material.
*
To define a digital output for the machielock status of the NEMO Pump, set $ISDVRCFG[n].$MLOCK_IO_I (n: equipment number) to a port number. This output is ON while the NEMO Pump is machinelocked. To define a digital output for the ready status of the NEMO Pump, set $ISDVRCFG[n].$READY_IO_I (n: equipment number) to a port number. This output is ON while the NEMO Pump servo is ready or NEMO Pump motion is disabled.
Procedure 12-27 Setting Up NEMO Pump Information NOTE 1 If you have multiple equipment, you must set up equipment items for each one. 2 The values of all items except NEMO Pump motion will be backed up to a file, NEMOPUMP.VR.
Steps 1 2 3 4
Press MENUS. Select SETUP. Press F1, TYPE. Select NEMO Pump. You will see a screen similar to the following.
NOTE The equipment number displayed in this screen as EQ# may not correspond with E# on the title line. SETUP NEMO Pump E1 EQ: 1 1 NEMO Pump motion: 2 Prepress rate: 3 Depress rate: 4 Volume per rev.: 5 Gear ratio: [TYPE]
DATA
- 914 -
STATUS EQUIP
JOINT 100% 1/5 ENABLE 15.00 % 10.00 % 20.000 cc/rev 6.500 > >
12.DISPENSE TOOL
B-82594EN-4/01
5
6
12.10.6
To select the number of the equipment you want to set up a Press NEXT, >. b Press F3, EQUIP. c Type the number of the equipment and press ENTER. Select items and set them as desired.
Setting Up Schedules You must set up the schedules before you can use the NEMO Pump. DiepsenseTool manipulates the NEMO Pump as follows, • When the robot starts dispensing, the NEMO Pump rotates at the specified Prepress rate until the specified Prepress time expires. • When the robot stops dispensing, the NEMO Pump rotates in reverse at the specified Depress rate until the specified Depress time expires. Fig. 12.10.6 shows an example of the effects of Prepress time and Depress time.
SS[1]
SE
t
Robot TCP Speed Eq ant-time SS time offset
Eq ant-time SE time offset
t
NEMO Pump Speed Prepress time= 0 Depress time = 0
Prepress rate NEMO Pump Speed Prepress time> 0 Depress time > 0
t Depress rate Prepress time
Depress time
Fig. 12.10.6 Effects of Using Prepress Time and Depress Time
- 915 -
12.DISPENSE TOOL
B-82594EN-4/01
NOTE The timing of the NEMO Pump motion is to be adjusted using Equip. ant-time, SS time offset and SE time offset. Refer to Subsection 12.2.4 “PROCESS TIMING PROTOCOLS” for information on the effects. Table 12.10.6 lists and describes each schedule item.
Item Prep.time (ms) default: 0 min: 0 max: 5000 Depr.time (ms) default: 0 min: 0 max: 5000
Table 12.10.6 Schdule Items Description This item specifies the time for prepressure motion of the NEMO Pump. When the robot starts dispensing, the NEMO Pump rotates at the specified Prepress rate until the specified Prep.time expires. This item specifies the time for depressure motion of the NEMO Pump. When the robot stops dispensing, the NEMO Pump rotates in reverse at the specified Depress rate until the specified Depr.time expires.
Procedure 12-28 Setting Up Schedules NOTE 1 If you have multiple equipment, you must set up equipment items for each one. 2 If you want to perform dispensing with the NEMO Pump, you must use the sealing schedules 1 to 50. 3 The values of Prep.time and Depr.time will be backed up to a file, NEMOPUMP.VR.
Steps 1 2 3 4
Press MENUS. Select SETUP. Press F1, TYPE. Select NEMO Pump. You will see a screen similar to the following. SETUP NEMO Pump E1 EQ: 1 1 NEMO Pump motion: 2 Prepress rate: 3 Depress rate: 4 Volume per rev.: 5 Gear ratio: [TYPE]
5
DATA
STATUS EQUIP
JOINT 100% 1/5 ENABLE 15.00 % 10.00 % 20.000 cc/rev 6.500 > >
Press F2, DATA. You will see a screen similar to the following.
- 916 -
12.DISPENSE TOOL
B-82594EN-4/01
NOTE The equipment number displayed in this screen as EQ# may not correspond with E# on the title line. DATA NEMO Pump EQ: 1
E1
Prep.time(ms) 1 2 3 4 5 6 … 49 50
[TYPE]
JOINT 100% 1/50
Depr.time(ms)
10 0 0 0 0 0
30 0 0 0 0 0
0 0
0 0
SETUP EQUIP
> >
Prep.time and Depr.time on the line n will be applied to dispensing with the schedule n. 6
7
12.10.7
To select the number of the equipment you want to set up a Press NEXT, >. b Press F3, EQUIP. c Type the number of the equipment and press ENTER. Select items and set them as desired.
NEMO Pump Status The NEMO Pump status screen displays the volume of dispensed material. Table 12.10.7 lists and describes each status item.
Item Volume dispensed (cc)
Volume per cycle (cc/cyc)
Table 12.10.7 Status Items Description This item indicates the volume of dispensed material. The value is calculated using the following equation. Volume dispensed (cc) = Volume per rev. (cc/rev) * Gear ratio * Motor revolution (rev) Motor revolution is read from $ISDVR[n].$REV_COUNT (n: equipment number). To reset Volume dispensed, set $ISDVR[n].$ REV_COUNT to 0. This item indicates the volume of dispensed material during the cycle. When UPDATEn.PC (n: equipment number) is executed, the value is updated using the following equiation. Volume per cycle (cc/cyc) = Volume dispensed (cc) at present - Volume dispensed (cc) at the previous UPDATEn.PC execution To measure the volume per cycle, insert a CALL instruction that calls UPDATEn.PC into the program.
- 917 -
12.DISPENSE TOOL
B-82594EN-4/01
Procedure 12-29 Displaying Status
Steps 1 2 3 4
Press MENUS. Select SETUP. Press F1, TYPE. Select NEMO Pump. You will see a screen similar to the following. SETUP NEMO Pump E1 EQ: 1 1 NEMO Pump motion: 2 Prepress rate: 3 Depress rate: 4 Volume per rev.: 5 Gear ratio: [TYPE]
5
DATA
STATUS EQUIP
JOINT 100% 1/5 ENABLE 15.00 % 10.00 % 20.000 cc/rev 6.500 > >
Press F3, STATUS. You will see a screen similar to the following.
NOTE The equipment number displayed in this screen as EQ# may not correspond with E# on the title line. SETUP NEMO Pump EQ: 1
E1
1 Volume dispensed: 2 Volume per cycle:
[TYPE]
6
12.10.8
SETUP EQUIP
JOINT 100% 572.01 cc 124.02 cc/cyc
> >
To select the number of the equipment you want to display a Press NEXT, >. b Press F3, EQUIP. c Type the number of the equipment and press ENTER.
Resetting Pulse Coder Alarms When you turn on the controller after disconnecting and reconnecting a process axis motor, you need to reset the serial pulsecoder. When this occurs, you will see a SRVO-062 BZAL (Group:0 Axis:n) and SRV0-075 Pulse not established (G:0 A:n) alarm, where "n" indicates the number of the process axis. Use Procedure 12-30 to reset these alarms
- 918 -
12.DISPENSE TOOL
B-82594EN-4/01
Procedure 12-30 Resetting Pulse Coder Alarms
Steps 1 2 3 4 5 6 7 8
Replace the ISD batteries with four new 1.5 volt alkaline batteries,size D. Observe the direction arrows in the battery box for proper orientation of the batteries. Press MENUS. Select SYSTEM. Press F1, [TYPE]. Select Variables. Move the cursor to $IS_MCR and press ENTER. Move the cursor to $spc_reset. Press the F4, TRUE, once. The value will quickly go back to FALSE.
CAUTION Do not press RESET at this point. Otherwise, you will have to restart this procedure from Step 1. 9 10
11
12.10.9
Turn off the controller and then turn it on so that the new value can take effect. If the SRVO-062 alarm is still present; there is a battery, cable or pulsecoder problem. Refer to FANUC Robot series R-30iA CONTROLLER MAINTENANCE MANUAL for further information. If a SRVO-075 alarm is present, rotate each axis that lost battery power by at least one motor revolution using the gun purge procedure. Refer to Subsection 12.3.8 for information on the gun purge.
Error Status Summary This section describes the error status of the NEMO Pump. The sequence of conditions that are monitored at all times is shown in Fig. 12.10.9 (a).
The following conditions are monitored at all times: If the process axis is not machinelocked If the servo of the process axis is in error status Post error number 95007: “ISDT-007 Servo not READY (G:0 A:%d)” with WARN severity If the speed command to the process axis is exceeding the limit Post error number 95002: “ISDT-002 Motor speed limit (G:0 A:%d)” with WARN severity Fig. 12.10.9 (a) Sequence of Conditions that are Monitored at All Times
- 919 -
12.DISPENSE TOOL
B-82594EN-4/01
The sequence of conditions that are checked at each SS[] instruction is shown in Fig. 12.10.9 (b). The following conditions are monitored at each SS[] instruction: If the 1st SS is executed If the process axis is not machinelocked If the servo of the process axis is in error status Post error number 51056: “SEAL-056 Dispenser not ready (E%s)” with PAUSE severity The schdule number used is larger than 50. Post error number 51038: “SEAL-038 Schedule number > 50 (E%d)” with WARN severity Fig. 12.10.9 (b) Sequence of Conditions that are Checked at Each SS[] Instruction
- 920 -
12.DISPENSE TOOL
B-82594EN-4/01
12.11
ISD GEAR METER
12.11.1
OVERVIEW You must set up DispenseTool configuration, I/O, schedules, and equipment information for the kind of dispensing equipment you are using. After you have set up the equipment, you can perform manual functions. The error status information in the "Error Status Summary" section describes how dispensing equipment signals are checked for incorrect status. CAUTION Chapter 12.3 DISPENSETOOL COMMON SETUP contains setup information and procedures you must perform to set up this equipment. Perform the setup procedures in Chapter 12.3 DISPENSETOOL COMMON SETUP in addition to the setup procedures in this chapter.
12.11.2
SETTING UP PROCESS AXES
Procedure 12-31 Setting Up Process Axes You must set up specific information about the hardware before you can use the ISD equipment. The “Process axis” is used to control the ISD equipment
Steps 1 2 3
Perform a controlled start. Refer to Section B.1.3 for information on the controlled start. Press MENU key. Select [MAINTENANCE]. You will see a screen similar to the following.
AUTO E1 CTRL START MENU 10% ROBOT MAINTENANCE 2/10 Setup Robot System Variables Group Robot Library/Option 1 R-2000iB/165F 0 Process Axis Control
[ TYPE ]
4
ORD NO
AUTO
Ext Axes 0 0
MANUAL
Move the cursor to “Process Axis Control”. - 921 -
12.DISPENSE TOOL
B-82594EN-4/01
5
Press F4,[ MANUAL]. You will see a screen similar to the following.
NOTE “Six Axes”means the number of Axes containing Ext Axes, but except Process Axes. “1 Process Axes” means the number of Process Axes. To Use multiple ISD equipments, set multiple Process Axes.
Current config: Six Axes + 1 Process Axes 0. Use current config Set new config Select?
6
Select “0. Use current config” or “1. Set new config”. If “1. Set new config” is selected, following screen is displayed. SELECT HARDWARE CONFIGURATION 51. FIVE Axes + 1 Process Axis (6ch) 52. FIVE Axes + 2 Process Axes 61. Six Axes + 1 Process Axes 62. Six Axes + 2 Process Axes 63. Six Axes + 3 Process Axes 64. Six Axes + 4 Process Axes
0. Next page Select?
7
Set hardware configration in the following screen.
*** Group 0 Proc Axis Installation *** 1. Display/Modify Proc axis 1~1 2. Add Proc axes 3. Delete Proc axes 4. EXIT
8 9
To add Process Axes, select “2.Add Proc axes”. Set each item for hardware configration. the example of Hardware configuration.is showed in Table 12.11.2.1.
- 922 -
12.DISPENSE TOOL
B-82594EN-4/01
Table 12.11.2.1 example of Haredware configuration ITEM
DESCRIPTION
Enter axes to add?
Process Axis Number to add
MOTOR SIZE
See the specification of the Motor.
MOTOR TYPE
See the specification of the Motor.
CURRENT LIMIT FOR AMPLIFIER
See the specification of the Amplifier.
CURRENT LIMIT FOR MOTOR
See the specification of the Moter.
AMPLIFIER NUMBER
2
AMPLIFIER TYPE
2
GEAR RATIO
1*
MAX JOINT SPEED SETTING
1: Default
MOTOR DIRECTION
1: TRUE **
EXP_ACCEL TIME
2: No Change
LOAD RATIO
1
Brake Number
2 ***
* GEAR RATIO must be set to 1. ** MOTOR DIRECTION must be set to 1:TRUE. *** If you want to use the robot brakes to control the ISD equipment, you must set BREAKE NUMBER to 2 or larger. NOTE To use multiple ISD Equipments, repeat procedure from Step 7 to Step9. 10
After Process axes is set, You will see the same screen as Step 7. Select “4. EXIT” and folowing screen is displayed.
Save ISDT.DT? Enter (1:Yes, 0:No)
11
Enter the value and the display returns to controlled start menu.
- 923 -
12.DISPENSE TOOL
B-82594EN-4/01
Assign Process Axes to ISD equipments. 12 Press MENU key. 13 Select [ Seal Config ] and then, following screen is displayed. AUTO
E1 CTRL START MENU 10%
Seal Config 4/13 DispenseTool Application Configuration EQ: 1 1 F Number: F00000 2 Number of equipment: 1 3 Number of guns: 1 4 Equipment type: ISD SERVO DISPENSER - ISD type: GEAR METER 5 - ISD Number: 1 6 Beadshaping/Atomizing Air: DISABLE 7 Remote start: DISABLE 8 Automatic purge: DISABLE Press FCTN then START (COLD) when done. [ TYPE ] EQUIP [CHOICE] >
14 15
Press NEXT key. Press F2,[ProcCFG] and following screen is displayed.
AUTO E1 CTRL START MENU 10% Seal Config Multiple Process Axes Mapping 1/9 Total available proc-axis number: 1 Proc Number Servo Type Servo Number ======================================== 1 Axis #1: N/A 0 2 Axis #2: N/A 0 3 Axis #3: N/A 0 4 Axis #4: N/A 0 5 Axis #5: N/A 0 6 Axis #6: N/A 0 7 Axis #7: N/A 0 [ TYPE ]
16 17 18 19
[CHOICE]
DONE >
Move the cursol to the number that was selected at Step 8 and 9. Press F4,[CHOICE]. Select [ELECTRIC]. If setup is completed, Press F5,[DONE], and you will see the screen as following.
- 924 -
12.DISPENSE TOOL
B-82594EN-4/01
AUTO E1 CTRL START MENU 10% Seal Config Setting up number information 1/4
1 F Number: 2 Max equipment number: 3 Total ISD number: 4 of which # of Dual ISD:
F00000 1 1 0
[ TYPE ]
20
DONE
Set number informaiton as Table 12.11.2.2.
Table 12.11.2.2 Setting up number information ITEM
DESCRIPTION
Max equipment number
Enter Total equipment number including both ISD and other equipments.
Total ISD number
Enter Total ISD equipment number.
of which # of Dual ISD
This item is for ISD Dual meter option.
21 22 23
After setting, press ENTER key . Set the configuration of ISD equipments. Press MENU key. Select [ISD Config], and you will see the secreen as following.
AUTO E1 CTRL START MENU 10% ISD Config Integral Servo Dispenser Config 1/16 Total number of ISD: 1 1 ISD #1 Dispenser Type: UNINIT 2 Servo Type: UNINIT 3 Axis Number: 0 4 Use 2K: NO 5 ISD #2 Dispenser Type: UNINIT 6 Servo Type: UNINIT 7 Axis Number: 0 8 Use 2K: NO
[ TYPE ]
24
[CHOICE]
Setup the ISD Configuration as Table 12.11.2.3.
- 925 -
12.DISPENSE TOOL
B-82594EN-4/01
Table12.11.2.3 Settiong up ISD Configuraiton ITEM
DESCRIPTION
Dispenser Type
The type of ISD equipment. Select GEAR METER
Servo Type
Enter the same value as Step 9.
Axis Number
Enter the same value as Step 9.
Use 2k (*)
If you enable Use 2k, select YES.
* Use 2k is applied for the system whose 1 process axes drive 2 meter. Usually, 2 different type of material are supplied for those 2 meters and they are mixed at dispense. If Use 2k is enabled, You must set additional items for Setting up Dispense Information ( Section 12.11.5 ).
12.11.3
Setting up Dispense Configuration You must set up the configuration of Dispense Tool to use ISD Gear Meter as Table 12.11.3.1. Table 12.11.3.1 Setting up Dispense Configuration ITEM
DESCRIPTION
Number of equipment Default:1 Min: 1 Max: 5
The total number of Dispense equipments
Equipment type Default: Vari[able]Orifice
The type of equipments.
Procedure 12-32 Setting up Dispense Tool Configuration 1 2 3
Perform a controlled start. Refer to Section B.1.3 for information on the controlled start. Press MENU key. Select [Seal Config] and you will see Dispense Configuration screen as below. AUTO
E1 CTRL START MENU 10%
Seal Config 4/13 DispenseTool Application Configuration EQ: 1 1 F Number: F00000 2 Number of equipment: 1 3 Number of guns: 1 4 Equipment type: ISD SERVO DISPENSER - ISD type: GEAR METER 5 - ISD Number: 1 6 Beadshaping/Atomizing Air: DISABLE 7 Remote start: DISABLE 8 Automatic purge: DISABLE Press FCTN then START (COLD) when done. [ TYPE ] EQUIP [CHOICE] >
- 926 -
12.DISPENSE TOOL
B-82594EN-4/01
4 5 6
Move the cursor to the appropriate item and set it as desired. To change the number of equipments, Move the cursol to “Number of Equipment” Press ENTER key and following message is displayed.
You have changed the number of equipment. Press YES to confirm your change and wait for new sysvar reallocation. YES [NO]
7
If you are sure that you want to change the number of equipments, Move the cursol to “YES” and press ENTER key.
NOTE You can configure multiple equipment of different types if you type a value larger than 1. 8
To select a specific piece of equipment, press F3,[EQUIP], and type the number of the piece of equipment. You will see a screen similar to the following. AUTO
E1 CTRL START MENU 10%
SealConfig 1/9 DispenseTool Application Configuration Eq: 2 1 Number of guns: 1 2 Equipment type: VARI ORIFICE - ISD type: N/A 3 - ISD Number: 0 4 Beadshaping/Atomizing Air: DISABLE 5 Remote start: DISABLE 6 Automatic purge: DISABLE 7 Bubble detected: DISABLE 8 Linear 2P calibration: DISABLE [ TYPE ]
9
12.11.4
EQUIP
>
Move the cursor to the appropriate item and set it as desired.
SETTING UP ISD I/O You must set up I/O to enable the dispensing equipment in your system to work with the Integral Servo Dispenser system. The Integral Servo Dispenser uses I/O unit Model A. Table 12.11.4.2 lists and describes the ISD inputs you can set. Table 12.11.4.1 lists and describes the ISD outputs you can set.
- 927 -
12.DISPENSE TOOL
B-82594EN-4/01
NOTE 1 The initial I/O setup you see on the I/O screens is the default I/O setup. To minimize installation setup, use this default I/O setup. 2 For safety reasons, the default values for the indexes of all I/O ports are zero. Be sure to set the indexes to the appropriate values before using the system. Use Procedure 12-33 to set up DispenseTool equipment I/O. Table 12.11.4.1 Integral Servo Dispenser Inputs ITEM
DESCRIPTION
Dispense Pressure Analog Input
This input is connected to the pressure transducer that measures the dispensing pressure.
Supply Pressure Analog Input
This input is connected to the pressure transducer that measures the supply pressure. Table 12.11.2.2 Integral Servo Dispenser Outputs ITEM
DESCRIPTION
ISD Valve A Digital output
This output is used to control the valves for the metering device. This output is controlled by the system according to the current meter operation mode.
ISD Valve B Digital output
This output is used to control the valves for the metering device. This output is controlled by the system according to the current meter operation mode.
ISD Status Group output
16 bit output indicates the status of the ISD system. The bits in this group output are defined as follows: • Bit 0 DISPENSER READY (1:READY TO DISPENSE) • Bit 1 METER EMPTY (1: METER REACHED STROKE LIMIT) • Bit 2 PREPRESSURE (1: PREPRESSURE IS IN PROGRESS, 0:COMPLETE) • Bit 3 SUPPLY HIGH PRESSURE (1: HIGH PRESSURE, 0: NORMAL) • Bit 4 SUPPLY LOW PRESSURE (1:LOW PRESSURE, 0: NORMAL) • Bit 5 DISPENSE HIGH PRESSURE (1: HIGH PRESSURE, 0: NORMAL) • Bit 6 DISPENSE LOW PRESSURE (1: LOW PRESSURE, 0: NORMAL) • Bit 7 METER DIRECTION (1: POSITIVE, 0: NEGATIVE) • Bit 8 VALVE1 (1: ON, 0: OFF) • Bit 9 VALVE2 (1: ON, 0: OFF) • Bit 10 VALVE3 (1: ON, 0: OFF) • Bit 11 VALVE4 (1: ON, 0: OFF) • Bit 12 OTA (1: OT, 0: NORMAL) • Bit 13 OTB (1: OT, 0: NORMAL) • Bit 14 ISD LOCKED (1:LOCKED, 0:NORMAL) • Bit 15 RESERVED
- 928 -
12.DISPENSE TOOL
B-82594EN-4/01
ITEM
DESCRIPTION
ISD Mode Group output
4 bit output indicates the current ISD operation mode as its binary value. The values are defined as follows: 1. Error mode 2. Relieve mode 3. Pre-pressure mode 4. Dispensing mode 5. Bypass mode 6. Jog mode 7. Wait for reload complete (single acting meter only) 8. Sleep mode
Meter Position Group output Default: 0
Reserved. Please set to 0.
Dispense Pressure Group output Units: psi
This output indicates the current dispense pressure value.
Supply Pressure Group output Units: psi
This output indicates the current supply pressure value.
Volume Dispensed Group output Units: cc
16bit output indicates the accumulative material volume dispensed. Units are in cc. This output reflects the value of the system variable $ISD_WORK[eq_n].$volume_disp, and the value can be set to zero by clearing the system variable.
ALC Bypass Digital output
The system continuously copies the value of $isd_work[#].$alc_bypass system variable into this output (where # indicates the equipment number) while ISD meter motion is DISABLED in the test cycle menu. This feature is to be used for customization purposes.
Procedure 12-33 Setting Up ISD I/O Note This procedure contains information about setting up ISD I/O only. For information about configuring, forcing, verifying, and simulating analog, digital, and group signals, refer to Chapter and Chapter .
Steps 1 2 3 4
Press MENU key. Select [I/O]. Press F1, [TYPE]. Select ISD. You will see either the input or output screen. You will see a screen similar to the following.
NOTE The number of the currently selected equipment is displayed in the middle of the title line on every screen. The currently selected equipment for the screens in this procedure is equipment 1, E1. - 929 -
12.DISPENSE TOOL
B-82594EN-4/01
AUTO E1 JOINT 10% ISD INPUT E1 ISD GEAR METER NAME IN PT SIM VALUE 1 Dispense Pressure: AI[ 0] * *** 2 Supply Pressure: AI[ 0] * ***
[ TYPE ] DETAIL
5
IN/OUT
[CHOICE]
>
To change between the input and output screens, press F3, [IN/OUT]. You will see a screen similar to the following.
AUTO E1 JOINT 10% ISD OUTPUT ISD GEAR METER NAME OUT PT SIM VALUE 1 ISD valve A: DO[ 2] * *** 2 ISD valve B: DO[ 0] * *** 3 ISD status: GO[ 0] * *** 4 ISD mode: GO[ 0] * *** 5 Meter Position: GO[ 0] * *** 6 Dispense Pressure: GO[ 0] * *** 7 Supply Pressure: GO[ 0] * *** 8 Volume Dispensed: GO[ 0] * *** 9 ALC bypass: DO[ 0] * *** [ TYPE ] DETAIL
6
12.11.5
IN/OUT
[CHOICE]
>
Select each item and set it as desired.
SETTING UP EQUIPMENT INFORMATION You must set up specific information about the dispensing equipment before you can use it. Equipmentsetup requires you to set up specific items and to perform specific calibration procedures. Table 12.11.5.1 lists and describes each equipment setup item. The items you must set up might vary depending on the way your system is set up.
NOTE Use Procedure 12-9 to set up equipment items.
You might also need to perform the following calibration procedures to set up your dispensing equipment, depending on the way your system is set up: • • •
Maximum meter speed calibration Bead shaping air calibration - only if bead shaping air is used Flow rate control calibration - 930 -
12.DISPENSE TOOL
B-82594EN-4/01
Table 12.11.5.1 Equipment Setup Items ITEM
DESCRIPTION
Material Factor default: 1.00 min: 0.01 max: 10.00
This item is the scale factor used in computing flow control (analog output). It can be changed as material viscosity and temperature changes.
Minimum Flow Rate default: 0 % min: 0 % max: 100 %
This item is the minimum flow command voltage that will be sent to the dispensing equipment while sealing. If the requested flow rate specified in the current Seal Schedule ever goes below the Minimum Flow Rate, theMinimum Flow Rate will be sent to the dispensing equipment.
Bead Shaping Factor* default: 1.00 min: 0.01 max: 10.00
This item is the scale factor used in computing the bead shaping air signal.
Bead Shaping Air AOUT Type* values: Volts, Current default: Volts
This item is the type of analog output: — Volts - Type II output - range 0-10 volts — Current - Type III output - range 1-5 volts Refer to Section for descriptions of type II and type III analog output signals.
Bead Shaping Max Out* default: 10.00 V range: 0.00 V to 10.00 V
This item sets the maximum analog voltage for bead shaping for the dispensing equipment. If the intended analog voltage exceeds this value, then an alarm will occur. Maximum voltage will not exceed this value.
Supply Max. Pressure default: 1500 psi min: 0 psi max: 9000 psi
This item sets the maximum supply A pressure for the dispensing equipment. If the pressure exceeds this value, an alarm will occur. If two-part material is used, this item is indicated as Supply Max. Press. (Mat - 1).
Supply Min. Pressure default: 0 psi min: 0 psi max: 4000 psi
This item sets the minimum supply A pressure for the dispensing equipment. If the pressure falls below this value, an alarm will occur. If two-part material is used, this item is indicated as Supply Min. Press. (Mat - 1).
Supply Max. Press (Mat- 2) ** default: 2000 psi min: 0 psi max: 9000 psi
This sets the maximum supply pressure for the material number 2. If the pressure exceeds this value, an alarm will occur. This item is effective only when two-part material is used
Supply Min. Press (Mat- 2) ** default: 0 psi min: 0 psi max: 4000 psi
This sets the minimum supply pressure for the material number 2. If the pressure falls below this value, an alarm will occur. This item is effective only when two-part material is used.
Dispense Max. Pressure default: 1500 psi min: 0 psi max: 9000 psi
This item sets the maximum dispense A pressure for the dispensing equipment. If the pressure exceeds this value, an alarm will occur. If two-part material is used, this item is indicated as Dispense Max. Press.(Mat- 1).
Dispense Min. Pressure default: 0 psi min: 0 psi max: 4000 psi
This item sets the minimum dispense A pressure for the dispensing equipment. If the pressure falls below this value, an alarm will occur. If two-part material is used, this item is indicated as Dispense Min. Press . (Mat 1) .
- 931 -
12.DISPENSE TOOL
B-82594EN-4/01
ITEM
DESCRIPTION
High Pressure Time Out default: 0 msec min: 0 msec max: 90000 msec
This item specifies the amount of time high pressure can be sustained before an alarm occurs.
Low Pressure Time Out default: 0 msec min: 0 msec max: 90000 msec
This item specifies the amount of time low pressure can be sustained before an alarm occurs.
Maximum Analog Output(Air)* default: 10.0 V min: 0.0 V max: 10.0 V
This item sets the maximum analog voltage for atomizing air for the dispensing equipment. If the intended analog voltage exceeds this value, an alarm will occur. Maximum voltage will not exceed this value.
Power Up Pressure default: 500 psi min: 0 psi max: 9000 psi
This item sets the pre-pressure value after the controller is turned on.
Use default ACC default: DISABLE
This item enables and disables the use of the Default ACC feature. If enabled, all motion instructions without the explicit ACC clause will use the De fault ACC value.
Default ACC default: 20 range: 0 - 150
This item is the value used for all motion instructions that do not have an explicit ACC clause specified when enabled.
Guns Used in Calibration default: INCOMPLETE min: 1 max: 6
This item specifies the guns that DispenseTool will use in equipment calibrations. Up to six guns can be used. Guns can be used only if they have been defined during DispenseTool configuration. Refer to Section 3.1 . The GunSelection for Calibrations item displays the status of the six possible guns using a six-character expression. The first character represents gun 1, the second character represents gun 2, the third character represents gun 3, and so on. If a gun has not been defined, it is represented by a *. You cannot change the value of a gun that has not been defined. To define the gun, refer to Section 12.3.1 . If a gun has been defined, you can specify whether it will be used during calibration: — Thegun number indicates that the gun will be used. — Theminus symbol, "- ", indicates that the gun will not be used. To change the value of a gun that has been defined, use the appropriate function keys.
Meter Max Speed
Refer to Section 12.2.6.4 for information on how to calibrate the meter maximum speed.
Flow Rate Control
Refer to Section 12.2.6.4 for information on how to calibrate the flow rate control.
Beadshaping cmd.
Refer to Section 12.2.6.3 for information on how to calibrate the bead shaping air pressure.
* Displayed if bead shaping air is used.
- 932 -
12.DISPENSE TOOL
B-82594EN-4/01
** Displayed if two part material is used. Two part material is set at Setting Up Process Axes (Section 12.11.2)
12.11.6
SETTING UP ISD INFORMATION You must set up specific information about the Integral Servo Dispenser (ISD) in addition to the equipment setup. ISD setup requires you to set up specific items and to perform specific calibration procedures. Table 12.11.6.1 lists and describes each ISD setup item. The items you must set up vary depending on the way your system is configured. You might also need to perform the following calibration procedure to set up the ISD, depending on the way your system is set up. Table 12.11.6.1 Equipment Setup Items ITEM
DESCRIPTION
Meter Area default: 600 000cc/rev min: -6000 000cc/rev max: 6000.000 cc/rev
This item is used to calculate the volume of dispensed material. The definition of this value is volume (cc) per one gear pump revolution.
Gear Ratio default: 2.431 min: -6000.000 max: 6000.000
This item specifies the motor-to-pump reduction ratio. This indicates the gear pump revolution per motor revolution. This value is used to calculate the volume of dispensed material.
Transducer Tuning
Refer to Section 12.11.7 for information on fine tuning pressure transducers.
Use Procedure 12-34 to set up equipment items.
Procedure 12-34 Setting Up Integral Servo Dispenser Items Steps 1 2 3 4
Press MENU key. Select [SETUP]. Press F1, [TYPE]. Select ISD. You will see a screen similar to the following.
AUTO E1 JOINT 10% ISD SETUP E1 ISD GEAR METER DISPENSE SYSTEM 1 Meter Area: 6000.000 cc/rev 2 Gear Ratio: 1.000 Calibrations: 3 Transducer Tuning
[ TYPE ] DETAIL
- 933 -
>
12.DISPENSE TOOL
B-82594EN-4/01
5
6 7
8
12.11.7
To select the equipment number, a Check the currently selected equipment number. The equipment number is displayed to the right of the screen name as E# , where # is the equipment number. If the number displayed is the equipment number you want, go to Step 6. b Press NEXT, >. c Press F3, [EQUIP]. d Type the number of the equipment and press ENTER key. Select each of the items and set them as desired. To display detailed information about calibration, move the cursor to the calibration you want and press F2, [DETAIL]. Refer to Section 12.11.7 for information on fine tuning pressure transducers. After all items have been set, turn off the controller and then turn it on again.
ISD TRANSDUCER FINE TUNING Transducer tuning is a procedure used by the ISD system to identify the relationship between the analog input reading from the transducers and the material pressure value. You need to set the current and pressure values at both a high and a low point. The system will then calculate the material pressure value based on the transducer current reading. Sometimes, fine tuning the transducers is necessary due to tolerances in the data sheet, changes due to age, and so forth. The ISD Transducer Tuning menu also allows you to further adjust the transducer characteristics based on actual gauge readings. Refer to Table 12.11.7.1 for information on ISD transducer tuning methods. Table 12.11.7.1 ISD Transducer Tuning Methods
If you want to
Use
Description
Procedure 12-35
Use this method when the system is installed initially, where transducer characteristics are known and stable.
Use the actual pressure and current Procedure 12-36 readings to tune the transducer
Use this method when a transducer has been used for a long time and you believe its characteristics have drifted away from the original settings.
Use the transducer data sheet provided by the manufacturer to tune the transducer
Table 12.11.7.2 lists and describes the ISD transducer tuning items that you must set up for each transducer in your system.
- 934 -
12.DISPENSE TOOL
B-82594EN-4/01
Table 12.11.7.2 ISD Transducer Tuning Setup Items ITEM
DESCRIPTION
Pressure Setpoint units: psi
This item displays the current pressure setpoint value.
Current ISD Mode
This item indicates the current operation mode of the ISD: • • • • • • •
ERROR RELIEVE PREPRESSURE REPOSITION DISPENSE BYPASS JOG
Analog Input Status units: mA and psi
This item displays the current value and the measured psi value for each transducer. Use this item to make sure that you are looking at the correct transducer and that the calculated psi value matches that of the pressure gauge reading after tuning.
Calib (Low) units: mA at psi default: 7.00 mA at 1000 psi
This item displays the transducer current value in mA at a known low pressure value. By linearly interpolating and extrapolating, the system measures the material pressure value from the transducer reading.
Calib (High) units: mA at psi default: 10.00 mA at 2000 psi
This item displays the transducer current value in mA at a known high pressure value. By linearly interpolating and extrapolating, the system measures the material pressure value from the transducer reading.
Procedure 12-35 Transducer Tuning Using a Data Sheet
Conditions • • •
You have the transducer data sheet provided by your transducer manufacturer. The system is equipped with a pressure gauge. The "Pressure A" and "Pressure B" items on the ISD INPUT screen have been set correctly. (Procedure 12-33 )
Steps 1 2 3 4
Press MENU key. Select [SETUP]. Press F1, [TYPE]. Select ISD. You will see a screen similar to the following.
- 935 -
12.DISPENSE TOOL
B-82594EN-4/01
AUTO E1 JOINT 10% ISD SETUP E1 ISD GEAR METER DISPENSE SYSTEM 1 Meter Area: 600.000 cc/rev 2 Gear Ratio: 1.200 Calibrations: 3 Transducer Tuning
[ TYPE ]
5
DETAIL
>
Move the cursor to Transducer Tuning and press F2, [DETAIL]. You will see a screen similar to the following.
AUTO E1 JOINT 10% ISD SETUP E1 ISD TRANSDUCER TUNING 1 Pressure setpoint: 1000.00psi Current ISD mode: PREPRESSUR Transducer A (AI[1] = 7.32mA, 1100 psi measured) 2 Calib (Low): 7.00mA at 1000psi 3 Calib (High): 10.00mA at 2000psi Transducer B (AI[2] = 10.13mA, 2050psi measured) 4 Calib (Low): 7.00mA at 1000psi 5 Calib (High): 10.00mA at 2000psi [ TYPE ] LISTING
6
7
8
USE Ain >
Move the cursor to Calib (Low) for the appropriate kind of transducer (either Transducer A or B). a Move the cursor over to mA and type in the mA value according to your data sheet. b Move the cursor over to psi and type in the psi value according to your data sheet. Move the cursor to Calib (High) for the appropriate kind of transducer (either Transducer A or B). a Move the cursor over to mA and type in the mA value according to your data sheet. b Move the cursor over to psi and type in the psi value according to your data sheet. Repeat Step 6 and Step 7 for all transducers in your system. The transducer characteristics are now updated and become effective immediately.
- 936 -
12.DISPENSE TOOL
B-82594EN-4/01
Procedure 12-36 Transducer Tuning Using Actual Pressure and Current Readings
Conditions • • •
The system is equipped with a pressure gauge. The "Pressure A" and "Pressure B" items on the ISD INPUT screen have been set correctly. (Procedure 12-33 ) You have reset any pulsecoder alarms. ( Procedure 12-37 )
1 2 3 4
Press MENU key. Select SETUP. Press F1, [TYPE]. Select ISD. You will see a screen similar to the following.
Steps
AUTO E1 JOINT 10% ISD SETUP E1 ISD GEAR METER DISPENSE SYSTEM 1 Meter Area: 600.000 cc/rev 2 Gear Ratio: 1.200 Calibrations: 3 Transducer Tuning
[ TYPE ]
5
DETAIL
>
Move the cursor to Transducer Tuning and press F2,[DETAIL]. You will see a screen similar to the following.
AUTO E1 JOINT 10% ISD SETUP E1 ISD TRANSDUCER TUNING 1 Pressure setpoint: 1000.00psi Current ISD mode: PREPRESSUR Transducer A (AI[1] = 7.32mA, 1100 psi measured) 2 Calib (Low): 7.00mA at 1000psi 3 Calib (High): 10.00mA at 2000psi Transducer B (AI[2] = 10.13mA, 2050psi measured) 4 Calib (Low): 7.00mA at 1000psi 5 Calib (High): 10.00mA at 2000psi [ TYPE ] LISTING
6
USE Ain >
Set the material pressure to a low pressure value, close to the lowest pressure range: • If it is a supply pressure, adjust it at the supply pump. • If it is a dispense pressure, adjust it by moving the cursor to Pressure setpoint, type in a low value, and press ENTER.
- 937 -
12.DISPENSE TOOL
B-82594EN-4/01
NOTE If you are adjusting the dispense pressure, make sure that Current ISD mode is set to PREPRESSUR. If it is not set to PREPRESSUR, you can change it by executing the PREPRESSURE macro. 7 8
Measure the actual pressure value from the pressure gauge. Move the cursor to Calib (Low) for the appropriate transducer (either Transducer A or B). a Move the cursor over to psi and type in the actual psi value that you just measured. b Move the cursor over to mA. Press and hold the SHIFT key and press F5, [Use AIN], to obtain the current mA value from the analog input. Set the material pressure to a high value: • If it is a supply pressure, adjust it at the supply pump. • If it is a dispense pressure, adjust it by moving the cursor to Pressure setpoint, type in a high value, and press ENTER key.
9
NOTE If you are adjusting the dispense pressure, make sure that Current ISD mode is set to PREPRESSUR. 10 11
12
Measure the actual pressure value from the pressure gauge. Move the cursor to Calib (High) for the appropriate transducer (either Transducer A or B). a Move the cursor over to psi and type in the actual psi value that you just measured. b Move the cursor over to mA. Press and hold the SHIFT key and press F5, [Use AIN], to obtain the current mA value from the analog input. Repeat Step 6 through Step 11 for all transducers in your system. The transducer characteristics are now calibrated and become effective immediately.
Resetting ISD Pulse Coder Alarms When you turn on the ISD after disconnecting and reconnecting a process axis motor, you need to reset the serial pulsecoder. When this occurs, you will see a SRVO-062 BZAL (Group:0 Axis:n) and SRV0-075 Pulse not established (G:0 A:n) alarm, where "n" indicates the number of the process axis. Use Procedure 12-37 to reset these alarms and prepare the ISD for mastering.
- 938 -
12.DISPENSE TOOL
B-82594EN-4/01
Procedure 12-37 Resetting ISD Pulse Coder Alarms
Conditions •
You see a SRVO-062 BZAL (Group:0 Axis:n) and SRVO-075 Pulse not established (G:0 A:n) alarm.
1
Replace the ISD batteries with four new 1.5 volt alkaline batteries,size D. Observe the direction arrows in the battery box for proper orientation of the batteries. Press MENU key. Select SYSTEM. Press F1, [TYPE].。 Select Variables. Move the cursor to $IS_MCR and press ENTER. Move the cursor to $spc_reset. Press the F4, [TRUE], once.
Steps
2 3 4 5 6 7 8
The value will quickly go back to FALSE.
CAUTION Do not press RESET at this point. Otherwise, you will have to restart this procedure from Step 1 . 9 10
11
Turn off the controller and then turn it on so that the new value can take effect. If the SRVO-062 alarm is still present; there is a battery, cable or pulsecoder problem. Refer to the FANUC Robotics SYSTEM R-30iA Controller Series Electrical Connection and Maintenance Manual for further information. If a SRVO-075 alarm is present, reset it as follows. It is not necessary to perform a Cold start after resetting the alarm.
NOTE Rotate each axis that lost battery power by at least one motor revolution in either direction.
12.11.8
ERROR STATUS SUMMARY This section describes the status of the ISD Gear Meter dispensing equipment signals when they are checked for incorrect status. The followingconventions are used in this section: • •
I/O signal names are shown in all capital letters. In Figure 12.11.8.1, DISPENSER E-STOP is an I/O signal name. Condition statements begin with the word "If." In Figure 12.11.8.1, the condition statements are labeled.
- 939 -
12.DISPENSE TOOL
B-82594EN-4/01
•
•
•
The step indented below a condition statement is executed if the condition statement is TRUE. In Figure 12.11.8.1 , for the first condition statement, the two lines that follow it will be executed if the condition statement is TRUE. If more than one step or series of condition statements is indented below a condition statement, the entire group of steps and conditions is marked with a bracket, as shown in Figure 12.11.8.1. E%d represents the equipment number displayed through the DispenseTool core software. E%s represents the equipment number displayed through a KAREL program. If you have only one equipment, E%d or E%s will be E1.
Figure 12.11.8.1 Example Signal Status At all times between the first SS[] in a seam until the error occurs or an SE is reached, the following conditions are being monitored: Condition statements
If the index number of the DISPENSER E-STOP input is nonzero The DISPENSER E-STOP input is read at 50ms intervals If the DISPENSER E-STOP input makes an ON to OFF transition, error 51079: “SEAL–079 Dispenser E-stop (E%d)” is posted with WARN severity and the gun is turned off.
Sequence of Conditions that are Monitored at All Times The sequence of conditions that are monitored at all times is shown in Figure 12.11.8.2.
- 940 -
12.DISPENSE TOOL
B-82594EN-4/01
Figure 12.11.8.2 Sequence of Conditions that are Monitored at All Times The following conditions are monitored at all times: If the index number of the DISPENSER E-STOP input is non-zero Every 500 ms the DISPENSER E-STOP input is checked If the DISPENSER E-STOP input makes an ON to OFF transition, post error 51079: “SEAL-079 Dispenser E-STOP (E%d)” with the severity found in the error table. The default is PAUSE severity. If the index number of Pressure A or B is non-zero Every 20 ms the Dispense pressure is monitored If the dispense pressure is higher than the “Dispense max pressure” setting for more than “High pressure Time out” setting, post error: “ISD-001 High pressure (dispense) E%d” with the severity found in the error table. The default is WARN severity. If the dispense pressure is lower than the “Dispense min pressure” setting for more than “Low pressure Time out” setting, post error: “ISD-002 Low pressure (dispense) E%d” with the severity found in the error table. The default is WARN severity. Every 20 ms the Supply pressure is monitored If the supply pressure is higher than the “Supply max pressure” setting for more than “High pressure Time out” setting, post error: “ISD-003 High pressure (supply) E%d” with the severity found in the error table. The default is WARN severity. If the supply pressure is lower than the “Supply min pressure” setting for more than “Low pressure Time out” setting, post error: “ISD-004 Low pressure (supply) E%d” with the severity found in the error table. The default is WARN severity.
Sequence of Conditions that are Checked at Each SS[] Instruction The sequence of conditions that are checked at each SS[] instruction is shown in Figure 12.11.8.3 . Figure 12.11.8.3
Sequence of Conditions that are Checked at Each SS[] Instruction
If the Servo Dispenser system is in ERROR state, it posts error 51114 “SEAL–114 Dispenser not ready (E%d)” with the severity found in the error table. The default is WARN severity.
- 941 -
12.DISPENSE TOOL
B-82594EN-4/01
Sequence when a JOB Program is Started The sequence of events that occurs when a teach pendant JOB program is started is shown in Figure 12.11.8.4.
NOTE The sequence shown in Figure 5–4 is executed only if the robot is in WET mode. If the robot is in DRY mode, the sequence is not executed. Figure 12.11.8.4 Signal Status when a Teach Pendant JOB Program is Started If the robot is in DRY run mode, skip all error checking and calibration complete checking and run the JOB. When a teach pendant JOB program is started, the following sequence is executed: If the index number of the DISPENSER E-STOP input is nonzero If the DISPENSER E-STOP input is OFF, post error 51079: “SEAL–079 Dispenser E-stop (E%d)” with the severity found in the error table. The default is WARN severity. If the index numbers of both DRUM A EMPTY and DRUM B EMPTY inputs are nonzero If the both DRUM A EMPTY and DRUM B EMPTY inputs are ON, post error 51051: “SEAL–051 Both Drums are empty (E%d)” with the severity found in the error table. The default is PAUSE severity. Otherwise, If only the DRUM A EMPTY input is ON, post error 51082: “SEAL–082 Drum A empty (E%d)” with the severity found in the error table. The default is WARN severity. Otherwise, If only the DRUM B EMPTY input is ON, post error 51083: “SEAL–083 Drum B empty (E%d)” with the severity found in the error table. The default is WARN severity.
Sequence when Execution is Between and SS[] and SE Instruction The sequence of events that occurs after the first SS[] instruction is executed in a seam until an error occurs, or an SE instruction is reached, is shown in Figure 12.11.8.5.
- 942 -
12.DISPENSE TOOL
B-82594EN-4/01
Figure 12.11.8.5 Signal Status when Execution is between an SS[] and SE Instruction If the Integral Servo Dispenser system detects that the meter has reached it stroke limit, it posts error 39005: “ISD-005 Meter empty (E%d) with the severity found in the error table. The default is WARN severity. The meter automatically reverses its direction, and will continue dispensing. If the commanded meter speed exceeds the motor speed limit, it posts error 39006: “ISD-006 Motor velocity limit (E%d)” with the severity found in the error table. The default is WARN severity. The meter speed will be reduced to its maximum speed, and will continue dispensing.
Conditions to be Monitored while Prepressurizing The conditions to be monitored while prepressurizing are shown in Figure12.11.8.6 Figure 12.11.8.6
Conditions Monitored while Prepressurizing
When the system is trying to increase the pressure, if the system could not reach the specified pressure within the specified meter travel distance, it posts error 39015: “ISD-015 Max prepressure distance (E%d)” with the severity found in the error table. The default is WARN severity. Note: Increase the $ISD_CONFIG[].$maxprp_strk value to avoid this condition.
- 943 -
APPENDIX
A.SPOT I/O SEQUENCE
B-82594EN-4/01
A
SPOT I/O SEQUENCE Contents of this appendix A.1 A.2 A.3 A.4 A.5 A.6 A.7
SPOT I/O SEQUENCE ............................................................948 SPOT MACRO.........................................................................952 WELD MODE..........................................................................954 MULTI APPLICATION ..........................................................956 APPLICATION STATUS ........................................................958 ALARM RECOVERY .............................................................959 DISABLE FAULT CHECKING ..............................................963
- 947 -
A.SPOT I/O SEQUENCE
A.1
B-82594EN-4/01
SPOT I/O SEQUENCE This section describes the timing chart of I/O which spot tool + performs. Please make it the reference in the case of an I/O setup of spot tool +, and an equipment setup. Fig. A.1 (a) and A.1 (b) are the sequence of typical spot welding by an air gun.
Fig. A.1 (a) Weld Timing Sequence When a Spot Instruction is Executed
Fig. A.1 (b) Timing Sequence When Quick Close Backup or Soft Touch Gun is Used
- 948 -
A.SPOT I/O SEQUENCE
B-82594EN-4/01
STP : Soft Touch Pressure(If used, assert for Soft Touch Time) VP : Valve Pressure OG : Open Gun Pressure
Fig. A.1 (c) Valve Pressure Settings
Fig. A.1 (d) and A.1 (e) are the sequence of set/reset type spot welding by an air gun. ROBOT MOTION
moving
at In position
stopped
moving
Close gun anticipation time CLOSE GUN
Open Gun time
Set Delay time
Device Set Shot Pin Delay time
Device Reset
WELD SCHEDULE
WELD INITIATE
WELD COMPLETE
Figure. A.1 (d) Spot sequence with SPOT(BU=C, S=x, BU=*)
- 949 -
A.SPOT I/O SEQUENCE ROBOT MOTION
moving
B-82594EN-4/01
at In position
stopped
moving
Close BU anticipation time GUN CLOSE
Reset Delay time
Device Set
Open Gun time + Open BU time + Shot pin Delay time
Shot Pin Delay time
Device Reset
WELD SCHEDULE
WELD INITIATE
WELD COMPLETE
Figure. A.1 (e) Spot sequence with SPOT(BU=*, S=x, BU=O)
Fig. A.1 (f) and Fig. A.1 (g) are the sequence for STUD welding.
Fig. A.1 (f) Normal Stud Weld Sequence
- 950 -
A.SPOT I/O SEQUENCE
B-82594EN-4/01
Fig. A.1 (g) Faulted Stud Weld Sequence
- 951 -
A.SPOT I/O SEQUENCE
A.2
B-82594EN-4/01
SPOT MACRO The SpotTool+ software provides predefined macro programs to assist in the spot welding process. There are 9 predefined macro commands. To use the predefined macro commands, you must assign the I/O signal used with each macro command to match the corresponding cell I/O signal. For some macro commands, you must also record a position. The macro command must be inserted at the point in the program where it is required for the robot and workcell to communicate properly. Table A.2 lists and describes the SpotTool+ predefined macros. Table A.2 also identifies the signal assignments that need to be made in each macro program. Note The predefined macros listed in Table A.2 might differ for customized software packages. Table A.2 Spot macros
Macro Instruction Name
Macro Program
clr of transfer enter I-zone
clr_tran ENTR1ZON
DO[...]=ON DO[...]=OFF WAIT DI[...]=ON
exit I-zone
EXIT1ZON
DO[...]=ON
SAFE ZONE
SAFEZONE
Move to home
mov_home
EXIT I-ZONE 1 EXIT I-ZONE 2 EXIT I-ZONE 3 EXIT I-ZONE 4 EXIT I-ZONE 5 EXIT I-ZONE 6 CALL GET_HOME[int, int] J PR[1] 100% FINE
I/O Signal Assignment
- 952 -
Description (bold type indicates the signal) SetClear of transfer output on Set Clear of Zone n output off. Waiting for Zone n is clear input to go on. n is the number of the zone, which is a parameter passed into the macro program. Set Clear of Zone n output on n is the number of the zone, which is a parameter passed into the macro program. SetClear of Zone 1output on SetClear of Zone 2output on SetClear of Zone 3output on SetClear of Zone 4output on SetClear of Zone 5output on SetClear of Zone 6output on This signal moves the robot to HOME position as defined in reference position 1. You can use the first of two optional integer parameters to select one of three defined home positions. Valid values for the first integer value of GET_HOME[int, int] are 1 through 3. The second optional integer parameter allows you to select a motion group. If you only have one motion group defined, the second integer value of GET_HOME[int, int] defaults to 1. Valid values for the second integer value of GET_HOME[int, int] are 1 through 5. NOTE To use the home macro command, you must record reference position 1 as the home position. When the robot is at the HOME position the UOP output ATPERCH will be ON.
A.SPOT I/O SEQUENCE
B-82594EN-4/01
Macro Instruction Name
Macro Program
move to repair
mov_repr
DO[...]=ON
at pounce
atpounce
open clamp early reposition clamp
opnclmer repos_cl
DO[...] = ON DO[...]=ON WAIT DI[...]=ON DO[...]=OFF DO[...]=ON DO[...]=ON WAIT DI[...]=ON DO[...]=OFF
I/O Signal Assignment
- 953 -
Description (bold type indicates the signal) Set At repair output ON NOTE To use the repair macro command, you must add position instructions to move the robot to the repair position. Set Process complete output ON Set At pounce output ON Wait for Leave pounce input Set At pounce output OFF Set Open clamps early output ON Set Reposition clamps output ON Waiting for Reposition clamp input to go ON Set Reposition clamps output OFF
A.SPOT I/O SEQUENCE
A.3
B-82594EN-4/01
WELD MODE •
• • •
PLC/CELL
Cell In signal WELD/NOWELD
TP Disabled - (1)
R-J3iC
Cell out signal Weld enabled
Spot command
The change in a robot's Weld mode is TP disabled : It can change by the input signal from PLC/CELL. –(1) TP enabled : It can change from the Soft panel screen. -(2) When the Enable weld signal(3) is assigned, a robot changes the weld mode of the weld controller by this signal. (ON:Enable, OFF:Disable) It does not depend on a robot's weld mode, a robot outputs weld signals, such as Weld schedule at the time of spot command execution and waits for the Weld complete signal. When the Weld mode is disabled and the Weld IO Sim is enabled, weld signals, such as weld schedules are not outputted and robot does not wait for the weld complete signal. TP
Soft Panel Screen Weld controller mode
TP Enabled - (2)
Weld Interface Enable weld -(3)
Weld mode （Weld controller mode） Disable
Weld Controller
Enable
Weld IO Sim
W/C
Weld schedule, Initiate
Disable
Enable
Weld complete
No output weld signals. No wait Weld Complete.
Weld processing with Weld mode and Weld IO sim Weld mode
Weld IO sim
Enable weld signal
Weld mode of W/C
Enable
Disable
ON OFF
WELD NOWELD
Enable
OFF
(unrelated)
Disable
- 954 -
Weld processing at Spot command Output the weld schedule signals and wait the weld complete signal No output weld signals No wait Weld Complete
A.SPOT I/O SEQUENCE
B-82594EN-4/01
NOTE 1 If the program select mode is STYLE, the condition for (1) is AUTO and Interlock, (2) is Isolate. 2 When not using Enable weld signal (3), it is necessary to change weld mode of W/C from PLC/CELL directly. When not performing this, welding may be performed even if a robot's weld mode is disabled. 3 About Weld IO Sim: This can be changed from Softpanel screen. The change by a signal cannot be performed. It can be used only when weld mode is disabled. It does not depend on the mode of a weld controller and welding is not performed. Waiting time is decided by setup (Weld-IO-sim/Weld duration) of a robot, and differs from the actual weld timer schedule.
- 955 -
A.SPOT I/O SEQUENCE
A.4
B-82594EN-4/01
MULTI APPLICATION The following menu items in control start menu are related to multi application. • Appl-select • Seal Config • Handling Config In spottool+, you can select following application tools. • DispenseTool plugin • HandlingTool plugin In the Appl-slect menu, you can select the using application. All teach pendant keys and LED indicators correspond to the currently selected application. The currently selected application is displayed in the middle of the screen name line on the teach pendant screen. If more than one application has been enabled during a controlled start, you can toggle between them by pressing FCTN and selecting Change APPL-Tool. The character abbreviations are as follows: DI for dispensing, HT for material handling, and SW for spot welding. If you have enabled more than one application (such as spot welding, dispensing, or material handling) during software installation, you must set the application mask item to the application you want to use in your program header. After you specify the application to use in your program header, the program instructions and function key labels will change to reflect the application you specified. Note: You can not use the different application instruction in a program.
NOTE The following operation is normally once performed at the time of system setup. About operation, the operator expert in control start operation.
STEP 1 2 3
Do Controlled start Press MENUS key Select NEXT then Appl-select
Appl selection
1/3
1 Spot Weld 2 Handling 3 Dispense [ TYPE ]
TRUE FALSE FALSE TRUE
- 956 -
FALSE
A.SPOT I/O SEQUENCE
B-82594EN-4/01
4
The item to be used set TRUE.
NOTE As default, Spot Weld is TRUE. About the detail of Handling and Dispense, refer to each application manual.
- 957 -
A.SPOT I/O SEQUENCE
A.5
B-82594EN-4/01
APPLICATION STATUS The Application Status screen displays the teach pendant key and LED indicators used for the currently selected application. Available applications are enabled at controlled start. The current application is selected either using the FCTN menu or from within a teach pendant program.
Item USERKEYS LEDS on TP
Procedure A-1
Table A.5 Application Status Screen Items Description This item lists the use of teach pendant user keys U1 through U7 for the currently selected application. This item lists the use of teach pendant LEDs L1 through L3 for the currently selected application.
Displaying Application Status
Step 1 2 3
Press STATUS. Press F1, [TYPE]. Select Appl-status. You will see a screen similar to the following.
Appl status SpotTool USERKEYSLEDS on TP U1 : GUN L1 : GUN ENBL U2 : BACKUP L2 : WELD ENBL U3 : EQUIP L3 : I/O ENBL U4 : MAN FCTNS U5 : STATUS U6 : I/O U7 : POSITION
NOTE The screen for the currently selected application will be displayed.
- 958 -
A.SPOT I/O SEQUENCE
B-82594EN-4/01
A.6
ALARM RECOVERY You can monitor faults from the ALARM RECOVERY screen. If a fault occurs while a production style is running, you can recover from the fault using the ALARM Recovery screen. This screen contains a description of the error and the appropriate actions you must take to recover from the error. ALARM Recovery Screen Example: ALARM Recovery ERROR:
A MAJOR ALARM input was received from the weld controller.
ACTION: Check the weld controller for the cause of this alarm. Press F4 [CHOICE] to select recovery option. Perform action, then press [CHOICE]. [CHOICE]
Procedure A-2
Displaying Alarm Recovery
Step 1 2 3 4
Press MENUS. Select ALARM. Press F1, [TYPE]. Select Recovery.
If a fault occurs for which no specific error or action text exists, you will see the following screen. ALARM Recovery Without Specific Error and Action Text: ALARM Recovery ERROR:
An undefined error has occurred (one for which no fault recovery sequence is provided).
ACTION: Press FAULT RESET to clear the error.
ALARM Recovery Errors and Actions Depending on the error that has occurred, you could see one of the following recovery choices.
- 959 -
A.SPOT I/O SEQUENCE
B-82594EN-4/01
- [CHOICE] Screens The screen displayed when you press F4, [CHOICE], varies depending on whether the fault is a weld fault, a non-weld fault, or a water saver fault. Refer to the following table for each [CHOICE] menu and description of each kind of [CHOICE] screen.
WARNING When you initiate or select Fast Fault Recovery, the program will be executed immediately. Be ready for the robot to move before you initiate or select Fast Fault Recovery; otherwise, you could injure personnel or damage equipment. NOTE Fast fault recovery items will be displayed only if the fast fault recovery option has been installed. - [CHOICE] Screens Condition Weld Fault without stud backup gun enabled
Non-weld fault
Water Saver Fault
Stud Welding Fault
Dispensing Fault Motion Fault
[CHOICE] Menu
1 2 3 4
Retry weld and continue program Skip weld and continue program Initiate fast fault recovery Abort all
1 2 3 4
Cont. Cont. Cont. Abort
1 2 3 4
Reset water saver; resume in WELD Bypass water sav; resume in NOSTROKE Initiate fast fault recovery Disable alarm
1 2 3 4
Skip Weld 5 Man Chg & Skip Retry Weld 6 Man Chg & Retry Chg gun & Retry 7 Fast fault recov Abort all
Weld/Wet 5 Fast fault recovery NoWeld/Dry 6 Disable alarm NoStrok/Dry this style
1 Initiate fast fault recovery 1 Jog to position where TP was enabled 2 Abort program 3 Continue from current position
- 960 -
A.SPOT I/O SEQUENCE
B-82594EN-4/01
Condition Material Handling Fault
[CHOICE] Menu
1 2 3 4
Abort program Continue from current position Fast Fault recov Disable alarm
- [CHOICE] Screen Menu Items Screen Weld Fault (SpotTool+)
Item Retry weld and continue program
Skip weld and continue program Initiate fast fault recovery
Abort all Non-Weld Fault (SpotTool+, DispenseTool, Material Handling, and Stud Welding)
Continue Weld/Wet
Continue Noweld/Dry
Continue Nostroke/Dry
Abort this style Fast fault recovery
Disable alarm Stud Welding Fault
Skip weld Retry weld
Change gun and skip*
Change gun and retry*
Fast fault recovery
Description This item automatically resets the fault and resumes the program. The weld that caused the fault will be retried. If the weld fails again, the program will pause and the appropriate ERROR/ACTION Recovery screen will be displayed. This item automatically resets the fault and resumes the program. The weld that caused the fault will not be retried. This item initiates the fast fault recovery sequence. This item will only be displayed if the fast fault recovery option has been installed. This items aborts the process. This item prompts the user to reset the fault (if required) and to press CYCLE START. When a CYCLE START is received, the program is resumed. This item prompts the user to reset the fault (if required) and to press CYCLE START. When a CYCLE START is received, the program is resumed, and NOWELD or DRY mode are set automatically. This item prompts the user to reset the fault (if required) and to press CYCLE START. When a CYCLE START is received, the program is resumed, and NOSTROKE and NOWELD or DRY mode are set automatically. This item aborts the current style. This item initiates the fast fault recovery sequence. This item will only be displayed if the fast fault recovery option has been installed. This item allows you to disable the fault. Refer to the next section for more information. Automatically resets the fault and resumes the program. The weld that caused the fault will not be retried. Automatically resets the fault and resumes the program. The weld that caused the fault will be retried. If the weld fails again, the program will pause and the appropriate ERROR/ACTION Recovery screen will be displayed. The robot drops off the currently attached gun in the tool changer, picks up the other gun, then skips the weld. Note You must reset the stud welding controller before a Change Gun and Skip Weld can occur. The robot drops off the currently attached gun in the tool changer, picks up the other gun, and then retries the weld. Note You must reset the stud welding controller before a Change Gun and Retry Weld can occur. The fast fault recovery sequence is initiated. This item will only be displayed if the fast fault recovery option has been installed.
- 961 -
A.SPOT I/O SEQUENCE Screen Stud Welding Fault
B-82594EN-4/01
Item Manual change and skip
Manual change and retry
Abort all Water Saver Fault (SpotTool+ only)
Reset water saver; resume in WELD Bypass water saver; resume in NOSTROKE Initiate fast fault recovery Disable alarm
Motion Fault (Definable Resume option)
Jog to position where TP was enabled Abort program Continue from current position
Material Handling Fault
Abort program Continue from current position
Fast Fault Recov. Disable alarm
Description The currently executing teach pendant program is completed in NOSTROKE and NOWELD modes and will return to the HOME position where manual repairs or a stud gun change can be done. When manual repairs or a stud gun change are completed, press CYCLE START; the robot will return in NOSTROKE and NOWELD modes to the position after the location where the original fault occurred, then continue welding. Note You must reset the stud welding controller before a Manual Change and Skip can occur. The currently executing teach pendant program is completed in NOSTROKE and NOWELD modes and will return to the HOME position where manual repairs or a stud gun change can be done. When manual repairs or a stud gun change are completed, press CYCLE START; the robot will return in NOSTROKE and NOWELD modes to the location where the fault occurred, and continue welding. Note You must reset the stud welding controller before a Manual Change and Retry can occur. This items aborts the process. Resets the water saver. If successful, the program is resumed with welding enabled. Bypasses the water saver and resumes the program in NOSTROKE. The fast fault recovery sequence is initiated. This item will only be displayed if the fast fault recovery option has been installed. This item allows you to disable the fault. Refer to the next section for more information. Jog the robot to a location that is within the stop tolerance. The robot will check again whether it is out of resume tolerance. If it is out of stop tolerance, the prompt box is displayed again. The program is aborted. The robot will move from the current position to the stop position and continue the program. The robot does not check whether it is out of stop tolerance, and the prompt box is not displayed again. The program is aborted. The robot will move from the current position to the stop position and continue the program. The robot does not check whether it is out of stop tolerance, and the prompt box is not displayed again. The fast fault recovery sequence is initiated. This item will only be displayed if the fast fault recovery option has been installed. This item allows you to disable the fault. Refer to the next section for more information. The Alarm Recovery screen is then redisplayed so that an additional recovery choice can be made.
- 962 -
A.SPOT I/O SEQUENCE
B-82594EN-4/01
A.7
DISABLE FAULT CHECKING During program execution, certain alarms involving inputs are monitored. If one of these alarms occurs, you will be given a choice of whether to disable the fault for a certain number of program execution cycles. You can only disable specific faults, which are shown in following. Spot Welding
Water saver OK Wtr flow OK X-former Gun detect OK Backup detect
You can only disable a fault after it has occurred, and an error message has been displayed. You will see a screen similar to the one shown in following. If you press F4, [CHOICE], and then select Disable Alarm, the fault that is being disabled is automatically added to the Disabled Faults screen. ALARM Recovery ERROR: Part Present 1 is not reading the part. ACTION: Check the wiring. Press F4 [CHOICE] to select recovery option. Perform action, then press [CHOICE]. [TYPE]
[CHOICE]
Disabled Faults Screen The Disabled Faults screen gives a status of the alarms that are currently disabled. You can also use the Disabled Faults screen to clear the disabled faults manually. The fault table is cleared (no faults are disabled) when you Cold start the controller. Otherwise, faults are not cleared automatically and the fault count will continue to increase. You can change the fault count in the Status Disabled Faults screen. A fault's count is incremented at the beginning of each job cycle after the fault is added to the table. All faults use the same maximum fault count. At the end of each job cycle, every fault count in the fault table is incremented by one. Each time, when certain faults occur, the table is checked: • If the fault is in the table and the count is less than the current maximum number of cycles disabled, the alarm is ignored. • If the count is greater than the current maximum number of cycles disabled, the alarm is displayed. • If the fault is not in the table, the Alarm Recovery screen is displayed with disable alarm as one of the choices. - 963 -
A.SPOT I/O SEQUENCE
B-82594EN-4/01
The following table lists and describes the items that are displayed on the Status Disabled Faults screen. Following procedure to display the Status Disabled Faults screen and to clear faults manually using this screen. Item FAULT NAME TYPE # SIM
STATUS CNT Configuration Menu Disabled Faults Option Default: ENABLED Max Cycles Disabled Min: 0 Max: 9999 Default: 20
Description This item displays the name of the fault. You cannot change the fault name on this screen. This item displays the type of input signal that failed. You cannot change the type on this screen. This item displays the port number of the input signal that failed. You cannot change the # on this screen. This item displays the simulated status of the input signal that failed: • U is unsimulated • Sis simulated You cannot change the simulated status on this screen. This item displays the current status of the input signal that failed. You cannot change the status on this screen. This item displays the number of cycles that have run since this fault was disabled. You can change the cycle count on this screen. This item allows you to specify whether you want to use the Disabled Faults option: • DISABLED means that the Disabled Faults option will not be used. • ENABLED means that the Disabled Faults option will be used. This item allows you to specify the number of cycles a fault will be disabled. If you set this to 0, the fault will be posted every time it occurs. If you set this to a number other than 0, the fault will be posted only when the number of cycles equals the Max Cycles Disabled you specified.
- 964 -
A.SPOT I/O SEQUENCE
B-82594EN-4/01
Procedure A-3
Disabling Fault Checking
Step 1 2 3 4
Press MENUS. Select STATUS. Press F1, [TYPE]. Select DisableFault. You will see a screen similar to the following. Status DsblFaults
1 2 3 4 5 6 7 8 9
FAULT NAME TYPE BU close detect DI[ Gun open detect DI[ Wtr saver fault DI[ DI[ DI[ DI[ DI[ DI[ DI[
1/10 # SIM STAT CNT 10] U OFF 8 10] U OFF 6 11] U OFF 0 0] U *** 0 0] U *** 0 0] U *** 0 0] U *** 0 0] U *** 0 0] U *** 0
[ TYPE ] CONFIG CLEARFLT
>
5 6
Review the fault status. To clear a single fault, a Move the cursor to the fault you want to clear. b Press F3, CLEARFLT.
7
To clear all of the faults listed, a Press NEXT, >. b Press F3, CLEARALL.
8
To enable or disable the Disabled Faults option, a Press F2, CONFIG. You will see a screen similar to the following. Status Disable Faults Configuration Menu 1 Disable Faults Option: 2 Max Cycles Disabled:
b c
ENABLED 20
Move the cursor to Disable Faults Option. Press the appropriate key: • To enable the Disable Faults option, press F4, ENABLE. • To disabled the Disable Faults option, press F5, DISABLE.
- 965 -
A.SPOT I/O SEQUENCE
B-82594EN-4/01
9
To set the maximum number of cycles a fault will be disabled, a Move the cursor to the fault you want. b Press F2, CONFIG. You will see a screen similar to the following. Status Disable Faults Configuration Menu 1 Disable Faults Option: 2 Max Cycles Disabled:
c d
ENABLED 20
Move the cursor to Max Cycles Disabled. Type the number of cycles you want and press ENTER.
- 966 -
B.APPENDIX
B-82594EN-4/01
B
APPENDIX This appendix summaries items necessary for using this model. It may also be used as an index. Contents of this appendix B.1 START MODE.........................................................................968 B.2 MASTERING...........................................................................975 B.3 SOFTWARE VERSION ..........................................................989 B.4 ROBOT AXIS STATUS ..........................................................992 B.5 DIAGNOSIS SCREEN ............................................................998 B.6 WORLD FRAME ORIGIN....................................................1004 B.7 I/O MODULE SETTING .......................................................1005 B.8 SETTINGTHE FSSB LINE .....................................................1011 B.9 POSITIONER SETUP............................................................1016 B.10 EXTENDED AXIS SETUP ...................................................1022 B.11 INDEPENDENT ADDITIONAL AXIS BOARD (NOBOT) STARTUP PROCEDURE......................................................1028
- 967 -
B.APPENDIX
B-82594EN-4/01
B.1
START MODE
B.1.1
Start Up Methods Robot controller has the following four start up methods(start mode):
Initial start When the unit is started in the initial start mode, all programs are deleted, and all settings are reset to their standard values. Upon the completion of the initial start, a controlled start is performed automatically.
Controlled start When the unit is started in the controlled start mode, a controlled start menu, which is a simple system, starts up. The controlled start menu cannot be used to operate the robot. The controlled start menu can, however, be used to change a system variable which normally cannot be changed, to read a system file, and to set the robot. From the menu displayed by pressing the Fctn key on the controlled start menu, a cold start can be made.
Cold start The cold start mode is used to perform normal power-up while power restoration is disabled. The program is aborted, and all output signals are turned off. Once the cold start has been completed, the robot can be operated. A cold start can be performed while power restoration is enabled, provided the necessary setting is made at power-up.
Hot start The hot start mode is used to perform normal power-up while power restoration is enabled. When the unit starts, the program runs and output signals are restored to the state existing prior to the last power-down. Once the hot start has been completed, the robot can be operated. The cold start or the hot start is started in usually operation. Which mode is used depends on whether the hot start is enable or disable. The initial start and the controlled start will be used when maintaining it. These modes will not be used in usually operation.
Fig. B.1.1 Start mode
- 968 -
B.APPENDIX
B-82594EN-4/01
B.1.2
Initial Start When the unit is started in the initial start mode, all programs are deleted, and all the settings are reset to their standard values. Once the initial start has been completed, a controlled start is performed automatically.
CAUTION At an initial start, programs and all data including settings will be lost. The factory-set mastering data is also erased. The initial start should be made only when the main printed circuit board or software is replaced. Before performing an initial start, therefore, make a backup copy of the necessary programs and system files. Procedure B-1
Initial start
Step 1
With the F1 key and the F5 key held down on the teach pendant, set the power breaker on the controller to ON. ***
2
Select 3, Init start.
3
Enter 1, (YES) to the confirmation message of initial start.
An initial start is performed. Upon the completion of the initial start, a controlled start is performed automatically, and the controlled start menu appears. - 969 -
B.APPENDIX
B.1.3
B-82594EN-4/01
Controlled Start When the unit is started in the controlled start mode, a controlled start menu, which is a simple system, starts up. The controlled start menu cannot be used to operate the robot. The controlled start menu can, however, be used to change a system variable which normally cannot be changed, to read a system file, and to set the robot. Press the Fctn key on the controlled start menu. A menu appears. From that menu, select 1 START (COLD). A cold start is performed. The following screens can be displayed from the menu displayed by pressing the MENU key on the controlled start menu:
Setting screens Settings can be made.
Software install screen Optional software can be added or deleted.
System variables screen System variables can be set. Even a system variable which cannot normally be changed (R0) can be changed. On the file screen of the controlled start menu, F4 is displayed as [RESTORE]. When the F4 key is pressed, all files are read automatically. To switch F4 to [BACKUP] as on other file screens, press the Fctn key. A menu appears. From that menu, select RESTORE/BACKUP.
File screen A program or system file can be saved and read. The system file can be read only from the controlled start menu.
Version ID Screen The software edition is displayed.
Alarm history screen The alarm history is displayed.
Port in:t screen A serial port is set. This screen is used to read a file from a Handy File or the like upon a controlled start.
Memory screen The memory status is displayed.
MAINTENANCE A robot setting can be changed. An additional axis can be set. A motion group can be added or deleted.
- 970 -
B.APPENDIX
B-82594EN-4/01
Max. number setting screen The numbers of resistor, macro, and user alarm can be changed.
Procedure B-2
Controlled start
Step 1
With the PREV key and the NEXT key held down on the teach pendant, set the power breaker on the controller to ON. V7.10P/01
2
Select 3 CONTROLLED START. The setting screen for the controlled start menu appears.
3
To operate the robot, a cold start must be performed. To do this, press the Fctn key. A menu appears. From that menu, select 1 START (COLD). A cold start is performed.
- 971 -
B.APPENDIX
B.1.4
B-82594EN-4/01
Cold Start The cold start mode is used when normal power-up is performed while power restoration is disabled. Upon a cold start, the following is performed: Each output signal of digital I/O, analog I/O, robot I/O, and group I/O is turned off or set to 0. The program is aborted, and the beginning of the program becomes the current line. The feedrate override is reset to the initial value. The manual feed coordinate system enters the JOINT state. The machine lock is released. The cold start procedure depends on the power restoration setting.
Procedure B-3
Cold start
Condition ■
Hot start must be set to invalid.
Step 1
Turn on the power breaker on the controller to ON. The following screen is displayed after the system stars by cold start.
- 972 -
B.APPENDIX
B-82594EN-4/01
Procedure B-4
Cold start
Condition ■
Hot start is set to disable
1
With the PREV key and the NEXT key held down on the teach pendant, set the power breaker on the controller to ON. The configuration menu is displayed.
2
Select “2. Cold start”. Cold start is executed and following is displayed.
Step
- 973 -
B.APPENDIX
B.1.5
B-82594EN-4/01
Hot Start The hot start mode is used when normal power-up is performed while power restoration is enabled. Upon a hot start, the following is performed: • Each output signal of digital I/O, analog I/O, robot I/O, and group I/O is set in the same manner as it was prior to the last power-down. • The program runs in the same way as it did prior to the last power-down. If the program was running up until the last power-down, the program enters the pause state. • The feedrate override, manual feed coordinate system, and machine lock are set in the same manner as they were prior to the last power-down.
CAUTION When a hot start is performed in the following state, each output signal of the digital I/O, analog I/O, robot I/O, and group I/O is turned off or set to 0: - When the I/O allocation is changed - When an I/O unit is mounted or removed - When the number of signals is changed on the I/O Link screen Procedure B-5
Hot start
Condition ■
Hot start must be set to enable.
1
Turn on the power breaker on the controller to ON. The screen which was being displayed at power off will be displayed on the screen of the teach pendant after a few seconds.
Step
- 974 -
B.APPENDIX
B-82594EN-4/01
B.2
MASTERING Mastering associates the angle of each axis of the robot with the pulse count of the absolute pulse coder (APC) connected to the motor of each axis. More specifically, mastering is performed by obtaining the pulse count read at the zero-degree position. The current position of the robot is determined by the pulse counts of the absolute pulse coders (APCs) for the axes. Since mastering data is factory-set, mastering is unnecessary in normal operation. If one of the following events occurs, however, mastering must be performed: • Mastering data is lost for some reason such as a drop in the voltage of the backup battery for C-MOS in the controller or memory erasing with an initial start. • The APC pulse counts are lost for some reason such as a drop in the voltage of the backup battery for APC pulse counts backup in the mechanical unit or exchange of pulse coder. • The pulse counts do not indicate the angles of the axes because the mechanical unit was hit bumped, etc.
CAUTION The robot data including mastering data and the pulse coder data are maintained independently by backup batteries. If the batteries go empty, data is lost. To prevent this, replace both batteries periodically. When the battery voltage drops, an alarm `BLAL' notifies the user. There are five types of mastering as listed below.
Type of mastering Jig mastering Mastering at the zero-degree positions Quick mastering Single axis mastering Setting mastering data
Table B.2 Mastering types Explanation Mastering is performed using a special jig. Jig mastering is performed at the factory. Mastering is performed with each axis of the robot aligned with the zero-degree position. The zero-degree position mark attached to each axis of the robot is referenced. The mastering position can be set at any position. To do this, reference points must be set in advance. Single axis mastering is that the mastering is performed every one axis. Mastering data is set in mastering counters directly.
CAUTION After the robot is installed, the quick mastering reference points should be stored in case the factory-adjusted settings are needed in mastering in the future. After mastering, be sure to perform positioning (calibration). Positioning means that the controller reads the current pulse counts and recognizes the current position. - 975 -
B.APPENDIX
B-82594EN-4/01
Fig. B.2 Mastering
The current position of the robot is determined by the following data: • Pulse count per degree (See mastering table 1.) This value is defined in system variable $PARAM_GROUP.$ENCSCALE. • Pulse count at the zero-degree position (See mastering table 2.) This data is stored in $DMR_GRP.$MASTER_COUN by mastering. In jig mastering, the pulse count at the jig position is received and converted to mastering data. In quick mastering, the pulse count at the quick mastering reference position defined by the user is received and converted to mastering data. • Current pulse count. The current pulse count is received from the by calibration. Mastering and calibration are performed on the Master/Cal screen [6 SYSTEM, Master/Cal].
NOTE Mastering by mistake may cause the robot to move unexpectedly and it is very dangerous. Therefore, the Master/Cal screen will be displayed only when the system variable, $MASTER_ENB, is set to 1 or 2. Press F5,DONE,which is displayed in the Master/Cal screen after mastering. $MASTER_ENG is automatically set to 0 and then the Master/Cal screen can not be displayed. If you want to display the Master/Cal screen again, set $MASTER_ENB to 1 in the system variable screen again.
- 976 -
B.APPENDIX
B-82594EN-4/01
B.2.1
Jig Mastering Jig mastering is performed at the factory using a special jig. This mastering is performed at the mastering position set beforehand. With this mastering, the accurate mastering can be performed by using the special jig. This mastering is usually unnecessary to perform it in normal operation because this is used at shipment. For details of jig mastering, refer to the manual for the mechanical unit.
Procedure B-6
Jig mastering
Condition ■
System variable $MASTER_ENB must be set to 1 or 2.
1 2 3 4
Press the MENUS key. The screen menu is displayed. Select ”0 ─ NEXT ─” and then select ”6 SYSTEM”. Press F1, [TYPE]. The screen change menu is displayed. Select “Master/Cal” on the screen change menu. The positioning screen appears.
5
Move the robot by jog feed to the mastering position. Release the brake on the manual brake control screen if necessary.
Step
- 977 -
B.APPENDIX
B-82594EN-4/01
6
Select “1 FIXTURE POSITION MASTER” and press the F4 key (yes). Mastering data is set.
7
Select “6 CALIBRATE” and press the F4 key (yes). Calibration is performed.
8
Press F5 “DONE”, after mastering.
9
Alternatively, to perform positioning, turn the power off, then turn it on again. Calibration is performed whenever the power is turned on.
- 978 -
B.APPENDIX
B-82594EN-4/01
B.2.2
Mastering at the Zero-degree Positions Mastering at the zero-degree positions is performed for the robot with its all axes at the zero-degree positions. On each axis of the robot, a zero-degree position mark is attached. Using these marks as a reference, move the robot by jog feed to the zero-degree positions for all axes. Mastering at the zero-degree positions cannot be performed as accurate by as other types of mastering because it relies on visual adjustment. Perform mastering at the zero-degree positions only as an emergency measure. For details of mastering at the zero-degree positions, refer to the manual for the mechanical unit.
Procedure B-7
Mastering at the zero-degree positions
Condition ■
System variable $MASTER_ENB must be set to 1 or 2.
1 2 3 4
Press the MENUS key. The screen menu is displayed. Select ”0 ─ NEXT ─” and then select ”6 SYSTEM”. Press F1, [TYPE]. The screen change menu is displayed. Select “Master/Cal” on the screen change menu. The Master/Cal screen appears.
5
Move the robot by jog feed to the zero-degree positions for all axes. Set brake control to off, if necessary.
Step
- 979 -
B.APPENDIX
B-82594EN-4/01
6
Select “2 ZERO POSITION MASTER” and press the F4 key (yes). Mastering data is set.
7
Select “6 CALIBRATE” and press the F4 key (yes). Calibration is performed.
8
Press F5 “DONE”, after mastering.
9
Alternatively, to perform calibration, turn the power off, then turn it on again. Calibration is performed whenever the power is turned on.
- 980 -
B.APPENDIX
B-82594EN-4/01
B.2.3
Quick Mastering Quick mastering allows mastering at any user-defined position. The pulse counts are calculated from the speed and angular displacement within one rotation of the APCs connected to the motors. Quick mastering uses the fact that the absolute angular displacement within one rotation is not lost. • If mastering data is lost due to the empty of the backup battery for the pulse coder, quick mastering can be used. • When the pulse coder is replaced or when mastering data in the robot controller is lost, quick mastering cannot be used. To perform simple mastering, a reference point set after mastering is necessary (→ reference point setting). The reference point is factory-set to the zero position.
Fig. B.2.3 Quick Mastering
Quick mastering uses the fact that the deviation of the angle of the axis from the reference point can accurately be compensated when it is within one rotation of the APC. For details of quick mastering, refer to the manual for the mechanical unit.
CAUTION If the robot is installed in such a way that the robot cannot be set to the 05 position, which is the reference point of initial simple mastering, the reference point of simple mastering should be stored after the installation. This must be done to store the factory-set mastering setting, providing for future mastering.
- 981 -
B.APPENDIX Procedure B-8
B-82594EN-4/01
Quick mastering
Condition ■ ■
System variable $MASTER_ENB must be set to 1 or 2. Quick mastering reference position (reference position) must be set.
1
Display the Master/Cal screen.
2
Jog the robot to the quick mastering position (reference position). If it is necessary, turn off the brake control. Select “3 QUICK MASTER” and press the F4 key (yes). Mastering data is set.
Step
3
4 5
Select “6 CALIBRATE” and press the F4 key (yes). Calibration is performed. Press F5 “DONE” after mastering.
- 982 -
B.APPENDIX
B-82594EN-4/01
Procedure B-9 Setting reference points for quick mastering (If the robot is installed in such a way that the robot cannot be set to the 05 position) CAUTION This operation cannot be executed if the mastering data is lost because of mechanical disassembly or maintenance. If that is the case, jig mastering or zero-degree positions mastering should be executed to restore the mastering data.
Condition ■
System variable $MASTER_ENB must be set to 1 or 2.
1 2
Select “6 SYSTEM” on the screen menu. Select “Master/Cal” on the screen change menu. The Master/Cal screen appears.
3
Move the robot by jog feed to the quick mastering reference position. Set brake control to off, if necessary. Select “5 SET QUICK MASTER REF” and press the F4 key (yes). The reference points for quick mastering are stored in memory.
Step
4
- 983 -
B.APPENDIX
B.2.4
B-82594EN-4/01
Single Axis Mastering User can select the arbitrary position for the mastering of each axis. Single axis mastering should be used when the mastering data of some axes is lost for some reason such as the drops of the voltage of the backup battery for pulse coder or exchanging of the pulse coder.
Items ACTUAL POS MSTR POS SEL ST
Table B.2.4 Settings for single axis mastering Descriptions The current position expressed by joint (degree) of the robot is displayed. Specifies the mastering position to the axis to be performed the single axis mastering. It is usually specified 0 degree. For the axis to be performed mastering, set this item to 1. It is usually 0. Display the state of completion of the single axis mastering. The value displayed at this item can not be directly changed. The values of $EACHMST_DON[1 to 9] are displayed at this column. - 0 Specifies that the mastering data has been lost. The single axis mastering need to be performed. - 1 The mastering data has been lost.(Only other interactive axes is performed mastering.) This axis need to be performed mastering. - 2 The mastering has been completed.
Refer to the manual of the mechanical unit for an accurate method of single axis mastering.
- 984 -
B.APPENDIX
B-82594EN-4/01
Procedure B-10
Single axis mastering
Condition ■
System variable $MASTER_ENBL must be set to 1.
1 2
Select “6 SYSTEM” on the screen menu. Select “Master/Cal” on the screen change menu. The Master/Cal screen appears.
3
Select ”4 SINGLE AXIS MASTER”. The single axis mastering screen is displayed.
4
Enter 1 to SEL setting field of the axis that you want to perform the mastering. SEL can be specified every one axis or plural axes simultaneously.
5
Jog the robot to the mastering position. Turn off the brake control if it is necessary.
Step
- 985 -
B.APPENDIX
B-82594EN-4/01
6
Enter the axis data of the mastering position.
7
Press F5 ”EXEC.” The mastering is performed. This operation causes that SEL is set to 0 and ST is set to 2 or 1.
8
When the single axis mastering is completed, press the PREV key to display the Master/Cal screen.
9
Select ”6 CALIBRATE” and press F4 ”YES.” The calibration is performed. Press F5 ”DONE”, after calibration.
10
- 986 -
B.APPENDIX
B-82594EN-4/01
B.2.5
Setting Mastering Data Mastering data can directly be set to the system variable. Setting mastering data can be performed when the pulse counts are not changed. • If C-MOS mastering data is lost for some reason such as an initial start, set the recorded mastering data. • Setting mastering data cannot be performed when pulse count data is lost.
Procedure B-11
Directly setting mastering data
Step 1 2
Select “6 SYSTEM” on the screen menu. Select “Variables” on the screen change menu. The system variable screen appears.
3
Change mastering data. Mastering data is stored in system variable $DMR_GRP.$MASTER_COUN.
- 987 -
B.APPENDIX
B-82594EN-4/01
4
Select “$DMR_GRP.”
5
Select “$MASTER_COUN” and enter mastering data.
6 7
Press the PREV key. Set “$MASTER_DONE” to “TRUE.”
8 9
Display the Master/Cal screen and select “6 CALIBRATE.” Press F5 ”DONE”, after calibration.
- 988 -
B.APPENDIX
B-82594EN-4/01
B.3
SOFTWARE VERSION Screens related to the software version display identification information of the controller. This information is to be reported to FANUC, if a failure occurs in the controller. The following are the screens related to the software version:
-
F2 “SOFTWARE” : Displays the software version screen. F3 “MOT_ID”: Displays the motor ID screen. F4 “MOT_INF”: Displays the motor information screen. F5 “SER_PAR”: Displays the servo parameter information screen.
Software version screen The software version screen displays the following information:
Software configuration The software configuration screen displays the software installed.
- 989 -
B.APPENDIX
B-82594EN-4/01
Motor information screen The motor information screen displays servo control information on each axis.
Servo parameter information screen The servo parameter information screen displays the ID of the servo parameter for each axis.
- 990 -
B.APPENDIX
B-82594EN-4/01
Procedure B-12
Software version screen
Step 1 2 3 4
Press MENUS key to display the screen menu. Select ”0 ─ NEXT ─” and then select ”4 STATUS” on the next page. Press F1 ”TYPE” to display the screen change menu. Select ”Version ID” . Software version screen is displayed.
-
F2 “SOFTWARE” : Displays the software version screen. F3 “MOT_ID”: Displays the motor ID screen. F4 “MOT_INF”: Displays the motor information screen. F5 “SER_PAR”: Displays the servo parameter information screen.
- 991 -
B.APPENDIX
B.4
B-82594EN-4/01
ROBOT AXIS STATUS The robot axis status screens displays the status of each axis motor of the robot. The status of each axis is updated in real time. This status information is used during maintenance.
Status 1 screen The status 1 screen displays the alarm status of the servo system. The status information consists of servo alarm status 1 (16 bits) and servo alarm status 2 (16 bits).
Flag 1 Flag 2
MSB OHAL B7 MCAL OHAL LVAL OVC HCAL HVAL DCAL FBAL ALDF
MCAL MOFAL EROFL CUER
Servo alarm status 1 Servo alarm status 2
Table B.4 (a) Servo Alarm Status 1 B14 B13 B12 LVAL OVC HCAL B6 B5 B4 MOFAL EROFL CUER
B11 HVAL B3 SSTB
Address: FC80h (L-axis), FCC0h (M-axis) B10 B9 B8 DCAL FBAL ALDF B2 B1 LSB PAWT SRDY SCRDY
Amplifier overheat alarm It indicates a low voltage alarm. It indicates an overcurrent (OVC) alarm. It indicates an high current alarm. It indicates an high voltage alarm. It indicates a regenerative discharge alarm. Disconnection alarm (ALDF indicates whether the disconnection is associated with the hardware or software.) Alarm distinction bit If an amplifier alarm (OHAL, LVAL, HCAL, FSAL, IPMAL, or DCLVAL) is raised while ALSF is set to 1, the alarm is detected by PSM. When both FBAL and ALDF are set to 1, the disconnection alarm is detected by the hardware. Amplifier MCC adhesion alarm Move command overflow alarm When this bit is set to 1, it indicates that an overflow occurred when the move command was distributed. Error counter overflow alarm for line tracking When this bit is set to 1, it indicates that the error counter has overflowed. Current offset error This bit is set to 1 when the current offset value of the A/D converter is higher than permitted.
- 992 -
B.APPENDIX
B-82594EN-4/01
SSTB
PAWT SRDY SCRDY
Servo standby signal After POWON, this signal is set to 1, and the system waits for ITP. When SSTB is set to 1, the host outputs ITPCON and generates ITP. Parameter change completion signal When the servo CPU finishes rewriting parameters, only 1ITP is set to 1. Servo ready signal While this flag is held to 1, a move command is accepted. Servo communication flag The servo CPU sets this flag to 1 once data writing to the shared RAM is completed. After reading the data, the host CPU resets the flag to 0.
OVL
FBAL
ALDF
1 1 0
0 0 1
1 0 1
MSB SRCMF B7 FSSBDC SRCMF
CLALM
FSAL DCLVAL BRAKE IPMAL
SFVEL
GUNSET
FSSBDC SVUCAL
AMUCAL
CHGAL NOAMP
Alarm Motor overload alarm (not used for a serial pulse coder) Amplifier overload alarm Pulse coder disconnection alarm (not used for a serial pulse coder)
Table B.4 (b) Servo Alarm Status 2 B14 B13 B12 CLALM FSAL DCLVAL B6 SCUCAL
B5 AMUCAL
B4 CHGAL
B11 BRAKE B3 NOAMP
Address: FC81h (L-axis), FCC1h (M-axis) B10 B9 B8 IPMAL SFVEL GUNSET B2
B1
LSB
Compensation warning flag When part of the position data is missing because of noise or some other reason, data compensation is performed. This data, however, should not be used for mastering or other purposes. To inform the host of this state, the flag is set to 1. It indicates a collision detection alarm. When the servo CPU detects a collision, the flag is set to 1. The host CPU starts alarm handling after a lapse of a predetermined period from when the flag is set to 1. Fan stop alarm Low DC Link voltage alarm Brake alarm of 6-axis amplifier IPM alarm IPM is an abbreviation for intelligent power module, which is a power component to replace IGBT. The IPM detects overheating and HC by itself. Soft float start permission signal When the velocity feedback falls below the velocity specified in a parameter, this flag is set to 1 to allow soft float to be started. Servo gun switch completion signal Once the resetting (initialization) of the pulse coder has been completed after the servo gun is switched, the signal is set to 1 only for 1ITP. FSSB disconnection alarm When a disconnection of FSSB is detected, this bit is set to 1. (Hardware detection by FSSBC) FSSB communication alarm When two consecutive alarms are detected in data communication between the slave and a servo module, this bit is set to 1. (Detected by the servo software) FSSB communication alarm When two consecutive alarms are detected in data communication between the servo module and a slave, this bit is set to 1. (Detected by the slave) Amplifier charge alarm No amplifier connection alarm This bit is set to 1 when an amplifier is not connected while the presence of the corresponding axis is specified (B3 of AXIS register set to 0).
- 993 -
B.APPENDIX
B-82594EN-4/01
Status 2 screen The status 2 screen indicates the pulse coder alarm status (12 bits).
Alarm Status
B7 OHAL SPHAL STBERR CRCERR DTERR OHAL CSAL BLAL PHAL RCAL BZAL CKAL
B6 CSAL
Pulse coder alarm status
Table B.4 (c) Pulse Coder Alarm Status MSB B10 SPHAL STBERR B5 B4 B3 B2 BLAL PHAL RCAL BZAL
B9 CRCERR B1 CKAL
When this bit is 1, it indicates a soft phase alarm (abnormal acceleration). When this bit is 1, it indicates a start/stop bit alarm. When this bit is 1, it indicates a CRC alarm. When this bit is 1, it indicates a data alarm. When this bit is 1, it indicates a over heat alarm. When this bit is 1, it indicates a check sum alarm. When this bit is 1, it indicates the low voltage alarm of the battery. When this bit is 1, it indicates a phase alarm. When this bit is 1, it indicates a rotating speed counter abnormal alarm When this bit is 1, it indicates an exhausted battery alarm. When this bit is 1, it indicates a clock alarm.
- 994 -
B8 DTERR LSB
B.APPENDIX
B-82594EN-4/01
Pulse screen The pulse screen displays the servo delay, machine position, and status of the motion command.
Position Error Machine Pulse Motion Command
Servo delay (pulses). Delay of the actual pulse to the command pulse Machine position (pulses). Actual absolute pulses Relative command pulses from the host (pulses)
Monitor screen The monitor screen displays the current values, and the status of the position, overtravel, and servo amplifier. Load to the motor and thermal loss can be estimated using the root-mean-square current values.
Ave. Max. Inpos OT VRDY
Average of the root-mean-square current values (A) Maximum of the root-mean-square current values (A) Position status (0 or 1) Overtravel status (0 or 1) Servo amplifier ready status (on or off)
- 995 -
B.APPENDIX
B-82594EN-4/01
Tracking screen The tracking screen displays the status of the tracking servo system.
Flag Bits 1 Flag Bits 2 Alarm Status Counter Value
Servo alarm status 1 Servo alarm status 2 Pulse coder alarm status Line tracking counter
For the servo and pulse coder alarm statuses, see Table B.4 (a), Table B.4 (b), and Table B.4 (c)
Disturbance torque screen The disturbance torque screen displays the disturbance torque to each motor (current torque and maximum and minimum torque for each ITP). The disturbance torque is indicated with the current values estimated from the difference between the scheduled and actual values of the pulse coder. If the maximum or minimum value set for the disturbance torque is exceeded, the collision detection function of the servo system regards a collision as occurring and turns the servo power off.
Current Max. Min.
Estimated disturbance torque to the servo motor (A) Maximum value of the above estimated disturbance torque (A) Minimum value of the above estimated disturbance torque (A)
- 996 -
B.APPENDIX
B-82594EN-4/01
Procedure B-13
Robot axis status screens
Step 1 2 3 4
Press the MENUS key to display the screen menu. Select “0 ─ NEXT ─” to display the next page, then select “4 STATUS.” Press the F1 key, “[TYPE]” to display the screen change menu. Select “Axis.” The robot axis status screens can be displayed.
-
5
F2 “STATUS 1”: Displays the status 1 screen. F3 “STATUS 2”: Displays the status 2 screen. F4 “PULSE”: Displays the pulse screen. F2 “MONITOR” on the next page: Displays the monitor screen. F3 “TRACKING” on the next page: Displays the tracking screen. F4 “DISTURB” on the next page: Displays the disturbance torque screen. When F2 REG.DIS is selected on the next page, the regenerative discharge screen appears. To change the group number, press F5 [UTIL]. A menu appears. On that menu, select 1 GROUP, then enter a desired group number.
- 997 -
B.APPENDIX
B-82594EN-4/01
B.5
DIAGNOSIS SCREEN
B.5.1
Outline This function is a function to show users very useful information at maintenance of the robot. Each information has help that shows the description and the recommended action. You can use the robot long time without trouble. The following items are shown. • Main (List) • Reducer diagnosis • Overheat diagnosis • Torque diagnosis • Disturbance diagnosis • OVC diagnosis • collision diagnosis • Help
B.5.2
About Reducer Diagnosis Servo diagnosis function includes reducer’s recommended overhaul time diagnosis. The overhaul time depends on the future motion of reducer. This function indicates the overhaul time in the motion of recent 50 hours. When the exchange or overhaul of the reducer is done, you have to reset parameters. Please refer to the manual for the mechanical unit.
- 998 -
B.APPENDIX
B-82594EN-4/01
B.5.3
Procedure
Procedure B-14
Diagnosis screen
Step 1 2 3 4 5 6
Procedure B-15
Press the MENUS key to bring up the screen menu. Select “4 STATUS” on the next page. Press F1“[TYPE]” to display the pull-up menu. Select “Axis”. Press [next] key until “diag” is shown above function key. Press F4“diag”. Diagnosis main screen is shown first.
Change diagnosis screen
Step 1
Each item is allocated to the function key. Press function key to show the item. For example, by pressing F3 key reducer diagnosis screen is shown.
- 999 -
B.APPENDIX
B.5.4
B-82594EN-4/01
2
You can change the allocation of function keys by pressing the [next] key.
3
To show the Axis screen again, press [PREV] key.
Each Item Main: Each item shows the value of the worst axis.
- 1000 -
B.APPENDIX
B-82594EN-4/01
Reducer: The time until the recommended overhaul of reducers
Over heat: The ratio of root mean square current to the rated current
Torque: The ratio of the current torque to the maximum.
- 1001 -
B.APPENDIX
B-82594EN-4/01
Disturbance: The ratio of the force observed by the servo software to the alarm threshold.
OVC: The: The ratio of the temperature simulated by the software to the alarm threshold.
- 1002 -
B.APPENDIX
B-82594EN-4/01
Collision detection: The count of the collision and the data of the last collision detection.
Help: Information of the last shown item
- 1003 -
B.APPENDIX
B.6
B-82594EN-4/01
WORLD FRAME ORIGIN This section describes the world frame origin of the each robot model (See Section 3.8,”SETTING COORDINATE SYSTEMS” for the world frame). When the user frame or tool frame is set, refer to this.
S series/LR Mate (Other than S-450) A crossing point between J1 axis and level plane which includes the J2 axis. (S-450U/L) Intersection of rotation axes U and g when the robot is set to the zero positions on all linear axes (S-450S) Position at which rotation axis U, moved parallel to itself in the horizontal direction, intersects with rotation axis q when the robot is set to the zero positions on all linear axes
M series (M-410i/M-500) Intersection of the J2-axis, moved parallel to itself, and the J1-axis
- 1004 -
B.APPENDIX
B-82594EN-4/01
B.7
I/O MODULE SETTING
FANUC I/O Link The FANUC I/O Link is a serial interface used for high-speed I/O signal (bit data) transmission between the Robot controller and I/O modules, such as the process I/O printed circuit board and I/O Unit-MODEL A. Using the FANUC I/O Link, one master and multiple slaves can be connected. Generally, the Robot controller is used as the master, with the I/O modules connected to the controller being used as slaves. Up to 16 slave groups can be connected to one I/O Link.
Fig. B.7 (a) FANUC I/O Link configuration
I/O signals The following I/Os are used for signal transmission between the Robot controller and system peripheral units, via the I/O modules connected to the FANUC I/O Link: • Digital I/O SDI[i]/SDO[i] • Group I/O GI[i]/GO[i] • Analog I/O AI[i]/AO[i] • Peripheral unit I/O UI[i]/UO[i] i = logical number
- 1005 -
B.APPENDIX
B-82594EN-4/01
I/O modules The following I/O modules can be connected to the Robot controller via the I/O Link: Table B.7 (a) I/O modules Abbreviation Process I/O printed circuit board (CA, CB, DA, EA, EB, FA) FANUC I/O Unit-MODEL A FANUC I/O Unit-MODEL B FANUC I/O Link connection unit Programmable Controller SERIES 90-30A
I/O Unit - A I/O Unit - B -
Assignment I/O logical number i is assigned to a physical number of I/O modules. I/O logical numbers can be redefined.
- Logical number I/O index used to reference an I/O in the Robot controller
- Physical number Number assigned to each signal pin of an I/O module. A specific signal pin of a particular I/O module can be specified with the rack, slot, and physical number.
- 1006 -
B.APPENDIX
B-82594EN-4/01
Fig. B.7 (b) Logical number and physical number assignment
Rack number Rack numbers indicate the hardware types and connection orders of I/O modules. I/O modules are classified into two major types: those having rack number 0, and those to which rack numbers are assigned in the order in which they are connected.
Slot number I/O modules whose rack numbers are 0 are assigned slot numbers in the order in which they are connected. When the rack number of an I/O module is a non-zero value, indicating the order in which it is connected, a slot number is used to indicate the I/O module part of that I/O module. I/O module parts include, for example, modules of I/O Unit-A and DI/DO units of I/O Unit-B.
- 1007 -
B.APPENDIX
B-82594EN-4/01
START PT (channel number) Digital I/Os and peripheral I/Os are assigned in groups of eight signals. Specify the first physical number for eight sequential signals. For group I/Os, specify the first physical number for the sequential signals specified in NUM PTS. For an analog I/O, specify a channel number. Table B.7 (b) Specifying rack and slot numbers for each I/O module I/O module Rack Slot Process I/O printed circuit board FANUC I/O Unit-MODEL A FANUC I/O Unit-MODEL B FANUC I/O Link connection unit Programmable Controller SERIES 90-30A
Always 0 (*1) (*1) Always 0 (*1)
(*2) Number indicated on the base unit Unit number (set with DIP switches) (*2) 1 (fixed)
NOTE *1 Numbers beginning with 1 are to be assigned to I/O modules, except those I/O modules having rack number 0, in the order in which they are connected. *2 To those I/O modules having rack number 0, numbers beginning with 1 are to be assigned in the order in which they are connected. Robot controller
Robot controller
Process I/O printed circuit board
Rack 0, slot 1
I/OUnit-B
Rack 1, slot 1
Connection unit
Rack 0, slot 2
90-30 A
Rack 2, slot 1
90-30 A
Rack 1, slot 1
Connection unit
Rack 0, slot 1
Fig. B.7 (c) Example of rack and slot specification
I/O Link setting When connected to the controller, some I/O modules require that the user make several additional specifications. Other I/O modules, however, do not require such specification.
- When additional specification is not necessary After connecting an I/O module to the Robot controller, via a cable, turn on the power. Data assignment is performed automatically.
- 1008 -
B.APPENDIX
B-82594EN-4/01
- When additional specification is necessary Specify the system variables from the Robot controller. Specification Process I/O printed circuit board (CA, CB, DA) FANUC I/O Unit-MODEL A FANUC I/O Unit-MODEL B FANUC I/O Link connection unit Programmable Controller SERIES 90-30A
Unnecessary Unnecessary Necessary Necessary Necessary
Number of available I/Os Up to 16 slave groups can be connected to each I/O Link. Therefore, up to 16 I/O modules can be connected to the Robot controller. The FANUC I/O Link supports 1024 inputs and 1024 outputs for a master. These I/Os are assigned to the slaves to enable the periodic transmission of I/O data between the master and slaves. The total number of I/Os used by the slaves connected to the FANUC I/O Link must satisfy the following: Number of inputs per I/O Link =< 1024 Number of outputs per I/O Link =< 1024 Therefore, I/Os can be expanded within the above range. For details of the number of I/Os used for each I/O module that becomes a slave, refer to the relevant I/O module manual. The process I/O printed circuit board, however, always uses 128 inputs and 128 outputs, regardless of its type.
Fig. B.7 (d) Relation between master and slave in I/O signal points
Teach pendant display On both the digital input and output screens, displayed on the teach pendant of the Robot controller, up to 256 signals can be displayed. Using these screens, a user can specify and change the assignment of up to 256 signals. On both the analog input and output screens, up to 25 channels can be displayed. Using these screens, a user can specify and change the assignment of up to 25 channels, on a channel-by-channel basis.
- 1009 -
B.APPENDIX
B-82594EN-4/01
I/O module manuals For details of each I/O module, refer to the following manuals: I/O module name Process I/O printed circuit board (CA, CB, DA, EA, EB, FA) FANUC I/O Unit-MODEL A FANUC I/O Unit-MODEL B FANUC I/O Link connection unit Programmable Controller SERIES 90-30A
Manual name FANUC Robot series R-30iA Controller Maintenance Manual FANUC I/O Unit-MODEL A Connection and Maintenance Manual FANUC I/O Unit-MODEL B Connection Manual FANUC I/O Link Connection Unit Specifications Programmable Controller SERIES 90-30A User’s Manual
- 1010 -
Drawing number B-82595EN B-61813E B-62163E A-68806 B-76014E
B.APPENDIX
B-82594EN-4/01
B.8
SETTINGTHE FSSB LINE This document describes the FSSB LINE and HARDWARE START AXIS setting that is necessary to set up when system has auxiliary axes.
B.8.1
Definition of FSSB line FSSB(FANUC Serial Servo Bus) line is defined as follows.
FSSB line 2 FSSB line that originates from COP10A-2 connector of axis control card
main board
COP10A-2 (Upper connector)
axis control card
Amplifier(robot)
COP10A-1 (Lower connector)
COP10B
FSSB line 3 FSSB line that originates from auxiliary axis board
- 1011 -
Amplifier
COP10A
FSSB line 1 FSSB line that originates from COP10A-1 connector of axis control card auxiliary axis board
Amplifier
Amplifier
B.APPENDIX
B.8.2
B-82594EN-4/01
Setting 1 (FSSB line) Please enter the number of FSSB line that added axis is connected to.
**** GROUP 2 INDEPENDENT AXES SETUP **** -- FSSB configuration setting -1: FSSB line 1 (main axis card) 2: FSSB line 2 (main axis card) 3: FSSB line 3 (auxiliary axis board) Select FSSB line > Default value = 1
Please enter the value from 1 to 3
There are three FSSB lines from 1 to 3. Usually, the first FSSB line is used unless the system has many auxiliary axes or multi robots. This setting is necessary for extended axis and each motion groups, except for group 1.
B.8.3
Setting 2 (Number of total axes on FSSB line 1) Please enter the number of total axes on FSSB line 1. This setting is necessary only when added axis is on FSSB line 2. Total number of axes on FSSB 1 >
Please enter the number of total axes on FSSB line 1. The number includes robot axes.
B.8.4
Setting 3 (Hardware start axis) Please enter the start axis number of the first axis in the total hardware configuration of the system. This setting is necessary only when you set up the first axis in a motion group. It is not necessary when you add 2nd or later auxiliary axis in the group.
**** GROUP 2 INDEPENDENT AXES SETUP **** -- Hardware start axis setting -Enter hardware start axis (Valid range: 1 - 16)
Please enter the number within valid range
- 1012 -
B.APPENDIX
B-82594EN-4/01
Valid range of hardware start axis differs according to the FSSB line to which auxiliary axis is connected. FSSB line
1 2 3
Valid hardware start axis 7~16 (*1) *~24 (*2) 25~40 (*3)
(*1) It is possible to use the number less than 7 when the robot does not have six axes. (*2) The lower limit of hardware start axis for 2nd FSSB line differs according to the total axis number that is connected to the 1st FSSB line. In case that total axis number on the 1st FSSB line is a multiple of 4: * = (Total axis number on the 1st FSSB line) + 1 In case that total axis number on the 1st FSSB line is not a multiple of 4: * = (Multiple of 4 that is greater than and nearest to the total axis number on the 1st FSSB line) + 1 (*3) The lower limit of hardware start axis for 3rd FSSB line is 25 irrespective of the number of axes on 1st and 2nd FSSB line.
B.8.5
Setup Examples
B.8.5.1
Example 1
axis
FSSB line 1
Amp.1
Amp.2
control card
Group 1 robot(6 axes)
Group 2 Independent axis(1 axis)
no axis
FSSB line 2
When system configuration is like above figure, please set up as follows. Motion group
FSSB line
1 2
1 1
Total number of axes on FSSB line 1 No need to set up No need to set up
- 1013 -
Hardware start axis
1 7
B.APPENDIX
B.8.5.2
B-82594EN-4/01
Example 2
axis
FSSB line 1
Amp.1
Amp.2
Amp.3
control card
Group 1 robot(6 axes) Amp.4
FSSB line 2
Group 2 robot(6 axes)
Group 3 Independent axis(1 axis)
Amp.5
Group 4 Independent axis(1 axis)
Group 5 Independent axis(1 axis)
When system configuration is like above figure, please set up as follows. Motion group
FSSB line
1 2 3 4 5
1 1 1 2 2
Total number of axes on FSSB line 1 No need to set up No need to set up No need to set up 13 No need to change(13)
Hardware start axis
1 7 13 17 (∗) 18
(∗) Hardware start axis of the 1st axis on the 2nd FSSB line must be the (multiple of 4) + 1. Hardware start axis of group 4 is not 14 but 17 for the above hardware configuration.
- 1014 -
B.APPENDIX
B-82594EN-4/01
B.8.5.3
Example 3
axis
Amp.1
FSSB line 1
Amp.2
Amp.3
control card
Group 1 robot(6 axes) FSSB line 2
auxiliary
Group 2 robot(6 axes)
Group 2 7th axis
no axis
FSSB line 3
Amp.4
Amp.5
Amp.6
axis board Group 3 robot(6 axes)
Group 4 robot(6 axes)
Group 5 Independent axis(1 axis)
When system configuration is like above figure, please set up as follows. Motion group
FSSB line
1 2 3 4 5
1 1 3 3 3
Total number of axes on FSSB line 1 No need to set up No need to set up No need to set up No need to set up No need to set up
Hardware start axis
1 7 25(∗) 31 37
(*) The number of hardware axis starts from 25 for 3rd FSSB line irrespective of the number of axes on 1st and 2nd FSSB line. Hardware start axis of group 3 is not 14 but 25 for the above hardware configuration.
- 1015 -
B.APPENDIX
B.9
B-82594EN-4/01
POSITIONER SETUP
Step 1 2 3
Turn ON the controller with “ PREV” key and F! key pressed. Then select “3. Controlled start”. Press MENUS key and select “9. MAINTENANCE”. You will see similar screen to the following one. Setup Robot System Variables Group Robot Library /Option 1 R-2000i/165F * 2 POSITIONER [Type] ORD_NO AUTO MANUAL
4
Ext Axs
Press arrow (↑,↓) keys and move the cursor to “POSITIONER”. Then press F4,”MANUAL”. You will see similar screen to the following ─ Hardware start axis setting ─ enter Hardware start axis (1..16)? Default value = 1
5
Enter axis number and press ENTER key. * Which axis in the system is assigned to 1st axis of POSITIONER is set in this screen. For example, if the system has R-2000i and POSITIONER, start axis number of POSOTIONER is 7 because R-2000i has 6 axes. You will see similar screen to the following ─ Kinematics Type Setting ─ 1:Known Kinematics 2:Unknown Kinematics Select Kinematics Type? default value = 1
6
If the measurements of offset values between POSITONER axes are accurately known, item 1 should be selected. Otherwise item 2 should be selected. You will see similar screen to following one. Group number is displayed instead of “?” in following screen. Total number of axes is displayed instead of “#” in following screen. Initial value of number of axes is 0. ****Group ? Total POSITIONER Axis=# 1.Display/Modify POSITIONER axis 2.Add POSITIONER axis 3.Delete POSITIONER axis 4.Exit Select item?
If you want to add POSITIONER axis, select “2. Add POSITIONER axes”. Then setup procedure starts. If you want to delete POSITIONER axis, select “3. Delete POSITIONER axes”. Then following screen is displayed. - 1016 -
B.APPENDIX
B-82594EN-4/01
POSITIONER Axis ? Was Deleted Press ENTER to Continue.
(* The deleted axis number is displayed instead of “?” in above screen.) After this setup, please set values according to the specification of the mechanism. Select the Motor size
7
****POSITIONER Axis 1 Initialization**** 33.ACb0.5 38.ACa12 43.ACa100 34.Acal 39.ACa22 44.ACa150 : : : : : : 0. Next page. Select Motor size?
8
Select the motor type. MOTOR TYPE 1./2000 6.F/3000 2./3000 7.F/2500 3.S/2000 8.L/3000 : : Select Motor Type?
9
Select Amplifier Current Limit. CURRENT LIMIT FOR AMPLIFIER 1. 2A 6. 60A 2. 4A 7. 80A 3. 12A 8. 100A : : Select Amplifier Current Limit?
10
Set amplifier number.
─ Amplifier number Setting ─ Enter Amplifier Number (1 → 16)?
11
Set amplifier type.
─ Amplifier Type Setting ─ Amplifier ? Type = # Enter (1:Change, 2:No Change)?
* Amplifier number which is set in previous procedure is displayed instead of “?”. * If 0 is displayed instead of “#”, this indicates that amp type is not set yet. If you select “1: Change” in above screen, you will see following screen. Select the amplifier type. SELECT AMP TYPE 1. A06B-6100 series 6 axes amplifier 2. A06B-6093 Beta series (FSSB)
- 1017 -
B.APPENDIX
B-82594EN-4/01
12
Select the axis type.
Axis Type Setting 1: Linear Axis 2: Rotary Axis Select Axis Type?
13
If the axis does linear motion, select item 1. If the axis does rotary motion, select item 2. Select the direction of the axis.
─ Direction Setting ─ 1: +X 3: +Y 5: +Z 2: -X 4: -Y 6: -Z Select Direction?
Directions in above screen indicate the directions of axes of the world coordinate system. The +/- direction must be considered in this setting. Example) World coordinate frame
· Linear axis
In this case, the direction should be set to “+Z”. · Rotary axis
In this case, the direction should be set to “+X”. 14 If you set the Kinematics Type to “Known Kinematics” in procedure 4., you will see the following screens. If the Kinematics is “Unknown Kinematics”, this procedure is skipped. Enter the Offset value in X direction. ─ Offset Setting ─ Enter Offset X (mm)?
Enter the Offset value in Y direction. Enter Offset Y (mm)?
- 1018 -
B.APPENDIX
B-82594EN-4/01
Enter the Offset value in Z direction. Enter Offset Z (mm)?
For 1st axis, offset values between the origin of the world coordinate and that of the axis must be set. For the 2nd or later axes, offset values between the origin of the axis and that of the previous axis must be set. Example)
In this case, offset values for (N)th axis must be set as follows. Offset X: 300mm Offset Y: 0mm Offset Z: - 250mm 15 Set Gear Ratio. For a linear axis, enter the distance of the motion which corresponds to one revolution of the axis of the motor. (UNIT: mm/rev) Following screen is displayed for linear axes. ─ Gear Ratio Setting ─ Enter Gear Ratio (mm/rev)?
For a rotary axis, enter the number of revolution of the motor which corresponds to one revolution of the axis. (UNIT: motor_rev / axis-rev) Following screen is displayed for rotary axes. ─ Gear Ratio Setting ─ Enter Gear Ratio (mot-rev/axs-rev)?
16
Set the maximum speed for the axis. You will see the similar screen to following one.
─ Maximum Speed Setting ─ Suggested Speed = 150.000 (mm/sec) (Calculated with Max Motor Speed) Enter (1: Change, 2: No Change)?
If you want to change suggested value, select “1: Change”. Then following screen will be displayed. Enter Max Speed (mm/sec)?
Enter Max speed.
- 1019 -
B.APPENDIX
B-82594EN-4/01
17
Set motion sign.
MOTOR DIRERCTION Ext_axs 1 Motion Sign = TRUE Enter ( 1: TRUE, 2: FALSE)?
18
Set the upper limit of the POSITIONER axis (UPPER LIMITS). Input unit of it by the “mm” in case of linear axis and by “degree” in case of rotary axis.
UPPER Enter
LIMITS Upper Limit
( deg ) ?
warning) Determine upper limit of POSITIONER axis by user. So, the following condition must be consisted: - = length of POSITIONER axis For example, if the length of POSITIONER axis is 100 mm, you may set the upper limit. = 50mm = -50mm 19 81D Set the lower limit of the POSITIONER axis (LOWER LIMITS). Input unit of it by the “mm” in case of linear axis and by “degree” in case of rotary axis. LOWER Enter
20
LIMITS Lower Limit
( deg ) ?
Set the mastering position data (MASTER POSITION).
MASTER POSITION Enter Master Position ( deg ) ?
21
Set the constant of acceleration/deceleration time (ACC/ DEC TIME) . Set the value when you change the constant of acceleration/ deceleration time of the first joint. In case of changing it, input “1”, or in case of using the recommending value, input “2”. ACC/DEC TIME Default acc_time1=256(ms) Enter ( 1: Change, 2: No Change ) ?
22
Set the value when you change the constant of acceleration/ deceleration time of the second joint. In case of changing it, input “1”. In case of using the recommending value, input “2”.
Default acc_time2=128(ms) Enter ( 1: Change, 2: No Change ) ?
23
Set the value when you change the constant of exponential acceleration/deceleration time of first joint. In case of changing it, input “1”. In case of using the recommending value, input “2”.
EXP_ACCEL TIME Default exp_accel time =0(ms) Enter (1: Change, 2: No Change)?
- 1020 -
B.APPENDIX
B-82594EN-4/01
24
Set the “Minimum Access Time”. This value is used when the real acceleration/deceleration time is smaller than specified time. In case of changing it, input “1”. In case of not changing, input “2”.
MIN_ACCEL TIME Default min_accel time =384(ms) Enter ( 1: Change, 2: No Change ) ?
25
Set the inertia ratio of all load inertia calculated in motor axis to inertia (to rotary inertia). On setting inertia ratio, its value must be 1< the value<5. On not setting it, input “0”.
Load Ratio is Load Inertia ( Kg*cm*s*2) Motor Inertia (Kg*cm*s*2) Enter Load ratio ? ( 0:None
26
1 → 5: Valid)
Set the brake number (0-4) using the POSITIONER axis.
BRAKE SETTING Enter Brake Number (0 → 4)?
27
Select the type of brake control. On valid of brake control, choose “1:Enable” and input the delay time of brake control. On invalid of it, choose “2:Disable”.
SERVO TIMEOUT Servo Off is Enable Enter (1: Enable 2: Disable)? Select?
(On choosing “1:Enable” ) Enter
28
Servo
Off
Time ?
(0.0 → 30.0
Sec)
Come back screen of step 6.
**** Group ? Total POSITIONER Axis = # **** 1.Display/Modify POSITIONER Axis = # 2.Add POSITIONER axis 3.Delete POSITIONER axis 4.Exit Select item ?
• • • •
In case of displaying/modifying the POSITIONER axis setting, select “1.Display/Modify Ext axis”. When you set the POSITIONER axis successively, select the item “2” and text and continues after the step 7 in this text. In case of deleting the POSITIONER axis, select “3.Delete Ext axis”. In case of finishing the setting, select “4.EXIT → 0.EXIT”.
- 1021 -
B.APPENDIX
B.10
B-82594EN-4/01
EXTENDED AXIS SETUP
Step 1
Turn ON the controller with “ PREV” key and “F → ” key pressed. Then select “3. Controlled start”. 2 Press MENU key and select “9. MAINTENANCE”. 3 You will see similar screen to the following one. Setup Robot System Variables Group Robot Library /Option 1 R-2000i/165F * Extended Axis Control [Type] ORD_NO AUTO MANUAL
Ext Axs
Press arrow(↑, ↓) keys and move the cursor to “Extended Axis Control”. Then press F4,”MANUAL”. 4 You will see similar screen to the following. Select the group of the extended axis and input its number. **** EXTENDED AXIS SELECT GROUP 0. EXIT 1. Group1
SETTING
PROGRMA ****
Display the information about extended axis of the selected group Group 1 Total Ext Axis = 1.Display/Modify Ext axis 2.Add Ext axes 3.Delete Ext axes 4.Exit Select?
E1 E2 E3 * * *
Select “2. Add Ext axes” in case of setting new extended axis. 5 Set the number of extended axis. For the first extended axis of the group, input “1”, for the second extended axis of the group, input ”2”, for the third axis of the group, input “3”. You should set the number from “1” in turn. Enter
6
axis
to
add
(1 → 3) ?
You will see the initial setup screen of extended axis. Select the kind of motor used extended axis. **** Ext 33.ACb0.5 34.ACa1 : : 0. Select ?
Axis 1 Initialization **** 38.ACa12 43.ACa100 39.ACa22 44.ACa150 : : : : Next page.
- 1022 -
B.APPENDIX
B-82594EN-4/01
7
Select the type of motor on screen. MOTOR TYPE 1. /2000 6.F/3000 2. /3000 7.F/2500 3. S/2000 8.L/3000 : : Select ?
8
9
Select the max current value of motor on screen. CURRENT
LIMIT
FOR
1. 2A 2. 4A 3. 12A : Select ?
6. 7. 8. :
60A 80A 100A
AMPLIFIER
Select the type of extended axis through the four types to the following. EXTENDED AXIS TYPE 1. Integrated Rail (Linear axis) 2. Integrated Arm (Rotary axis) 3. Auxiliary Linear Axis 4. Auxiliary Rotary Axis Select ?
Warning 1) Integrated: Robot coordinate is added to the distance of extended axis. The world coordinates are unchanged by the changed extended axis. So the current position changes only the distance transferred by the extended axis. Auxiliary: Robot coordinate is NOT added to the distance of extended axis. World coordinate is transferred with changed extended axis, and remains the fixed robot coordinate. Warning 2) Integrated Rail (Linear axis): Set the direction of attached extended axis to the direction (X,Y,Z) of world coordinate Direction 1:X 2:Y 3:Z Enter Direction (1 → 3) ?
Integrated Arml (Rotary axis): Set the offset length to Z direction between the origin of rotary center of extended axis and the origin of robot coordinate Enter
Off
Set
Length (mm) ?
Next, set the arm length of extended axis. Correspondence of the X-axis of robot coordinate and the rotary axis of extended axis: Set the offset length to the Y direction between the origin of rotary center of extended axis and the origin of robot coordinate. Correspondence of the Y-axis of robot coordinate and the rotary axis of extended axis: - 1023 -
B.APPENDIX
B-82594EN-4/01
Set the offset length to the X direction between the origin of rotary center of extended axis and the origin of robot coordinate. Correspondence of the Z-axis of robot coordinate and the rotary axis of extended axis: Set the offset length to the X direction between the origin of rotary center of extended axis and the origin of robot coordinate. Enter
Arm
Length (mm) ?
Finally, set the direction of attached extended axis. Input the direction of the rotary axis to the axis (X,Y,Z) of world coordinate 10 Set the gear ratio (GEAR RATIO). For linear axis, the gear ratio is in “mm” of travel per revolution of motor. For rotary axis, the gear ratio is in motor turns per single rotations of the rotary axis. For linear axis: GEAR
RATIO
For a linear axis it is the number of Mm's traveled for one rotation of the Motor Enter Gear Ratio ? (mm)
For rotary axis: GEAR RATIO Enter Gear
11
Ratio ?
Set the max joint speed. You will see the max rotary numbers and gear ratio on screen. With Changing, input “1”and the value. With using the recommending value, input “2”.
MAX JOINT SPEED Suggested Speed = ( Calculated with Enter ( 1: Change,
SETTING 150.000 ( deg / s ) Max motor speed) 2: No Change ) ?
In case of changing the max speed Enter Max Speed (mm/sec) ?
12
Set the direction of extended axis to the motor axis. If the motion direction is positive to the positive rotation of motor, input “1”. If the motion direction is negative to the negative rotation of motor, input “2”.
MOTOR DIRERCTION Ext_axs 1 Motion Sign = TRUE Enter ( 1: TRUE, 2: FALSE) ?
- 1024 -
B.APPENDIX
B-82594EN-4/01
13
Set the upper limit of the extended axis (UPPER LIMITS). Input unit of it by the “mm” degree in case of linear axis and by “degree” in case of rotary axis.
UPPER Enter
LIMITS Upper Limit
( deg ) ?
warning) Determine upper limit of extended axis by user. So, the following condition must be consisted: - = length of extended axis For example, if the length of extended axis is 100 mm, you may set the upper limit. = 50mm = -50mm 14 Set the lower joint orient area of the extended axis (LOWER LIMITS). Input unit of it by the “mm” degree in case of linear axis and by “degree” in case of rotary axis. LOWER Enter
15
LIMITS Lower Limit
( deg ) ?
Set the mastering position data (MASTER POSITION).
MASTER POSITION Enter Master Position ( deg ) ?
16
Set the constant of acceleration/deceleration time (ACC/ DEC TIME). Set the value when you change the constant of acceleration/ deceleration time of the first joint. In case of changing it, input “1”, or in case of using the recommending value, input “2”.
ACC/DEC TIME Default acc_time1=256(ms) Enter ( 1: Change, 2: No Change ) ?
Set the value when you change the constant of acceleration/deceleration time of the second joint. In case of changing it, input “1”, or in case of using the recommending value, input “2”. Default acc_time2=128(ms) Enter ( 1: Change, 2: No Change ) ?
17
Set the value when you change the constant of exponential acceleration/deceleration time of first joint. In case of changing it, input “1”, or in case of using the recommending value, input “2”.
EXP_ACCEL TIME Default exp_accel time =0(ms) Enter ( 1: Change, 2: No Change ) ?
- 1025 -
B.APPENDIX
B-82594EN-4/01
18
Set the “Minimum Access Time”. This value is used when the real acceleration/deceleration time is smaller than specified time. In case of changing it, input “1”, or in case of not changing, input “2”.
MIN_ACCEL TIME Default min_accel time =384(ms) Enter ( 1: Change, 2: No Change ) ?
19
Set the inertia ratio of all load inertia calculated in motor axis to inertia (to rotary inertia). On setting inertia ratio, its value must be 1< the value<5. On not setting it, input “0”.
Load Ratio is Load Inertia ( Kg*cm*s*2) Motor Inertia (Kg*cm*s*2) Enter Load ratio ? ( 0:None
20
1→5: Valid)
Set the amplifier number (AMP NUMBER).
SELECT AMP NUMBER Enter amplifier number (1 → 16) ?
21
Set the type of amplifier (AMP TYPE).
SELECT AMP TYPE 1. A06B-6100 series 6 axes amplifier 2. A06B-6093 Beta series (FSSB)
22
Set the brake number (0-4) using the POSITIONER axis.
BRAKE Enter
23
SETTING Brake Number (0 → 4)?
Select the type of brake control. For brake control, choose “1:Enable” and input the delay time of brake control. To disable brake control, choose “2:Disable”.
SERVO TIMEOUT Servo Off is Enable Enter (1: Enable 2: Disable) ? Select?
(On choosing “1:Enable” ) Enter
Servo
Off
- 1026 -
Time ?
(0.0 → 30.0
Sec)
B.APPENDIX
B-82594EN-4/01
24
You will see a screen similar to the following.
**** Group 1 Total Ext Axis = **** 1.Display/Modify Ext axis 2.Add Ext axes 3.Delete Ext axes 4.EXIT Select?
• • • •
In case of displaying/modifying the extended axis setting, select “1.Display/Modify Ext axis”. When you set the extended axis successively, select the item “2” and text and continues after the step 5 in this text. In case of deleting the extended axis, select “3.Delete Ext axis”. In case of finishing the setting, select “EXIT→4.EXIT”.
- 1027 -
B.APPENDIX
B.11
B-82594EN-4/01
INDEPENDENT ADDITIONAL AXIS BOARD (NOBOT) STARTUP PROCEDURE
Step 1
Execute control start: Press and hold down the “PREV” and “F →” keys and turn the power switch ON. Then, select 3. Control start. 2 On the teach pendant, select Screen selection, then 9. Robot setting. 3 The following screen appears: Setup Robot System Variables Group Robot Library /Option Ext Axs 1 S-430iF Floor Mnt 0 2 NOBOT 0 [Type] ORD_NO AUTO MANUAL
Position the cursor on 1NOBOT and press the F4 key, MANUAL. 4 The following screen appears. For this setting item, specify that the first axis of the independent additional axis board (NOBOT) should be the n-th axis in the entire system. For the S-430iF plus NOBOT, for example, because the S-430iF as the first group is a 6-axis robot, the first axis of the independent additional axis board (NOBOT) as the second group will be the seventh. ─ Hardware start axis setting ─ enter Hardware start axis (1..16)? Default value = 1
5
The following screen appears. The “?” on the screen will be replaced by a group number. The “#” on the screen will be replaced by the number of axes of the NOBOT currently set. **** Group ? Total Nobot Axis = # 1.Display/Modify Nobot axis 1 → 6 2.Add Nobot axis 3.Delete Nobot axis 4.Exit Select item?
To add an axis of the independent additional axis board (NOBOT), select “2: Add Nobot axis.” To delete an axis, select “3: Delete Nobot axis.” If 3 is selected, the following screen appears. To return to the above screen, press the Enter key. Nobot Axis? Was Deleted Press ENTER to Continue.
(The “?” on the screen will be replaced by the number of the axis just deleted.) For the subsequent settings, use the values mentioned in the specifications of the mechanical unit of the robot.
- 1028 -
B.APPENDIX
B-82594EN-4/01
6
From the screen, select the size of the motor used for an axis of the independent additional axis board (NOBOT). **** Nobot Axis 1 Initialization **** 33.ACb0.5 38.ACa12 43.ACa100 34.ACa1 39.ACa22 44.ACa150 : : : : : : 0. Next page. Select Motor size?
7
Select a motor type from the screen. MOTOR
TYPE 1. /2000 2. /3000 3. S/2000 : Select Motor Type?
8
6.F/3000 7.F/2500 8.L/3000 :
From the screen, select the maximum current control value of the motor (maximum permissible current value of the amplifier). CURRENT
LIMIT
FOR
AMPLIFIER
1. 2A 6. 60A 2. 4A 7. 80A 3. 12A 8. 100A : : Select Amplifier Current Limit?
9
Set the amplifier number. ─ Amplifier number Setting ─ Enter Amplifier Number (1→16)?
10
Set the amplifier type.
─ Amplifier Type Setting ─ Amplifier ? Type = # Enter (1: Change, 2: No Change)?
* *
The “?” on the screen will be replaced by the amplifier number set previously. If 0 is displayed in place of “#,” this indicates that no amplifier has been set. To change the amplifier type, select “1: Change.” The following screen appears: SELECT
AMP TYPE 1. A06B-6100 2. A06B-6093
series 6 axes amplifier Beta series (FSSB)
Select an amplifier type.
- 1029 -
B.APPENDIX
B-82594EN-4/01
11
Select the axis type of the independent additional axis board (NOBOT).
Axis Type Setting ─ 1: Linear Axis 2: Rotary Axis Select Axis Type?
12
Linear Axis: Linear axis Rotary Axis: Rotary axis Enter the gear reduction ratio. For a linear axis, enter the distance of travel along the axis due to one rotation of the motor (in mm). For a rotary axis, enter the number of revolutions of the motor required for one rotation about the output axis.
─ Gear Ratio Setting ─ Enter Gear Ratio ?
13
Set the maximum axis speed. A suggested value is calculated with the maximum motor speed and the gear ratio and displayed on the screen. To change the value, enter 1 and enter a new value. To use the suggested value, enter 2.
─ Maximum Speed Setting ─ Suggested Speed = 150.000 ( mm / sec ) ( Calculated with Max Motor Speed) Enter ( 1: Change, 2: No Change ) ?
To change the maximum speed, use the following screen: Enter
14
Max
Speed
(mm/sec)
?
Enter the maximum speed. Set the axis direction in relation to the motor. If the direction of rotation about the axis due to the forward rotation of the motor is plus, enter 1 for TRUE; if minus, enter 2 for FALSE.
MOTOR DIRERCTION Motion Sign = TRUE Enter ( 1: TRUE, 2: FALSE) ?
15
Enter the upper limit (UPPER LIMITS) of the axis operation range in mm for a linear axis and in deg. for a rotary axis. UPPER Enter
Note)
LIMITS Upper Limit
( deg ) ?
The user must decide on the upper limit. The upper limit and the lower limit, to be entered next, must satisfy the following condition: - = Axis length For example, if the axis length is 100 mm, the following limits may be entered: = 50 mm = -50 mm
- 1030 -
B.APPENDIX
B-82594EN-4/01
16
Enter the lower limit (LOWER LIMITS) of the axis operation range in mm for a linear axis and in deg. for a rotary axis. LOWER Enter
17
LIMITS Lower Limit
( deg ) ?
Enter the mastering position. MASTER POSITION Enter Master Position ( deg ) ?
18
Set the acceleration/deceleration time constant. To change the first acceleration/deceleration time constant for each axis, enter 1 and then a new value. To use the suggested value, enter 2. ACC/DEC TIME Default Value of acc_time1=256(ms) Enter ( 1: Change, 2: No Change ) ?
To change the second acceleration/deceleration time constant for each axis, enter 1 and then a new value. To use the suggested value, enter 2. Default Value of acc_time2=128(ms) Enter ( 1: Change, 2: No Change ) ?
19
Set the minimum acceleration/deceleration time. The acceleration and other instructions will use this value if the actual acceleration/ deceleration time is below the time specified here. To change the time, enter 1 and then a new value. To use the suggested value, enter 2. MIN_ACCEL TIME Default Value of min_accel time =384(ms) Enter ( 1: Change, 2: No Change ) ?
20
Set the ratio of the motor phase conversion total load inertia to the inertia (rotor inertia ratio). The inertia ratio must be larger than 1 and less than 5. To set no ratio, enter 0. Load
Ratio is Load Inertia ( Kg*cm*s*2*) Motor Inertia (Kg*cm*s*2*) Enter Load ratio ? ( 0:None
21
1 → 5: Valid)
Set the brake number: Enter the number of the brake used for the axis, in the range of 0 to 4. BRAKE Enter
- 1031 -
SETTING Brake Number (0→4)
B.APPENDIX
B-82594EN-4/01
22
Specify whether to enable or disable brake control. To enable it, select “1: Enable” and then the brake control delay time. To disable it, select “2: Disable.” SERVO TIMEOUT Servo Off is Enable Enter (1: Enable 2: Disable) ? Select?
(If 1: Enable is selected) Enter
23
Servo
Off
Time ?
(0.0 → 30.0
Sec)
The system returns to the screen in step 6.
**** Group ? Total Nobot Axis = # 1.Display/Modify Nobot axis 1 → 6 2.Add Nobot axis 3.Delete Nobot axis 4.Exit Select item?
•
To display/change the settings of the independent additional axis board (NOBOT), select 1. Display/Modify Nobot axis. • To set up another axis of the independent additional axis board (NOBOT), select 2. and repeat the procedure starting at step 7. • To delete an axis of the independent additional axis board (NOBOT), select 3. Delete Nobot axis. • To exit from the screen, select 4. Exit, then 0. EXIT. This is the end of the procedure.
- 1032 -
B-82594EN-4/01
C
APPENDIX
C.ALARM CODES
ALARM CODES This part of this manual describes alarm codes, alarm severity, causes, and actions. Contents of this appendix C.1 DESCRIPTION OF AN ALARM CODE TABLE ................1034 C.2 ALARM CODES....................................................................1045
- 1033 -
C.ALARM CODES
C.1
APPENDIX
B-82594EN-4/01
DESCRIPTION OF AN ALARM CODE TABLE Message
Alarm code SRVO-001 SERVO
OPERATING
PANEL
E-stop
Alarm severity
Alarm code
Alarm ID: Alarm type Alarm number Alarm message: Description of the alarm Alarm severity NONE WARN PAUSE.L PAUSE.G STOP.L STOP.G SERVO ABORT.L ABORT.G SERVO 2 SYSTEM Range
Program
Robot
Does not stop.
Does not stop.
Halts.
Decelerates and stops.
Terminates forcibly.
Power to the servo system Not turned off
Stops immediately. Decelerates and stops.
Turned off Not turned off
Stops immediately.
Turned off
Range ----------Local Global Local Global Global Local Global Global Global
Range in which the alarm is applied when multiple programs run simultaneously (multitask function) Local Global
The alarm is applied only to a program which has caused the alarm. The alarm is applied to all programs.
Alarm An alarm is issued when a failure occurs while the program is taught or played back or when the emergency stop signal or another alarm signal is input from a peripheral unit. The alarm is issued to notify the operator of the failure so the operator can halt processing for safety's sake.
NOTE If an alarm whose number is not described herein occurs, contact FANUC Robotics.
- 1034 -
APPENDIX
B-82594EN-4/01
C.ALARM CODES
Alarm codes display or indication When an alarm is issued, the alarm LED lights on the teach pendant and the alarm message is displayed in the first and second line of the screen. The operator can find out which alarm has been issued by looking at the LED and message.
Fig. C.1 (a) Alarm Display
Alarm severity How to operate the program or the robot until the program or the robot stops depends on the seriousness of the cause of the alarm. This "seriousness" is called alarm severity. The degree of alarm severity is indicated as follows:
Alarm severity
Table C.1 (a) Alarm severity Description
WARN alarm
A WARN alarm warns the operator of a comparatively minor or unimportant failure. The WARN alarm does not affect the operation of the robot. When the WARN alarm occurs, no corresponding LED on the teach pendant or the machine operator’s panel lights. To prevent a possible failure, appropriate action should be taken. PAUSE alarm When a PAUSE alarm occurs, the execution of the program is halted, and the operation of the robot is stopped after the operation in progress is completed. Appropriate action must be taken for the alarm before the program is restarted. STOP alarm When a STOP alarm occurs, the execution of the program is halted, and the robot is decelerated until it is stopped. Appropriate action must be taken for the alarm before the program is restarted. SERVO alarm When a SERVO alarm occurs, the power to the servo system is turned off to halt the execution of the program and to stop the robot immediately. A SERVO alarm is issued for safety’s sake or when a failure occurs during robot operation. ABORT alarm When an ABORT alarm occurs, the execution of the program is forcibly terminated, and the robot is decelerated until it is stopped. SERVO 2 alarm When a SERVO 2 alarm occurs, the power to the servo system is turned off to forcibly terminate the program and to stop the robot immediately. A SERVO alarm is issued for safety’s sake or when a failure occurs during robot operation. SYSTEM alarm A SYSTEM alarm is issued when a major system failure occurs. When the SYSTEM alarm is issued, every robot in the system is disabled. After taking appropriate action for the alarm, turn the power off, the turn it on again.
- 1035 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
Alarm screen On the alarm screen, the current alarm is displayed. By pressing the F3 key, it is possible to switch between the alarm occurrence screen and the alarm history screen. In addition, the following alarm screens are provided to narrow down screen display according to alarm type: Motioin alarm screen ...................Displays alarms related to the operation of the robot, such as servo alarms. System alarm screen ....................Displays alarms related to the robot controller, such as the system alarms. Application alarm screen .............Displays application-specific alarms. Comm alarm screen .....................Displays alarms related to communication functions. To display the [Alarm] screen, use the procedure below.
- Procedure Displaying the [Alarm] screen a. Press [MENUS]. b. Press [ALARM]. c. To display the motion alarm history that displays operation-related alarms only, press [F1([TYPE])] and select [Motion Log]. d. To display the system alarm history that displays system-related alarms only, press [F1([TYPE])] and select [System Log]. e. To display the application alarm history that displays application-related alarms only, press [F1([TYPE])] and select [Appl Log]. e. To display the communication alarm history that displays communication-related alarms only, press [F1([TYPE])] and select [Comm Log].
Active alarm screen The active alarm screen displays only active alarm(s). Once the alarms have been eliminated by alarm clear signal input, the active alarm screen reads "THERE ARE NO ACTIVE ALARMS." The screen displays the alarm(s) output after the last alarm clear signal input. When the delete key (+ shift) is pressed on the alarm history screen, the corresponding alarm is cleared from the active alarm screen. The screen shows alarms having a severity level of PAUSE or higher. WARN or NONE alarms or resets are not displayed. Some PAUSE alarms or severer alarms may not be displayed if system variables such as $ER_NOHIS are set accordingly. If multiple alarms are detected, the screen displays the alarms in the opposite order to that in which they were detected. Up to 100 lines can be displayed. If an alarm has a cause code, the cause code is displayed below the alarm display line. - 1036 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
Fig. C.1 (b) Procedure for Displaying the Active Alarm Screen and Alarm History Screen MENU key pressed, then 4 ALARM selected
Alarm key pressed
Automatically displayed when an alarm is output
Active alarm screen displayed F3 [ACTIVE] pressed
F3 [HIST] pressed
Alarm history screen displayed
Automatic alarm display function When an alarm which will cause the system to stop (PAUSE or severer alarm) is detected, the automatic alarm screen display function automatically displays the alarm screen. This function frees the operator of having to display the alarm screen and enables the direct cause of the system failure to be found quickly.
NOTE 1 Once the display requirements are satisfied, the alarm screen is automatically displayed even if an alarm is detected at start-up. The automatic alarm display is performed irrespective of the start mode. 2 If an alarm is detected when a CRT is connected, the alarm screen is displayed on both the teach pendant and the CRT. The requirements for automatic alarm screen display are as described below: • When the flag of the automatic alarm screen display function is set On the system setting screen, select AUTO.DISPLAY OF ALARM MENU to enable or disable the automatic display function. The function is disabled by default. For this change to take effect, the power must be turned off and then on again. -> See Section 3.14. • When the Auto. display of alarm menu flag for an alarm severity level is set $ER_SEV_NOAUTO[] sets whether automatic alarm screen display is enabled or disabled for each alarm severity level. There are seven levels of alarm severity. NONE and WARN alarms will not affect program execution or robot operation and will not instigate the automatic display. Automatic display is enabled for PAUSE and severer alarms by default. The setting can be changed on the system variable screen.
- 1037 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
System variable
Corresponding alarm severity level
Standard setting
$ER_SEV_NOAUTO [1] $ER_SEV_NOAUTO [2] $ER_SEV_NOAUTO [3] $ER_SEV_NOAUTO [4] $ER_SEV_NOAUTO [5]
PAUSE STOP SERVO ABORT SYSTEM
TRUE TRUE TRUE TRUE TRUE
FALSE: Automatic alarm screen display is disabled. TRUE: Automatic alarm screen display is enabled.
NOTE f a PAUSE alarm is detected, followed by an ABORT alarm, when the automatic display of a PAUSE alarm is disabled, automatic display is not performed during fault output. •
Automatic display of a particular alarm can be disabled. The automatic alarm screen display function can be disabled for a particular alarm. Up to ten such alarms can be set on the system variable screen. If a specified alarm is detected while automatic alarm screen display is enabled, the alarm screen will not be automatically displayed. This setting is made with the following system variables:
System variable $ER_NOAUTO. $NOAUTO_ENB
$ER_NOAUTO. $NOAUTO_NUM $ER_NAOUTO. $NOAUTO_CODE [1 to 10]
Description Enables or disables the function to suppress automatic alarm screen display for an alarm specified in $ER_NOAUTO.NOAUTO_CODE[] while the automatic alarm screen display is enabled. • FALSE: The function to suppress automatic alarm screen display is disabled. • TRUE: The function to suppress automatic alarm screen display is enabled. Sets the number of alarms set in $ER_NOAUTO.NOAUTO_CODE[]. Error number consisting of alarm ID and alarm number Example 11 002 (Servo 002 alarm) Alarm ID Alarm number Alarm ID → See Section C.2.
For the alarms listed below, which are caused by a user operation and which cause the system to stop, $ER_NOAUTO.$NOAUTO_ENB is set to TRUE by default. When the setting is changed to FALSE, the corresponding alarm screen is automatically displayed. Servo 001 Servo 002 Servo 003 Servo 004 Servo 005 Servo 012
Operator’s panel emergency stop Teach pendant emergency stop Deadman’s switch Fence open Teach pendant released (mount/unmount button of the teach pendant pressed) Power restoration
When an alarm set in $ER_NOAUTO.$NOAUTO_CODE[] and another alarm are detected in that order while $ER_NOAUTO.$NOAUTO_ENB is set to TRUE, automatic display is not performed. - 1038 -
APPENDIX
B-82594EN-4/01
•
C.ALARM CODES
When fault output is in progress If the alarm screen is automatically displayed each time a PAUSE or severer alarm is detected, the alarm screen may be displayed while alarm recovery or setting check is being performed on another screen. The screens will be frequently switched, which can interfere with recovery and other operations. To prevent this from occurring, automatic display is not performed while an alarm is active. Whether there is an active alarm can be checked by the fault signal output. While the fault signal is output irrespective of the servo start-up, automatic display is not performed even if an alarm is detected.
NOTE 1 When a PAUSE, STOP, or ABORT alarm is detected, the fault signal is output with the servo system started. Each time an alarm clear signal is input, the fault signal is reset. If continuous monitoring is performed to raise an alarm (NO ARC PROCESS I/O BOARD, for instance), automatic alarm display may be performed at each reset input. 2 When a SERVO or SYSTEM alarm is detected, the fault signal is reset after the servo system starts.
Automatic return function The automatic return function displays the screen which was displayed until automatic screen display when an alarm clear signal is input. This function is used together with the automatic display function. The automatic return function operates as described below: • When the automatic alarm screen display function is enabled, the alarm screen is automatically displayed if an alarm is raised. When the alarm is eliminated by the input of an alarm clear signal, the previous screen is automatically displayed. • If the alarm screen is not displayed automatically because of an alarm but displayed by means of menu selection, the previous screen is not displayed even if an alarm clear signal is input. • If another screen is displayed before an alarm clear signal is input, the automatic return function does not operate. • The automatic return function operates when the fault signal output is turned off. • If the power is turned off or on after the alarm screen is displayed by the automatic display function, the automatic return function does not work after the start-up. This is not affected by the start mode (cold start, hot start, etc.).
- 1039 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
Procedure D-1 Displaying the alarm occurrence alarm history/alarm detail information Step 1 Press the MENUS key to display the screen menu. 2 Select "4 ALARM". The alarm occurrence screen is displayed. If an alarm is detected, the active alarm screen is automatically displayed.
3
To display the alarm history screen, press F3 [HIST]. When F3 [ACTIVE] is pressed, the active alarm screen appears again.
NOTE The latest alarm is assigned number 1. To view messages that are currently not on the screen, press the F5, HELP, then press the right arrow key. 4
To display the alarm detail screen, press the F5 "HELP" key.
- 1040 -
APPENDIX
B-82594EN-4/01
C.ALARM CODES
5
To return to the alarm history screen, press the PREV key.
6
To delete all the alarm histories, press and hold down the SHIFT key, then press the F4 "CLEAR" key.
NOTE When system variable $ER_NOHIS = 1, NONE alarms or WARN alarms are not recorded. When $ER_NOHIS=2, resets are not recorded in the alarm history. When $ER_NOHIS=3, resets, WARN alarms, and NONE alarms are not recorded.
- 1041 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
Procedure D-2 Halt caused by a major alarms and recoveries
Halt caused by a major alarm Step 1 When an alarm is issued, the running program is halted, and PAUSED or END is displayed on the screen of the teach pendant. An alarm message is also displayed on the screen of the teach pendant and the ALARM lamp lights.
- Recovery from a deadman switch alarm (SERVO-003) Step 1 Press and hold down the deadman switch, then press the RESET key.
- Eliminating an overtravel alarm (servo 005) Step 1 Press the MENU key to display the screen menu.
2
Press 0 NEXT PAGE, then select 6 SYSTEM on the next page. Press F1 [TYPE], then select OT RELEASE. The OT Release screen appears.
- 1042 -
APPENDIX
B-82594EN-4/01
3 4 5
C.ALARM CODES
Press F2 [RELEASE] to release the overtravel axis. While holding down the shift key, press the alarm clear button. While holding down the shift key, press the jog key to move the tool along the overtravel axis into the movable range.
- Recovery from a broken wrist alarm (SERVO-006) Step 1 Press and hold down the SHIFT key, then press the RESET key.
2
While pressing the SHIFT key, press the appropriate jog key to move the robot to a position where it can be repaired.
- Recovery from a pulse mismatch alarm, a BZAL alarm and a RCAL alarm (SRVO-038, 062, 063) Step 1 Press the MENUS key to display the screen menu.
2
Press "0 -- NEXT --" and then select "6 SYSTEM" on the next page. Press F1 "[TYPE]" and then select "Variables". A system variable screen is displayed.
3
Set TRUE to $MCR.$SPC_RESET. (This system variable is automatically set to FALSE soon again.) Press RESET key to release a alarm.
4
NOTE The mastering data may be correct even if a pulse count mismatch alarm is detected. If the mastering data is correct, mastering need not be performed. Merely set $DMR_GRP.$MASTER_DONE to true, then select 6 MASTER/CAL on the positioning screen. - 1043 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
- Recovery from other alarms Step 1 Remove the cause of an alarm. For example, correct the program. 2 Press the RESET key to reset the alarm. Then, the alarm message disappears on the screen of the teach pendant. The ALARM LED goes off.
- 1044 -
APPENDIX
B-82594EN-4/01
C.2
C.ALARM CODES
ALARM CODES
SRVO Error Codes ( ID = 11 ) SRVO-001 SERVO Operator panel E-stop [Cause] The EMERGENCY STOP button on the operator panel or operation box was pressed. [Remedy] 1. Twist the operator panel EMERGENCY STOP button clockwise to release it, then press RESET. 2. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-002 SERVO Teach pendant E-stop [Cause] The EMERGENCY STOP button on the teach pendant was pressed. [Remedy] 1. Twist the teach pendant EMERGENCY STOP button clockwise to release it, then press RESET. 2. If this alarm cannot be reset, replace the teach pendant. SRVO-003 SERVO Deadman switch released [Cause] The deadman switch was not pressed when the teach pendant was enabled. [Remedy] 1. Press the deadman switch to release it, then press RESET. If the deadman switch is three position switch type, press the deadman switch to middle position to release it, then press RESET. 2. If this alarm cannot be reset, replace the teach pendant. SRVO-004 SERVO Fence open [Cause] The safety door or fence is opened. [Remedy] 1. Close the safe fence after checking that a worker is not inside a safe fence, then press RESET. 2. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-005 SERVO Robot overtravel [Cause] A hardware limit switch on an axis was tripped. Usually, the movement of the robot is prevented from exceeding a limit beyond the maximum range of movement (software limits) for each axis. However, when the robot is shipped, the overtravel state is set for transit. [Remedy] 1. Hold down the shift key, and press RESET to reset the alarm. 2. Still hold down the shift key, and jog to bring all axes into the movable range. 3. If this alarm cannot be reset, Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. NOTE 1 The direction of jog of each axis is limited until the alarm is released. It cannot
jog to the direction where the axis moved when the alarm is occurred. 2 In the robot calibration incomplete status, you can release the above note1 limitation with the overtravel release screen [System / OT release]. SRVO-006 SERVO Hand broken [Cause] A safety hand has broken. If no broken hand can be found, however, the most likely cause is the HBK signal of a robot connection cable being at the 0V level. [Remedy] 1. Hold down the shift key, and press RESET to reset the alarm.
- 1045 -
C.ALARM CODES 2.
3.
APPENDIX
B-82594EN-4/01
While holding down the shift key, position the tool to the workplace by performing jog feed. Replace the safety hand or check the safety joint cable. If the Hand broken signal is not in use, it can be disabled in the system config screen / Hand broken setting. After measures, hold down the shift key, and press RESET. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”.
SRVO-007 SERVO External emergency stops [Cause] The external emergency stop push button is pressed. [Remedy] 1. If using external emergency stop, clear source of fault and press RESET. 2. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-009 SERVO Pneumatic pressure alarm [Cause] The pneumatic pressure alarm indicates the presence of a defect. If the pneumatic pressure alarm is not detected, however, the most likely cause is the PPABN signal of a robot connection cable being at the 0V level. [Remedy] 1. Repair the pneumatic pressure or check the cable. 2. If the pneumatic pressure signal is not in use, it can be disabled in the system config screen. 3. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-010 SERVO Belt broken [Cause] The belt broken robot digital input is asserted. [Remedy] 1. If the belt is found to be defective in any way, repair it and then press the reset key. 2. When the belt is found to be normal, signal RDI [7] in the robot connection cable may be abnormal. Check the cable. NOTE
In the robot series whose system variable($PARAM_GROUP.$BELT_ENABLE) is TRUE, this alarm is detected. SRVO-011 SERVO TP released while enabled [Cause] The teach pendant attachment switch on the operator’s panel was operated while the teach pendant was enabled. [Remedy] Reconnect the teach pendant cable to continue operation with the teach pendant is disabled. SRVO-012 SERVO Power failure recovery [Cause] Normal power on (hot start). [Remedy] This is just a notification. No action is needed for this message. SRVO-014 SERVO Fan motor abnormal(%d),CPU STOP [Cause] A fan motor in the control unit is abnormal. Number in the bracket indicates which fan is abnormal. (1) : fan above the slot1 (2) : fan above the slot2 (3) : both fans [Remedy] Check the fan motors and fan motor connection cables. Replace any faulty fan motor(s). Refer to the Controller Maintenance Manual, “Troubleshooting using the error code” for more details.
- 1046 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
NOTE
After this alarm occurred, robot will stop in one minute and teach pendant will not be operated. Because temperature of CPU will rise if fan stops, all process of CPU will be restricted to prevent mal-function or failure of CPU. SRVO-015 SERVO System over heat [Cause] The temperature of the control unit is higher than the specified value. [Remedy] 1. If the ambient temperature is higher than the specified temperature (45℃), provide ventilation to reduce the ambient temperature to the specified value. 2. Check that the fans are operating normally. If not, check the fan motors and fan motor connection cables. Replace any faulty fan motor(s) and/or cable(s). 3. If the thermostat on the main board is faulty, replace the main board. You have to save the all files to memory card or any such devices before this operation.
- 1047 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SRVO-018 SERVO Brake abnormal [Cause] The current for brake exceeded the specification. [Remedy] There is possibility that robot connection cable may short. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-021 SERVO SRDY off (Group:%d Axis:%d) [Cause] The ready signal of the servo amplifier corresponding to displayed group and axis was turned off. [Remedy] 1. Refer to those cause/measures when the alarm history is confirmed and other alarms are occurred at the same time. 2. If this alarm is occurred after add axis or modification of axis’s setup, confirm whether a set content is correct. And the mistake is found, modify it. Especially, confirm whether to find the mistake in the hardware start axis number, the amplifier number, and the amplifier type. 3. Confirm the setting of the machine lock for the multi group. - Advance to measures 4 when all motion groups machine lock are released. - Release the machine lock of the robot when the robot (six axis amplifier) is a machine lock. Note: When six axis amplifier is made a machine lock, the amplifier subordinate to this turns off and SRDY is turned off. - In the multi axis amplifier case, set the machine lock the same value with the axes allocated to this amplifier mutually. For instance, when G2-J1 and G3-J1 are allocated to a common two-axis amplifier, the setting of the machine lock of G2 and G3 should be the same. 4. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. About auxiliary axis, refer to the Auxiliary Axis Option Maintenance Manual. NOTE 1 When six axis amplifier is made a machine lock, the amplifier subordinate to
this turns off and SRDY is turned off. 2 There is a possibility when the specification of the teach pendant is not correct compared with the controller. For instance, when the teach pendant of the RIA/CE specification is used in the controller of non-RIA/CE specification, this alarm might occur. Connect the correct teach pendant corresponding to the controller. SRVO-022 SERVO SRDY on (Group:%d Axis:%d) [Cause] SRDY was already on when an attempt was made to turn on the MCC with HRDY. (HRDY is the signal sent from the host to the servo system to specify whether to turn the servo amplifier’s MCC on or off. SRDY is the signal sent from the servo system to the host to indicate whether a servo amplifier’s MCC is on or off.) [Remedy] 1. Replace the servo amplifier applicable to the alarm message. 2. Replace the servo card module or the auxiliary axis board applicable to the alarm message. SRVO-023 SERVO Stop error excess(G:%d A:%d) [Cause] When the robot stopped, the servo positional error exceeded a specified value ($PARAM_GROUP.$STOPERLIM). This alarm means that the robot cannot reach a taught point or cannot keep a taught posture. Probable cause: 1. Overload 2. External force to the robot - 1048 -
APPENDIX
B-82594EN-4/01
3. 4. 5. 6. 7. 8. 9. 10. [Remedy] 1. 2. 3. 4. 5. 6. 7. 8. 9.
C.ALARM CODES
Disconnection or misconnection of the motor power cable or brake cable Incorrect setup for the robot which has 2 axis brake option Insufficient torque by low voltage of power supply Brake failure (includes mis-setting of brake number for auxiliary axis) Aux. brake unit failure for aux. axis Amplifier failure Motor failure Motor power cable or brake cable failure Check whether the duty and applied load exceed the rating. If so, reduce the duty or applied load. Check whether the robot is pushed or pulled by external force. If so, remove the external force to the robot or modify the taught point. Check whether the power line of the robot connection cable or the cable in the mechanical unit are down. Check whether the motor power cable/connector and brake cable/connector are connected correctly. Especially, check whether the power cable/connector aren’t connected to other motors. Check whether the robot setup (setting of 2BK or 6BK) is correct, if used robot has 2BK option. Measure the supplied voltage. Then, check whether the voltage is matched to the controller specification. Check whether the motor brake is released properly when Reset or the robot moves. First of all, check whether the setting of brake number is correct when this alarm occurs on auxiliary axis When this alarm occurs on the auxiliary axis which brake is controlled by the aux. brake unit, check the fuse on the aux. brake unit. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. About auxiliary axis, refer to the Auxiliary Axis Option Maintenance Manual.
SRVO-024 SERVO Move error excess(G:%d A:%d) [Cause] When the robot moved, the servo positional error exceeded a specified value ($PARAM_GROUP.$MOVER_OFFST). This alarm means that the excessive path deviation occurs. Probable cause: Same as described above (SRVO-023) [Remedy] Perform the same action as that described for the previous item (SRVO-023). However, it doesn't relate to the brake option setting in this case. SRVO-025 SERVO Motn dt overflow (G:%d A:%d) [Cause] Motion command is too large. [Remedy] 1. Perform a cold start : - Turn off the robot. - On the teach pendant, press and hold the SHIFT and RESET keys. - While still pressing the SHIFT and RESET keys, turn on the robot. 2. If the error is not cleared, document the events that led to the error. SRVO-026 WARN Motor speed limit(G:%d A:%d) [Cause] An attempt was made to exceed the maximum rated motor speed ($PARAM_GROUP.$MOT_SPD_LIM). The motor speed is clamped to its maximum rated value. No action is needed for this warning message.
- 1049 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SRVO-027 WARN Robot not mastered(Group:%d) [Cause] An attempt was made to perform calibration, but mastering has not yet been completed. [Remedy] Perform mastering from the calibration screen [6 SYSTEM Master/Cal]. SRVO-030 SERVO Brake on hold (Group:%d) [Cause] When the Brake on hold function is enabled, this alarm is issued whenever a hold signal is input. [Remedy] 1. This is just a notification. You do not have to do anything for this message. 2. If you do not use this function, disable [Brake on hold] on the general item setting screen [6 SETUP General] and do power cycle. SRVO-031 SERVO User servo alarm (Group:%d) [Cause] A user servo alarm was issued. This alarm is occurred when system variable $MCR_GRP[i].$SOFT_ALARM is set to TRUE. [Remedy] Confirm the cause of making above-mentioned system variable TRUE and do measures. SRVO-033 WARN Robot not calibrated(Grp:%d) [Cause] An attempt was made to set a reference point for quick mastering, but calibration has not yet been completed. [Remedy] Perform calibration by following the procedure below. 1. Turn on the power. 2. Execute [CALIBRATION] from the calibration screen [6 SYSTEM Master/Cal]. SRVO-034 WARN Ref pos not set (Group:%d) [Cause] An attempt was made to perform quick mastering, but a required reference point has not yet been set. [Remedy] Set a reference point for simple mastering from the calibration screen. SRVO-035 WARN Joint speed limit(G:%d A:%d) [Cause] An attempt was made to exceed the maximum joint speed ($PARAM_GROUP.$JNTVELLIM). The joint speed is clamped to its maximum rated value. No action is needed for this warning message. SRVO-036 SERVO Inpos time over (G:%d A:%d) [Cause] The in-position monitor time ($PARAM_GROUP.$IMPOS_TIME) has elapsed, but the robot cannot reach a taught point within the specified in-position ($PARAM_GROUP.$STOPTOL). [Remedy] Perform the same action as that described for SRVO-023 (Stop error excess). SRVO-037 SERVO IMSTP input (Group:%d) [Cause] The *IMSTP signal, which is a peripheral device I/O signal, is OFF. [Remedy] Turn on the *IMSTP signal. SRVO-038 SERVO2 Pulse mismatch (G:%d A:%d) [Cause] A pulse count detected at power-on differs from one detected at power-off. The following are thought. 1. File (SYSMAST.SV) that saved in the state at an axis position different from a present axis position was loaded. 2. Software brake setting is wrong. 3. A wrong brake type was set to the robot with two-axis brake option. 4. File (SYSMAST.SV) that saved with other robots was loaded. - 1050 -
APPENDIX
B-82594EN-4/01
5. 6. [Remedy] 1. 2.
C.ALARM CODES
The axis position was changed with a brake release unit while the controller power is off. The axis fell while the controller power is off due to the brake trouble. Refer SRVO-222 when occurring with SRVO-222. For the above cause 2 and 3, confirm the setup or brake type setting and correct setting. For the above cause 4, re-load SYSMAST.SV of the robot. Afterwards, PULSE RESET operation should be done. There are the following two methods. Method 1: Move the cursor to $MCR.$SPC_RESET on the system variable screen, and select F4 TRUE. It becomes TRUE momentarily, it writes in FALSE at once. Then push the reset button. Method 2: F3 RES_PCA is pushed on the MASTER/CAL screen, and select F4 YES. Then push the alarm release button. Check whether the robot position on Teach Pendant is correct. If incorrect, re-mastering is required.
NOTE
The MASTER/CAL screen is not usually displayed. The worker who has the operation qualification does. SRVO-040 WARN Mastered at mark pos(G:%d) [Cause] Zero position master is done with mark position (not with zero position). No action is needed for this warning message. SRVO-041 SERVO2 MOFAL alarm (Grp:%d Ax:%d) [Cause] A value of the internal motion command is too big. [Remedy] Document the events that led to the error, and contact your FANUC technical representative. SRVO-043 SERVO DCAL alarm(Group:%d Axis:%d) [Cause] The energy produced by regenerative discharge is excessive. As a result, all the generated energy cannot be dissipated as heat. [Remedy] 1. This alarm may occur if the axis is subjected to frequent acceleration/deceleration or if the axis is vertical and generates a large amount of regenerative energy. If this alarm has occurred, relax the conditions. 2. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-044 SERVO HVAL alarm(Group:%d Axis:%d) [Cause] The DC voltage (DC link voltage) of the main circuit power supply is abnormally high. [Remedy] Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-045 SERVO HCAL alarm(Group:%d Axis:%d) [Cause] An excessively high current flowed through the main circuit of the servo amplifier. [Remedy] Turn off the controller power, and disconnect the power cable from the servo amplifier indicated by the alarm message. Also disconnect the brake cable to avoid the axis falling unexpectedly. 1. In the above condition, supply controller power again and check if this alarm occurs again. If this alarm occurs again, replace the servo amplifier. 2. About the power cable, check the insulation of their U, V, W and the GND lines each other. If there is a short-circuit, replace the power cable. 3. About the power cable, measure the resistance between their U and V,V and W and W and U with an ohmmeter that has a very low resistance range. If the resistances at the - 1051 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
three places are different from each other, the motor, the power cable is defective. Check each item in detail and replace it if necessary. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code” for more details. About auxiliary axis, refer to the Auxiliary Axis Option Maintenance Manual. SRVO-046 SERVO2 OVC alarm (Group:%d Axis:%d) [Cause] The root-mean-square current value which is calculated internally by the servo system exceeds the maximum permissible value. This alarm is issued to protect the motor and amplifier from a damage of thermal destruction. Probable cause: 1. Overload 2. External force to the robot 3. Disconnection of the brake cable 4. Insufficient torque by low voltage of power supply 5. Brake failure (includes mis-setting of brake number for auxiliary axis) 6. Aux. brake unit failure for aux. axis 7. Amplifier failure 8. Motor failure 9. Motor power cable or brake cable failure [Remedy] 1. Check whether the duty and applied load exceed the rating. If so, reduce the duty or applied load. 2. Check whether the robot is pushed or pulled by external force. If so, remove the external force to the robot or modify the taught point. 3. Check whether the brake cable/connector are connected correctly. 4. Measure the supplied voltage. Then, check whether the voltage is matched to the controller specification. 5. Check whether the motor brake is released properly when Reset or the robot moves. First of all, check whether the setting of brake number is correct when this alarm occurs on auxiliary axis 6. When this alarm occurs on the auxiliary axis which brake is controlled by the aux. brake unit, check the fuse on the aux. brake unit. 7. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. About auxiliary axis, refer to the Auxiliary Axis Option Maintenance Manual. SRVO-047 SERVO LVAL alarm(Group:%d Axis:%d) [Cause] The control power supply voltage to servo amplifier is excessively low. [Remedy] There is possibility the troubles of the servo amplifier and/or the power supply unit. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. About auxiliary axis, refer to the Auxiliary Axis Option Maintenance Manual. SRVO-049 SERVO OHAL1 alarm (Grp:%d Ax:%d) [Cause] The thermostat in the transfer worked. Alternatively, the fuse in the servo amplifier has blown. [Remedy] Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-050 SERVO Collision Detect alarm (G:%d A:%d) [Cause] A collision was detected. (An excessively large disturbance torque was estimated by the servo software.) Probable cause are: 1. Collision (Tip stick) / External force to the robot 2. Overload / Heavy acceleration 3. Increasing of the friction by low temperature - 1052 -
APPENDIX
B-82594EN-4/01
4. 5. 6. 7. 8. 9. 10. 11. [Remedy] 1. 2. 3.
4. 5. 6. 7. 8. 9.
C.ALARM CODES
Insufficient torque by low voltage of power supply Brake failure (includes mis-setting of brake number for auxiliary axis) Aux. brake unit failure for aux. axis Amplifier failure Emergency stop unit failure Motor failure Motor power cable or brake cable failure Reducer failure Check whether the robot has collided with an object. To release this alarm, press and hold the SHIFT and RESET keys. Release only RESET key. Still pressing the SHIFT key, and press any jog key to the axis away from the collision. Check whether the payload (mass, center of gravity, and inertia) are set correctly. Check whether the applied load exceed the rating. If so, reduce the applied load. If you use the “ACC” override more than 100, please reduce the value of ACC override. Allowable disturbance threshold level can be changed from STATUS/Axis/Disturb screen. If this alarm occurs when the robot is used after long time interval or when the temperature is very low, run the robot with low speed for a while before running with normal speed. Check whether the motor power cable/connector and brake cable/connector are connected correctly. Especially, check whether the power cable/connector aren’t connected to other motors. Measure the supplied voltage. Then, check whether the voltage is matched to the controller specification. Check whether the motor brake is released properly when Reset or the robot moves. First of all, check whether the setting of brake number is correct when this alarm occurs on auxiliary axis When this alarm occurs on the auxiliary axis which brake is controlled by the aux. brake unit, check the fuse on the aux. brake unit. There might be a failure with the following parts. Replace it or document the events that led to the error, and contact your FANUC technical representative. - Aux. brake unit (if it is used.) - Servo amplifier - Servo motor - Robot connection cable (power/brake line) - Cable in the mechanical unit (power/brake line) - Reducer
SRVO-051 SERVO2 CUER alarm(Group:%d Axis:%d) [Cause] The offset of current feedback value is excessively large. Current detection circuit failure in the amplifier [Remedy] Replace the servo amplifier. SRVO-053 WARN Disturbance excess(G:%d A:%d) [Cause] Disturbance estimated in the software exceeds the threshold value. There is possibility that SRVO-050 occurs when the robot runs leaving this warning. [Remedy] 1. Check whether the payload (mass, center of gravity, and inertia) are set correctly. 2. Check whether the applied load exceed the rating. If so, reduce the applied load. 3. If this alarm occurs when the robot is used after long time interval or when the temperature is very low, run the robot with low speed for a while before running with normal speed.
- 1053 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SRVO-055 SERVO2 FSSB com error 1 (G:%d A:%d) [Cause] A communication error has occurred between the main board and servo amplifier. (from main board to servo amplifier.) [Remedy] Troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. About auxiliary axis, refer to the Auxiliary Axis Option Maintenance Manual. SRVO-056 SERVO2 FSSB com error 2 (G:%d A:%d) [Cause] A communication error has occurred between the main board and servo amplifier. (from servo amplifier to main board.) [Remedy] Troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. About auxiliary axis, refer to the Auxiliary Axis Option Maintenance Manual. SRVO-057 SERVO2 FSSB disconnect (G:%d A:%d) [Cause] Communication was interrupted between the main board and servo amplifier. [Remedy] Troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. About auxiliary axis, refer to the Auxiliary Axis Option Maintenance Manual. SRVO-058 SYSTEM FSSB %d init error (%d) [Cause] FSSB initializing is failed. [Remedy] Troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. When you contact your FANUC technical representative, document the number in the alarm message. NOTE
Need power cycle to release this alarm. SRVO-059 SYSTEM Servo amp init error [Cause] Servo amplifier initializing is failed. [Remedy] Check the servo amplifier and its wiring. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code” for more details. NOTE
Need power cycle to release this alarm. SRVO-062 SERVO2 BZAL alarm(Group:%d Axis:%d) [Cause] This alarm is issued when the battery for backing up the absolute position data of the pulse coder is not connected or empty. The battery cable inside the robot may have become disconnected When it occurs, even a new battery. [Remedy] Correct the cause of the alarm, then turn on the power again after doing PULSE RESET operation. Mastering is required. There are the following two methods for PULSE RESET. Method 1: Move the cursor to $MCR.$SPC_RESET on the system variable screen, and select F4 TRUE. It becomes TRUE momentarily, it writes in FALSE at once. Then push the reset button. Method 2: F3 RES_PCA is pushed on the MASTER/CAL screen, and select F4 YES. Then push the alarm release button. NOTE
The MASTER/CAL screen is not usually displayed. The worker who has the operation qualification does.
- 1054 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SRVO-064 SERVO2 PHAL alarm(Group:%d Axis:%d) [Cause] This alarm is issued when the phase of a pulse signal generated by the pulse coder is abnormal. [Remedy] Replace the pulse coder. After replacing, perform mastering. NOTE
If this alarm occurs along with a SRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070 STBERR, disregard this alarm and refer to the other three alarm remedies. SRVO-065 WARN BLAL alarm(Group:%d Axis:%d) [Cause] The battery voltage for the pulse coder has dropped below the allowable minimum. [Remedy] Replace the battery. NOTE
When this alarm is issued, immediately replace the battery while the system power is turned on. If the BZAL alarm is issued because the battery is not replaced in time, position data will be lost, thus necessitating robot mastering. SRVO-067 SERVO2 OHAL2 alarm (Grp:%d Ax:%d) [Cause] The temperature inside the pulse coder has become too high, causing the built-in thermostat to actuate. [Remedy] 1. Check the operating conditions of the robot. If any of the rating specified for the robot, such as its rated duty cycle or load, are exceeded, modify the use of the robot such that the ratings are not exceeded. 2. If this alarm is issued, even when the power is turned on and the motor has not overheated, replace the motor. SRVO-068 SERVO2 DTERR alarm (Grp:%d Ax:%d) [Cause] A request signal was sent to the serial pulse coder, but no serial data was returned. [Remedy] Refer to the SRVO-070 Remedy. SRVO-069 SERVO2 CRCERR alarm (Grp:%d Ax:%d) [Cause] Serial data changed during transfer. [Remedy] Refer to the SRVO-070 Remedy. SRVO-070 SERVO2 STBERR alarm (Grp:%d Ax:%d) [Cause] A serial data start bit or stop bit error occurred. [Remedy] 1. Check the connection of the cable between the pulse coder and servo amplifier.(If the alarm is occurred at robot axes, check the connection of the robot interconnection cable (for the pulse coder)). 2. Check the shielding of the above cable is connected securely to the grounding plate. 3. Replace the pulse coder. 4. Replace the servo amplifier. 5. Replace the robot interconnection cable (for the pulse coder). SRVO-071 SERVO2 SPHAL alarm (Grp:%d Ax:%d) [Cause] The excessively large feedback speed was detected. [Remedy] 1. This alarm does not indicate the main cause of the problem if issued together with the PHAL alarm (SRVO-064). 2. It might be mis-detection by the noise. Check whether the ground/shield is connected correctly. If possible, enhance the ground/shield. 3. Replace the pulse coder of the motor. Mastering is required. - 1055 -
C.ALARM CODES 4. 5. 6.
APPENDIX
B-82594EN-4/01
Replace the servo amplifier Replace the robot connection cable Replace the cable in the mechanical unit
SRVO-072 SERVO2 PMAL alarm(Group:%d Axis:%d) [Cause] The pulse coder may be faulty. [Remedy] Replace the pulse coder, then perform mastering. SRVO-073 SERVO2 CMAL alarm(Group:%d Axis:%d) [Cause] The pulse coder may be faulty, or noise may be causing the pulse coder to malfunction. [Remedy] 1. Improve the shielding. 2. Replace the pulse coder, then perform mastering. SRVO-074 SERVO2 LDAL alarm(Group:%d Axis:%d) [Cause] The LED on the pulse coder has become disconnected. [Remedy] Replace the pulse coder, then perform mastering. SRVO-075 WARN Pulse not established(G:%d A:%d) [Cause] The absolute position of the pulse coder has not yet been established. This alarm appears normally after SRVO-062 BZAL or SRVO-073 CMAL. [Remedy] Reset the alarm, and jog the axis on which the alarm has occurred until the same alarm does not occur again. (Jog one motor revolution). This alarm must be cleared before the mastering. SRVO-076 SERVO Tip Stick Detection(G:%d A:%d) [Cause] An excessive disturbance was calculated in the servo software at the beginning of motion. (An abnormal load was detected. The cause may be welding.) [Remedy] Perform the same action as that described for SRVO-050 (CLALM alarm). NOTE
The threshold level for the tip stick detection cannot be changed from STATUS/Axis/Disturb screen. SRVO-078 SERVO Servo param update(G:%d A:%d) [Cause] Servo parameter has been updated. [Remedy] Press reset button. SRVO-081 WARN EROFL alarm (Track enc:%d) [Cause] The pulse count for the line tracking encoder (incremental pulse coder) has overflowed. [Remedy] 1. Reduce the encoder speed (conveyor speed). 2. Replace the incremental pulse coder for the line tracking. 3. Replace the line tracking cable. 4. Replace the line tracking I/F board. SRVO-082 WARN DAL alarm(Track encoder:%d) [Cause] The line tracking pulse coder has not been connected. [Remedy] 1. Check the connection cable at each end (the line tracking I/F board and the pulse coder) 2. Check whether the shielding of the connection cable is connected securely to the grounding plate. 3. Replace the line tracking cable. 4. Replace the pulse coder. 5. Replace the line tracking I/F board. - 1056 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SRVO-084 WARN BZAL alarm (Track enc:%d) [Cause] This alarm is issued when the battery for backing up the absolute position data for the pulse coder is not connected. [Remedy] See the description for SRVO-062 BZAL alarm. SRVO-086 WARN PHAL alarm (Track enc:%d) [Cause] This alarm is issued when the phase of a pulse signal generated by the pulse coder is abnormal. [Remedy] See the description for SRVO-064 PHAL alarm. SRVO-087 WARN BLAL alarm (Track enc:%d) [Cause] This alarm is issued when the battery voltage for backing up the absolute position data of the pulse coder has dropped below the allowable minimum. [Remedy] See the description for SRVO-065 BLAL alarm. SRVO-089 WARN OHAL2 alarm (Track enc:%d) [Cause] The motor has overheated. [Remedy] See the description for SRVO-067 OHAL2 alarm. SRVO-090 WARN DTERR alarm (Track enc:%d) [Cause] An error occurred during communication between the pulse coder and the line tracking I/F board. [Remedy] 1. Check the connection cable at each end (the line tracking I/F board and the pulse coder) 2. Check whether the shielding of the connection cable is connected securely to the grounding plate. 3. Replace the line tracking cable. 4. Replace the pulse coder. 5. Replace the line tracking I/F board. SRVO-091 WARN CRCERR alarm (Track enc:%d) [Cause] An error occurred during communication between the pulse coder and the line tracking I/F board. [Remedy] 1. Check the connection cable at each end (the line tracking I/F board and the pulse coder) 2. Check whether the shielding of the connection cable is connected securely to the grounding plate. 3. Replace the line tracking cable. 4. Replace the pulse coder. 5. Replace the line tracking I/F board. SRVO-092 WARN STBERR alarm (Track enc:%d) [Cause] An error occurred during communication between the pulse coder and the line tracking I/F board. [Remedy] 1. Check the connection cable at each end (the line tracking I/F board and the pulse coder) 2. Check whether the shielding of the connection cable is connected securely to the grounding plate. 3. Replace the line tracking cable. 4. Replace the pulse coder. 5. Replace the line tracking I/F board.
- 1057 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SRVO-093 WARN SPHAL alarm (Track enc:%d) [Cause] An excessive speed was detected with the line tracking encoder. [Remedy] 1. This alarm does not indicate the main cause of the problem if issued together with the PHAL alarm (SRVO-086). Refer to SRVO-086. 2. Reduce the encoder speed (conveyor speed). 3. Check whether the shield of the line tracking cable is connected to earth bar in the controller. 4. Replace the absolute pulse coder for the line tracking. 5. Replace the line tracking cable. 6. Replace the line tracking I/F board. SRVO-094 WARN PMAL alarm (Track enc:%d) [Cause] The pulse coder may be faulty. [Remedy] See the description for Servo- 072 PMAL alarm. SRVO-095 WARN CMAL alarm (Track enc:%d) [Cause] It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. [Remedy] 1. Reinforce the earth of the flange of the motor. 2. Replace the pulse coder. SRVO-096 WARN LDAL alarm (Track enc:%d) [Cause] The LED on the pulse coder has become disconnected. [Remedy] See the description for SRVO-074 LDAL alarm. SRVO-097 WARN Pulse not established(Enc:%d) [Cause] The absolute position of the pulse coder has not yet been established. [Remedy] See the description for SRVO-075 Pulse not established. SRVO-101 SERVO Robot overtravel(Robot:%d) [Cause] A Robot overtravel limit switch has pressed. [Remedy] Refer to SRVO-005. SRVO-102 SERVO Hand broken (Robot:%d) [Cause] The hand broken (*HBK) robot input is asserted. [Remedy] Refer to SRVO-006. SRVO-103 SERVO Air pressure alarm(Rbt:%d) [Cause] The pneumatic pressure (PPABN) robot input is asserted. [Remedy] Refer to SRVO-009. SRVO-105 SERVO Door open or E.Stop SRVO-106 SERVO Door open/E.Stop(Robot:%d) [Cause] 1. Controller door is opened or E.stop signals are detected for a quite short time. 2. The specification of the teach pendant is not correct compared with the controller or the controller hardware trouble [Remedy] 1. Close controller door. And press RESET. 2. Check the specification of the teach pendant is not correct compared with the controller. For instance, the teach pendant of the RIA/CE specification is used in the controller of non-RIA/CE specification, this alarm might occur. Connect the teach pendant corresponding to the controller.
- 1058 -
APPENDIX
B-82594EN-4/01
3.
C.ALARM CODES
Troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”.
SRVO-108 SERVO Press RESET to enable robot [Cause] When the enable/disable switch is set to “Enable,” it is necessary to press a reset. [Remedy] To enable the robot, press the reset key. SRVO-111 SERVO Softfloat time out(G:%d) [Cause] Follow-up time is over when softfloat is OFF. (When $SFLT_ERRTYP=0) [Remedy] 1. Check whether external force is not applied to the robot before the softfloat is turned on. 2. Check whether the robot does not move as posture greatly changes during softfloat. 3. If needed, make $SFLT_FUPTIM larger. SRVO-112 PAUSE Softfloat time out(G:%d) [Cause] Follow-up time is over when softfloat is OFF. (When $SFLT_ERRTYP=1) [Remedy] Perform the same action as that described for above item (SRVO-111). SRVO-121 SERVO Excessive acc/dec time(G:%d) [Cause] Acceleration time is much longer. [Remedy] Document the events that led to the error, and contact your FANUC technical representative. SRVO-122 SERVO Bad last ang(internal)(G:%d) [Cause] Last angle update request does not match current angle. [Remedy] Document the events that led to the error, and contact your FANUC technical representative. SRVO-125 WARN Quick stop speed over (G:%d) [Cause] The quick stop speed is too much high. [Remedy] Reduce the speed when a quick stop is executed. SRVO-126 SERVO Quick stop error (G:%d) [Cause] Program was over in process of quick stop. [Remedy] Press reset. SRVO-131 SERVO LVAL(PSM) alarm(G:%d A:%d) [Cause] The control power supply voltage on the power supply module is abnormally low. [Remedy] 1. Check the input power supply. 2. Replace the power supply module. SRVO-133 SERVO FSAL(PSM) alarm (G:%d A:%d) [Cause] Cooling fan for Control circuit of the power supply module stops. [Remedy] 1. Check the status of the cooling fan. And replace it if it was abnormal. 2. Replace the power supply module. SRVO-134 SERVO DCLVAL(PSM) alarm (G:%d A:%d) [Cause] The DC voltage (DC link voltage) of the main circuit power supply on the power supply module is abnormally low. [Remedy] Check the phase voltage of the three–phase input to the power supply module. Refer to the R-J3iB Mate CONTROLLER MAINTENACE MANUAL for more details.
- 1059 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SRVO-135 SERVO FSAL alarm (G:%d A:%d) [Cause] Cooling fan for Control circuit stops. [Remedy] 1. Replace the internal fan motor of the auxiliary servo amplifier that is indicated by the alarm message. 2. Replace the servo amplifier that is indicated by the alarm message. SRVO-136 SERVO DCLVAL alarm (G:%d A:%d) [Cause] The servo amplifier DC current (DC link voltage) is abnormally low. [Remedy] – This alarm occurred when robot is moving. 1. Check the input voltage to the controller is within the rated voltage and no phase is lack. And check the setting of the transformer is correct. 2. It is possible that an instant disconnection of power source causes this alarm. Check whether an instant disconnection occurred. 3. Replace the E–stop unit. 4. Replace the servo amplifier. – If this alarm occurred before the magnetic contactor is turned on : 1. Check whether the circuit breaker in the emergency stop unit is OFF. If it is OFF, check the servo amplifier and the wiring between the servo amplifier and the emergency stop unit. If anything is abnormal, replace it. Else turn on the breaker. 2. Check the input voltage to the controller is within the rated voltage and no phase is lack. And check the setting of the transformer is correct.. 3. Replace the E–stop unit. 4. Replace the servo amplifier. – In auxiliary axis system and If this alarm occurred right after pushing emergency stop button. 1. Check whether the auxiliary axis unit is installed correctly. About auxiliary axis, refer to the Auxiliary Axis Option Maintenance Manual. SRVO-138 SERVO SDAL alarm (G:%d A:%d) [Cause] A pulse coder signal error was detected by the software. The probable cause is noise or a failure (disconnection) in the pulse coder internal circuit. [Remedy] 1. If a normal operation can be resumed by turning the controller power off and on again, it is likely that the cause is noise. Enhance the shielding of the pulse coder cable. 2. If a normal operation cannot be resumed by cycle power, the pulse coder is defective. Replace it, and perform mastering. SRVO-156 SERVO IPMAL alarm (G:%d A:%d) [Cause] Abnormally high current flowed through the main circuit of the servo amplifier. [Remedy] Refer to the remedy of SRVO-045. SRVO-157 SERVO CHGAL alarm (G:%d A:%d) [Cause] Charge of the capacitor of DC link voltage on the servo amplifier could not finish within specified time. [Remedy] 1. Replace the emergency stop unit. 2. Replace the servo amplifier. 3. Replace the auxiliary axis amplifier if in auxiliary axis system.
- 1060 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SRVO-171 WARN MotorSpd lim/DVC(G:%d A:%d) [Cause] Motor can not rotate as fast as the calculated speed required for the current motion. [Remedy] This is just a notification. No action is needed for this warning message. SRVO-179 WARN Motor torque limit(G:%d A:%d) [Cause] The torque of the axis has exceeded the limit. [Remedy] This is just a notification. No action is needed for this warning message. SRVO-182 PAUSE Needed init. has not been done [Cause] This is an error internal to the system. A system variable or internal work memory has not been initialized normally. [Remedy] 1. Turn the power off and on again. 2. If the alarm is still issued, document the events that led to the error, and contact your FANUC technical representative. SRVO-183 PAUSE ROBOT isn't ready [Cause] Servo is off. [Remedy] Remove the factor that turned servo off, and press the reset button. SRVO-184 PAUSE Other task is processing [Cause] The data area that this instruction tried to use had been locked by another task. [Remedy] 1. If this alarm is occurred when the Payload Estimation is restarted, execute the Payload Estimation after it waits for a while. 2. Execute the Payload Estimation after power cycle. 3. If the alarm is still issued, document the events that led to the error, and contact your FANUC technical representative. SRVO-185 PAUSE Data is for other group [Cause] This is an error internal to the system. [Remedy] 1. Execute the Payload Estimation after power cycle. 2. If the alarm is still issued, document the events that led to the error, and contact your FANUC technical representative. SRVO-186 PAUSE Needed Data has not been got [Cause] This is an error internal to the system. [Remedy] 1. Execute the Payload Estimation after power cycle. 2. If the alarm is still issued, document the events that led to the error, and contact your FANUC technical representative. SRVO-187 PAUSE Need specfing Mass [Cause] Estimating the load information of this type requires specifying the mass of the load. [Remedy] Specify the mass of the load before Payload Estimation. SRVO-188 PAUSE Memory is lacking [Cause] System could not allocate the enough memory area on the DRAM for Payload Estimation. [Remedy] 1. Execute the Payload Estimation after power cycle. 2. If the alarm is still issued, need to update the memory size of DRAM. Contact the sales personnel.
- 1061 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SRVO-191 SYSTEM Illegal Joint Speed (G:%d A:%d) [Cause] The motion command exceeded specification. [Remedy] Internal motion error. Document the events that led to the error, and contact your FANUC technical representative. NOTE
Need power cycle to release this alarm. SRVO-194 SERVO Servo disconnect [Cause] A servo disconnect input signal is turned off. [Remedy] 1. If a servo disconnect switch is connected, release the switch, and then press reset. 2. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. Troubles of related parts are thought. SRVO-199 PAUSE Control Stop [Cause] Control Stop was done. [Remedy] After this alarm, Fence open or SVOFF input alarm is detected. See the remedy of those alarms. SRVO-201 SERVO Panel E-stop or SVEMG abnormal [Cause] The EMERGENCY STOP button on the operator’s panel/operation box was pressed, but the EMERGENCY STOP line was not disconnected. [Remedy] 1. Release the operator panel EMERGENCY STOP button, then press RESET. 2. When the operator panel EMERGENCY STOP button is pushed again, and this alarm occurs again, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. NOTE
This alarm might occur when the emergency stop button is pushed slowly. In this case, the above remedy 2 is unnecessary. SRVO-202 SERVO TP E-stop or SVEMG abnormal [Cause] The EMERGENCY STOP button on the Teach Pendant was pressed, but the EMERGENCY STOP line was not disconnected. [Remedy] 1. Release the TP EMERGENCY STOP button, then press RESET. 2. When the TP EMERGENCY STOP button is pushed again, and this alarm occurs again, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. NOTE
This alarm might occur when the emergency stop button is pushed slowly. In this case, the above remedy 2 is unnecessary. SRVO-204 SYSTEM External(SVEMG abnormal) E-stop [Cause] The external emergency stop push button was pressed, but the EMERGENCY STOP line was not disconnected. [Remedy] The troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. NOTE
Need power cycle to release this alarm.
- 1062 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SRVO-205 SYSTEM Fence open(SVEMG abnormal) [Cause] Fence circuit was opened, but the EMERGENCY STOP line was not disconnected. [Remedy] The troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. NOTE
Need power cycle to release this alarm. SRVO-206 SYSTEM Deadman switch (SVEMG abnormal) [Cause] The teach pendant deadman switch was released while the teach pendant was enabled, but the EMERGENCY STOP line was not disconnected. [Remedy] The troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. NOTE
Need power cycle to release this alarm. SRVO-207 SERVO TP switch abnormal or Door open [Cause] The EMERGENCY STOP line has been disconnected although there is no e-stop factor. [Remedy] 1. Replace the teach pendant. 2. Replace the teach pendant cable. 3. Replace the operator’s panel/operation box. 4. Replace the E–stop unit. 5. Replace the servo amplifier. SRVO-209 SERVO Robot-%d SVEMG abnormal [Cause] Abnormality of the emergency stop line was detected at the 2nd or later robot. [Remedy] 1. Replace the emergency stop unit of displayed robot in the alarm message. 2. Replace the servo amplifier of displayed robot in the alarm message. 3. Document the events that led to the error, and contact your FANUC technical representative. SRVO-211 SERVO TP OFF in T1,T2 [Cause] The teach pendant was disabled while the mode switch was set in the T1 or T2 position and robot 1 and 2 were disconnected. Alternatively, there is a failure in the hardware. [Remedy] 1. Set the teach pendant enable/disable switch to on, and press the reset key. 2. Document the events that led to the error, and contact your FANUC technical representative. SRVO-213 SERVO Panel Board fuse blown [Cause] The fuse on the panel board has blown. [Remedy] Replace the fuse on the panel board. Refer to the Controller Maintenance Manual,”Troubleshooting using the error code” for more details. SRVO-214 SERVO 6ch amplifier fuse blown(R:%d) [Cause] The fuse in the 6ch. amplifier has blown. The number in the bracket indicates on which 6ch. amplifier the blown fuse is. [Remedy] Replace the fuse on the 6ch. amplifier. Refer to the Controller Maintenance Manual,”Troubleshooting using the error code” for more details.
- 1063 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SRVO-215 SERVO Brake Unit fuse blown(R:%d) [Cause] The fuse on the brake unit or tool(gun) change unit has blown. The number in the bracket indicates to which 6ch. amplifier that brake unit is connected. [Remedy] Replace this fuse after replacing the brake cable because it may be defective. (If this fuse has blown, it may be caused by some defect of the brake cable.) Refer to the Auxiliary Axis Option Maintenance Manual for more details. SRVO-216 SERVO OVC(total) (%d) [Cause] The current flowing through the robot cable has exceeded its limit. [Remedy] 1. Slow the motion of the robot where possible. Check the robot operation conditions. If the robot is used with a condition exceeding the duty or load weight robot rating, reduce the load condition value to the specification range. 2. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-218 SERVO Ext.E-stop/ServoDisconnect [Cause] The external emergency stop signal or the servo disconnect signal is asserted. [Remedy] 1. Release the external emergency stop signal and press RESET. 2. If the servo disconnect signal is used, release it and press RESET. SRVO-220 SERVO SDI fuse blown [Cause] Fuse for SDI has blown. [Remedy] Replace the fuse on the main board or main board itself. Refer to the R-30iA Mate Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-221 SERVO Lack of DSP (G:%d A:%d) [Cause] The DSP (servo control CPU) for this axis was not found, though it was specified in the system variable $AXISORDER. [Remedy] Check that the number of DSPs on the board for DSP is sufficient for the quantity specified in $SCR_GRP[].$AXISORDER[]. Replace the board for DSP with one having sufficient DSPs if necessary. Alternatively, change the setting of $AXISORDER. SRVO-222 SERVO Lack of Amp (Amp:%d) [Cause] The servo amplifiers were not found at the power up sequence. [Remedy] 1. When any LED on the servo amplifier does not light with the power supply of the controller turned on, the power is not supplied to the servo amplifier. Confirm whether there is neither disconnecting nor loosening in each connector on the servo amplifier and the emergency stop unit. 2. Turn off the power of the controller, disconnect the pulse coder cable JF1,JF2 from the servo amplifier and turn on the power of the controller again. If this alarm dose not occur, the pulse coder cable may have ground fault.(The LED of the servo amplifier may display blinking “-“ in this case.) 3. If servo amplifier of R-J3iB is connected to the R-30iA system, this alarm could occur. In that case, replace the servo amplifer with the correct one. 4. Replace the servo amplifier for auxiliary axis. 5. Replace the 6-Axis servo amplifier. 6. Replace the optical fiber cable. 7. Replace the servo card or the auxiliary axis servo card.
- 1064 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SRVO-223 SERVO DSP dry run (%d,%d) [Cause] Servo system initialization was stopped because of a hardware failure or improper software setting. The controller has been started in the DSP dry run mode. [Remedy] 1. When the first number is 1,5,6, or 11: Alarm is caused by software setting. Check whether DSP dry run mode is set($scr.$startup_cnd = 12) or setting of hardware start axis number. 2. When the first number is 2,3,4, or 7: Replace the servo card. 3. When the first number is 8 or 10: Refer to SRVO-058. 4. When the first number is 9: Check whether servo amplifier is connected or not. Check whether power is supplied to the amplifier or not. Check whether fuse on the amplifier is blown or not. Replace FSSB cable(optical fiber cable). Replace servo amplifier. 5. When the first number is 12: Refer to SRVO-059. 6. When the first number is 13 or 14: Document the events that led to the error, and contact your FANUC technical representative. SRVO-230 SERVO Chain 1 abnormal %x,%x SRVO-231 SERVO Chain 2 abnormal %x,%x [Cause] 1. A mismatch occurred between duplicate safety signals. 2. There is a possibility that the specification of the teach pendant is incorrect when occurring immediately after turning on of the power supply. For instance, this might occur if the teach pendant of non-RIA/CE specification is connected with the controller of the RIA/CE specification. [Remedy] 1. In case of the above cause 2, connect a correct teach pendant. 2. Confirm the history of the alarm on the Alarm Log screen. If occurring with either “Operator panel E-stop”, “Teach pendant E-stop” or “Deadman switch released”, the emergency stop button is released, and it presses again. For deadman switch, the deadman switch is gripped once and it released again. Chain abnormal state was released if occurring SRVO-236” Chain failure is repaired”. Release e-stop button, deadman and Press reset button. 3. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. After measures, the release operation of chain abnormal state is necessary. 1) F4 "RES_1CH" is pressed on the Alarm Active screen. 2) The reset button is pressed. SRVO-232 SERVO NTED input [Cause] The NTED (non-teacher enabling device) was detected. [Remedy] 1. Press the NTED (non-teacher enabling device), and then press the reset key. 2. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-233 SERVO TP OFF in T1,T2/Door open [Cause] The mode switch is set in the T1 or T2 position, and the teach pendant is disabled. Alternatively, the controller door is open. Still alternatively, there is a failure in the hardware. - 1065 -
C.ALARM CODES [Remedy] 1. 2.
APPENDIX
B-82594EN-4/01
After setting the teach pendant enable/disable switch to on, close the controller door, and press the reset key. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”.
SRVO-234 WARN Deadman switch released [Cause] The deadman switch on the teach pendant was released. [Remedy] This is just a notification. No action is needed for this warning message. SRVO-235 SERVO Short term Chain abnormal [Cause] A temporary chain failure was detected. [Remedy] 1. Press the e-stop button on the teach pendant or the operator panel again. If occurring SRVO-236” Chain failure is repaired”. Release e-stop button and Press reset button. 2. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. After measures, the release operation of chain abnormal state is necessary. 1) F4 "RES_1CH" is pressed on the Alarm Active screen. 2) The reset button is pressed. SRVO-236 WARN Chain failure is repaired [Cause] A chain failure was removed. When the system checked for the chain failure again, the chain failure had been removed. [Remedy] Press the reset key. SRVO-237 WARN Cannot reset chain failure [Cause] An attempt to reset the chain failure failed. [Remedy] Refer to the remedy of SRVO-230. SRVO-240 SERVO Chain 1 (FENCE) abnormal SRVO-241 SERVO Chain 2 (FENCE) abnormal [Cause] Although the fence circuit was disconnected, the emergency stop line was not disconnected. The emergency stop circuit is faulty. [Remedy] The troubles of the panel board, the e-stop unit or other related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. After measures, the release operation of chain abnormal state is necessary. 1) F4 "RES_1CH" is pressed on the Alarm Active screen. 2) The reset button is pressed. SRVO-242 SERVO Chain 1 (EXEMG) abnormal SRVO-243 SERVO Chain 2 (EXEMG) abnormal [Cause] Although the external emergency stop circuit was disconnected, the emergency stop line was not disconnected. The emergency stop circuit is faulty. [Remedy] Refer to the remedy of SRVO-240. SRVO-244 SERVO Chain 1 abnormal(Rbt:%d) SRVO-245 SERVO Chain 2 abnormal(Rbt:%d) SRVO-246 SERVO Chain 1 abnormal(EX_robot) SRVO-247 SERVO Chain 2 abnormal(EX_robot) [Cause] An abnormal chain occurred with the robot displayed in (). Refer to the Cause and Remedy of SRVO-230.
- 1066 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SRVO-248 SERVO Deadman switch status abnormal [Cause] Status of two DIs of deadman switch does not match. (Chain failure of deadman switch) [Remedy] 1. Release both deadman switches once. If SRVO-236 Chain failure is repaired occurred, there is no hardware problem. 2. When SRVO-236 does not occur, please replace hardware in following order. - Teach pendant - Cable between teach pendant and panel board - Panel board - Cable between panel board and main board After measures, the release operation of chain abnormal state is necessary. 1) F4 "RES_1CH" is pressed on the Alarm Active screen. 2) The reset button is pressed. NOTE
This alarm could occur when deadman switch is pressed halfway. In this case, the above remedy 2 is unnecessary. SRVO-251 SERVO DB relay abnormal(G:%d A:%d) [Cause] A failure was detected in the internal relay(DB relay) of the servo amplifier. [Remedy] Replace the servo amplifier. SRVO-252 SERVO Current detect abnl(G:%d A:%d) [Cause] A failure was detected in the current detection circuit inside the servo amplifier. [Remedy] Replace the servo amplifier. SRVO-253 SERVO Amp internal over heat(G:%d A:%d) [Cause] An overheat was detected inside the servo amplifier. [Remedy] Replace the servo amplifier. SRVO-254 SERVO E-STOP circuit abnormal (KA5) [Cause] Welding occurs at the safety relay of emergency stop unit. [Remedy] Replace the emergency stop unit. SRVO-255 SERVO E-STOP circuit abnormal (KM2) [Cause] Welding occurs at the safety relay of emergency stop unit. [Remedy] Replace the emergency stop unit. SRVO-256 SERVO MCC control circuit abnormal (AMP) [Cause] MCC control signal from 6ch. amplifier is abnormal. [Remedy] Replace 6ch. amplifier. SRVO-266 SERVO FENCE1 status abnormal SRVO-267 SERVO FENCE2 status abnormal [Cause] The FENCE circuit is abnormal. (Chain failure of FENCE signal) [Remedy] There are miswiring of the FENCE signal or the troubles of related parts. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. After measures, the release operation of chain abnormal state is necessary. 1) F4 "RES_1CH" is pressed on the Alarm Active screen. 2) The reset button is pressed. SRVO-268 SERVO SVOFF1 status abnormal SRVO-269 SERVO SVOFF2 status abnormal [Cause] The SVOFF circuit is abnormal. (Chain failure of SVOFF signal) - 1067 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
[Remedy] There are miswiring of the SVOFF signal or the troubles of related parts. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. After measures, the release operation of chain abnormal state is necessary. 1) F4 "RES_1CH" is pressed on the Alarm Active screen. 2) The reset button is pressed. SRVO-270 SERVO EXEMG1 status abnormal SRVO-271 SERVO EXEMG2 status abnormal [Cause] The EXEMG circuit is abnormal. (Chain failure of EXEMG signal) [Remedy] There are miswiring of the EXEMG signal or the troubles of related parts. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. After measures, the release operation of chain abnormal state is necessary. 1) F4 "RES_1CH" is pressed on the Alarm Active screen. 2) The reset button is pressed. SRVO-272 SERVO SVDISC1 status abnormal SRVO-273 SERVO SVDISC2 status abnormal [Cause] The SVDISC circuit is abnormal. (Chain failure of SVDISC signal) [Remedy] There are miswiring of the SVDISC signal or the troubles of related parts. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. After measures, the release operation of chain abnormal state is necessary. 1) F4 "RES_1CH" is pressed on the Alarm Active screen. 2) The reset button is pressed. SRVO-274 SERVO NTED1 status abnormal SRVO-275 SERVO NTED2 status abnormal [Cause] The NTED circuit is abnormal. (Chain failure of NTED signal) [Remedy] There are miswiring of the NTED signal or the troubles of related parts. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. After measures, the release operation of chain abnormal state is necessary. 1) F4 "RES_1CH" is pressed on the Alarm Active screen. 2) The reset button is pressed. SRVO-276 SERVO Disable on T2 mode [Cause] The robot cannot operate in the T2 mode. [Remedy] Set the mode switch to the T1 or AUTO position. SRVO-277 SYSTEM Panel E-stop(SVEMG abnormal) [Cause] The EMERGENCY STOP button on the operator’s panel/operation box was pressed, but the EMERGENCY STOP line was not disconnected. [Remedy] 1. Release the operator panel EMERGENCY STOP button, then the controller power cycle again. 2. When the operator panel EMERGENCY STOP button is pushed again, and this alarm occurs again, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code” (SRVO-201). NOTE 1 Need power cycle to release this alarm. 2 This alarm might occur when the emergency stop button is pushed slowly. In
this case, the above remedy 2 is unnecessary.
- 1068 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SRVO-278 SYSTEM TP E-stop(SVEMG abnormal) [Cause] The EMERGENCY STOP button on the Teach Pendant was pressed, but the EMERGENCY STOP line was not disconnected. [Remedy] 1. Release the TP EMERGENCY STOP button, then the controller power cycle again. 2. When the TP EMERGENCY STOP button is pushed again, and this alarm occurs again, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”(SRVO-202). NOTE 1 Need power cycle to release this alarm. 2 This alarm might occur when the emergency stop button is pushed slowly. In
this case, the above remedy 2 is unnecessary. SRVO-280 SERVO SVOFF input [Cause] The SVOFF (servo off signal) was input. [Remedy] 1. Find out what caused the SVOFF to be input, and remove the cause. Press the RESET button. 2. If this alarm cannot be reset, the troubles of related parts are thought. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-282 SERVO Chain 1 (SVOFF) abnormal SRVO-283 SERVO Chain 2 (SVOFF) abnormal [Cause] Although the SVOFF (servo off signal) circuit was disconnected, the emergency stop line was not disconnected. The emergency stop circuit is faulty. [Remedy] Refer to the remedy of SRVO-240. SRVO-290 SERVO DClink HC alarm(G:%d A:%d) [Cause] The DC link current of the servo amplifier is abnormally high. [Remedy] Refer to the remedy of SRVO-045. SRVO-291 SERVO IPM over heat (G:%d A:%d) [Cause] It was detected that the IPM element in the amplifier had overheated. [Remedy] 1. Check whether the amplifier fan rotates normally. 2. Decrease the duty cycle of operation. 3. If this symptom occurs frequently, replace the amplifier. About auxiliary axis, refer to the Auxiliary Axis Option Maintenance Manual. SRVO-292 WARN EXT.FAN alarm (G:%d A:%d) [Cause] The external fan for the servo amplifier module(SVM, αiSV) is faulty. [Remedy] Replace the cooling fan. About auxiliary axis, refer to the Auxiliary Axis Option Maintenance Manual. SRVO-293 SERVO DClink(PSM) HCAL(G:%d A:%d) [Cause] The three–phase input power supply is abnormal or the power supply module is faulty. [Remedy] 1. Check the three–phase input power supply. 2. Replace the power supply module. SRVO-294 SERVO EXT.FAN(PSM) alarm(G:%d A:%d) [Cause] The external fan for the power supply module is faulty. [Remedy] Replace the external fan.
- 1069 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SRVO-295 SERVO SVM COM alarm(G:%d A:%d) [Cause] A communication error occurred between the power supply module and the servo amplifier module. [Remedy] 1. Replace the cable between the power supply module and the servo amplifier module. 2. Replace the power supply module. 3. Replace the servo amplifier module. SRVO-296 SERVO PSM DISCHG alm(G:%d A:%d) [Cause] 1. The cooling fan for the regenerative resistance of the power supply module stops. 2. The use condition is too hard for the regenerative resistance of the power supply module. [Remedy] 1. Check the fan for the regenerative resistor is working. If it stops, replace the fan. 2. Lower the teaching speed in the program. 3. Replace the power supply module. SRVO-297 SERVO PSM LowVolt alm(G:%d A:%d) [Cause] The voltage of the PSM control power supply has dropped. [Remedy] 1. Check that the three-phase input voltage is low. 2. Replace the power supply module. 3. Replace the servo amplifier module. SRVO-298 SYSTEM SRVO velocity alm(G:%d A:%d) [Cause] The speed calculated in the servo software is abnormal. [Remedy] Document the events that led to the error, and contact your FANUC technical representative. NOTE
Need power cycle to release this alarm. SRVO-300 SERVO Hand broken/HBK disabled SRVO-301 SERVO Hand broken/HBK dsbl(Rbt:%d) [Cause] When the HBK(hand-broken) setting is disabled, a hand-broken signal was detected. [Remedy] To remove the alarm condition, press the reset button. SRVO-302 SERVO Set Hand broken to ENABLE SRVO-303 SERVO Set HBK to ENABLE(Rbt:%d) [Cause] When the HBK(hand-broken) setting is disabled, a hand-broken signal was input. HBK setting is incorrect. [Remedy] Check whether the hand-broken signal circuit is connected to the robot. If the circuit is connected to the robot, enable the hand-broken setting. SRVO-305 SYSTEM Unit Change(G%d,%s) [Cause] The model of robot was changed. [Remedy] Turn off and on the controller power supply. SRVO-310 SERVO ABC Unexpected Motion(G:%d) [Cause] A current robot position that software calculates is abnormal. [Remedy] 1. Mastering data could be wrong. Confirm whether wrong backup data is restored or mastering has been executed at wrong position. Please execute mastering in that case. 2. Document the events that led to the error, and contact your FANUC technical representative.
- 1070 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SRVO-315 PAUSE MPDT failed(G:%d A:%d) [Cause] Magnetic Phase Detection (MPDT) for 3rd party motor was failed. Probable cause: 1. The motor power cable is disconnected. 2. The axis falls down by the gravity during performing of MPDT. 3. Other alarm occurs during performing of MPDT. 4. The motor cannot move due to large load or friction. [Remedy] 1. Check whether the motor power cable is connected correctly. 2. MPDT cannot be applied for gravity axis. If possible, change the posture. 3. Remove the reason of other alarm which occurs at same time. 4. Check whether the axis which requires to perform MPDT does not contact with any object. 5. Confirm that brake is not engaged. SRVO-316 PAUSE MPDT time is up(G:%d A:%d) [Cause] Magnetic Phase Detection (MPDT) process time is up. Probable cause: 1. The axis falls down by the gravity during performing of MPDT. 2. Other alarm occurs during performing of MPDT. [Remedy] 1. MPDT cannot be applied for gravity axis. If possible, change the posture. 2. Remove the reason of other alarm which occurs at same time. SRVO-317 PAUSE MPDT cannot start(Machine Lock) [Cause] Magnetic Phase Detection (MPDT) process cannot start because machine lock is enabled for that group. [Remedy] Disable machine lock for that group. SRVO-318 PAUSE MPDT cannot start(SRDY Off) [Cause] Magnetic Phase Detection (MPDT) process cannot start because servo ready (SRDY) is off. [Remedy] Remove the reason of servo ready (SRDY) off. SRVO-332 SERVO Power off to reset CMAL [Cause] Power off is required to reset CMAL alarm. [Remedy] Turn off/on the controller. And then, perform the mastering. SRVO-333 SYSTEM Power off to reset [Cause] Power off is required. [Remedy] Turn off/on the controller. NOTE
Need power cycle to release this alarm. SRVO-335 SERVO DCS OFFCHK alarm %x,%x [Cause] A fault was detected in the safety signal input circuit. [Remedy] Replace the panel board. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”.
- 1071 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SRVO-336 SERVO DCS RAMCHK alarm %x,%x SRVO-337 SERVO DCS PRMCHK alarm %x,%x SRVO-338 SERVO DCS FLOW alarm %x,%x SRVO-339 SERVO DCS MISC alarm %x,%x SRVO-340 SERVO DCS T1 TCP speed(G%d) %x,%x SRVO-341 SERVO DCS T1 flange speed(G%d) %x,%x SRVO-342 SERVO DCS Cartesian position(G%d) %x,%x SRVO-343 SERVO DCS Cartesian speed(G%d) %x,%x SRVO-344 SERVO DCS GRP alarm(G%d) %x,%x SRVO-345 SERVO DCS Joint position(G%d,A%d) %x,%x SRVO-346 SERVO DCS Joint speed(G%d,A%d) %x,%x SRVO-347 SERVO DCS AXS alarm(G%d,A%d) %x,%x [Cause] Internal error of software. [Remedy] Document the events that led to the error, and contact your FANUC technical representative. SRVO-348 SERVO DCS MCC OFF alarm %x,%x [Cause] An OFF instruction was issued to the electromagnetic contactor, but the electromagnetic contactor did not turn OFF. [Remedy] 1. Replace the emergency stop unit. 2. Replace the panel board. 3. If there is any signal to be connected to the emergency stop unit, check to see if there is any problem with the signal source. 4. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-349 SERVO DCS MCC ON alarm %x,%x [Cause] An ON instruction was issued to the electromagnetic contactor, but the electromagnetic contactor did not turn ON. [Remedy] 1. Replace the emergency stop unit. 2. Replace the panel board. 3. Replace the servo amplifier. 4. Refer to the Controller Maintenance Manual, “Troubleshooting using the error code”. SRVO-350 SERVO DCS CPU alarm %x,%x SRVO-351 SERVO DCS CRC alarm %x,%x SRVO-352 SERVO DCS COUNT1 alarm %x,%x SRVO-353 SERVO DCS COUNT2 alarm %x,%x SRVO-354 SERVO DCS DICHK alarm %x,%x SRVO-355 SERVO DCS ITP_TIME alarm %x,%x SRVO-356 SERVO DCS ITP_SCAN alarm %x,%x SRVO-357 SERVO DCS ENABLED alarm %x,%x SRVO-358 SERVO DCS INVPRM alarm %x,%x SRVO-359 SERVO DCS SYSTEM alarm %x,%x [Cause] Internal error of software. [Remedy] Document the events that led to the error, and contact your FANUC technical representative. SRVO-360 SERVO DCS CC_TCP alarm(G%d) %x,%x SRVO-361 SERVO DCS CC_FP alarm(G%d) %x,%x SRVO-362 SERVO DCS CC_TCPS alarm(G%d) %x,%x SRVO-363 SERVO DCS CC_FPS alarm(G%d) %x,%x SRVO-364 SERVO DCS PRMCRC alarm(G%d) %x,%x [Cause] Internal error of software. [Remedy] Document the events that led to the error, and contact your FANUC technical representative. - 1072 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SRVO-365 SERVO DCS FB_CMP alarm(G%d,A%d) %x,%x SRVO-366 SERVO DCS FB_INFO alarm(G%d,A%d) %x,%x SRVO-367 SERVO DCS CC_JPOS alarm(G%d,A%d) %x,%x SRVO-368 SERVO DCS CC_JSPD alarm(G%d,A%d) %x,%x [Cause] Internal error of software. [Remedy] Document the events that led to the error, and contact your FANUC technical representative. SRVO-370 SERVO SVON1 status abnormal SRVO-371 SERVO SVON2 status abnormal [Cause] A chain alarm was detected with the panel board internal signal(SVON). [Remedy] Replace the panel board. For the procedure of recovery from this alarm, refer the description of SRVO-230 or 231. NOTE If this alarm is issued, do not reset the chain error alarm until the failure is
checked and corrected. If you continue to use robot with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. SRVO-372 SERVO OPEMG1 status abnormal SRVO-373 SERVO OPEMG2 status abnormal [Cause] A chain alarm was detected with the emergency stop switch on the panel board. [Remedy] 1. Replace the panel board. 2. Replace the teach pendant cable. 3. Replace the teach pendant. 4. Replace the emergency stop button on the panel board. For the procedure of recovery from this alarm, refer the description of SRVO-230 or 231. NOTE If this alarm is issued, do not reset the chain error alarm until the failure is
checked and corrected. If you continue to use robot with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails. SRVO-374 SERVO MODE11 status abnormal SRVO-375 SERVO MODE12 status abnormal SRVO-376 SERVO MODE21 status abnormal SRVO-377 SERVO MODE22 status abnormal [Cause] A chain alarm was detected with the mode switch signal. [Remedy] 1. Check the mode switch and its cable. Replace them if a defect is found. 2. Replace the panel board. For the procedure of recovery from this alarm, refer the description of SRVO-230 or 231. NOTE If this alarm is issued, do not reset the chain error alarm until the failure is
checked and corrected. If you continue to use robot with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.
- 1073 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SRVO-378 SERVO OPSFTY11 status abnormal SRVO-379 SERVO OPSFTY12 status abnormal SRVO-380 SERVO OPSFTY21 status abnormal SRVO-381 SERVO OPSFTY22 status abnormal SRVO-382 SERVO OPSFTY31 status abnormal SRVO-383 SERVO OPSFTY32 status abnormal SRVO-384 SERVO OPSFTY41 status abnormal SRVO-385 SERVO OPSFTY42 status abnormal [Cause] A chain alarm was detected with the OPSFTY signal. [Remedy] 1. Check whether the circuitry connected to the dual input signal(OPSFTY) is faulty. 2. Check whether the timing of the dual input signal(OPSFTY) satisfies the timing specification. 3. Replace the panel board. For the procedure of recovery from this alarm, refer the description of SRVO-230 or 231. NOTE If this alarm is issued, do not reset the chain error alarm until the failure is
checked and corrected. If you continue to use robot with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.
- 1074 -
APPENDIX
B-82594EN-4/01
C.ALARM CODES
SYST Error Codes ( ID = 24 ) SYST-001 PAUSE.G HOLD button is being pressed [Cause] You attempted an operation while the hold button (input) is pressed. [Remedy] Clear the hold button (input), and try the same operation. SYST-002 PAUSE.G HOLD is locked by program [Cause] The condition that the robot is being held in is locked by the program and cannot be cleared. If a HOLD statement is executed in a KAREL program, the held condition can only be cleared by the same program using the UNHOLD statement/action, or by aborting the program. If you attempt a motion in such a condition, this error message is displayed. [Remedy] Wait until the UNHOLD statement is executed by the karel program, or abort the KAREL program. SYST-003 WARN TP is enabled [Cause] The attempted operation could not be done because the teach pendant is enabled. [Remedy] Disable the teach pendant, and try the same operation again. SYST-004 WARN SOP is enabled [Cause] The attempted operation could not be done because the System Operator Panel is enabled. [Remedy] Turn the REMOTE switch on the SOP to REMOTE side, and try the same operation again. SYST-005 WARN UOP is the master device [Cause] The attempted operation could not be done because the User Operator Panel is enabled. [Remedy] Turn the REMOTE switch to local (if the operation is attempted from the SOP), or set the $RMT_MASTER system variable correctly. SYST-006 WARN CRT is the master device [Cause] The attempted operation could not be done because CRT is the master device. [Remedy] 1 2
To perform the operation from the operator's panel, set the remote switch to the local position. To perform the operation from the remote unit, set an appropriate value for $RMT_MASTER.
SYST-007 WARN NETWORK is the master device [Cause] The attempted operation could not be done because the NETWORK command processor is the master device. [Remedy] 1 To perform the operation from the operator's panel, set the remote switch to the local position. 2 To perform the operation from the remote unit, set an appropriate value for $RMT_MASTER. SYST-008 WARN Nothing is the master device [Cause] The system variable $RMT_MASTER is set to disable all devices. Therefore, no remote device can issue motion. [Remedy] 1 To perform the operation from the operator's panel, set the remote switch to the local position. 2 To perform the operation from the remote unit, set an appropriate value for $RMT_MASTER.
- 1075 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SYST-009 WARN Safety Fence open [Cause] The attempted operation could not be done because the safety fence is open. [Remedy] Close the safety fence and try the same operation again. SYST-010 WARN Max num task reached [Cause] The number of tasks has reached the maximum allowed. [Remedy] Abort one of the running task. SYST-011 WARN Failed to run task [Cause] The system has failed to run the program. [Remedy] Determine the cause of the alarm on the alarm cause screen. Then, eliminate the cause. SYST-012 WARN Not in remote [Cause] Remote condition is not satisfied. [Remedy] Turn the remote switch on. SYST-013 WARN Invalid program number [Cause] The specified PNS number is not within its valid range. [Remedy] Specify a program number that is within the valid range of 1 to 9999. SYST-014 WARN Program select failed [Cause] PNS operation has failed. [Remedy] Determine the cause of the alarm on the alarm cause screen. Then, eliminate the cause. SYST-015 WARN Robot Service Request failed [Cause] RSR operation has failed. [Remedy] Determine the cause of the alarm on the alarm cause screen. Then, eliminate the cause. SYST-016 WARN ENBL signal is off [Cause] ENBL signal on the User Operator Panel is off. [Remedy] Set ENBL signal ON. SYST-017 WARN Single step operation effective [Cause] Single step operation is effective. [Remedy] Disable single step switch. SYST-018 WARN Continuing from different line [Cause] You attempted to continue program execution from a line different that the paused line. [Remedy] Respond YES or NO in the prompt box on at the teach pendant. SYST-019 WARN Program not selected [Cause] Program has not been selected. [Remedy] Select a program from the program select menu on the teach pendant, or by using PNS. SYST-020 WARN Program not verified by PNS [Cause] The program specified by PNS is different then the program currently selected. [Remedy] Select a correct program from the program select menu on the teach pendant. SYST-021 WARN System not ready, press RESET [Cause] Because program verification failed, program start-up is disabled. [Remedy] Press RESET to clear the error condition.
- 1076 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SYST-022 WARN PNS not zero, cannot continue [Cause] A paused program cannot continue if PNS input ports are not zero. [Remedy] Input an error clear signal to set all PNS inputs to 0, then input a start signal. SYST-023 SYSTEM Teach Pendant communication error [Cause] A communication cable is broken. [Remedy] Check the communication cable. Replace the cable if necessary. SYST-024 WARN PNSTROBE is OFF. Cannot start exec [Cause] Prod_start could not be processed because PNSTROBE is off. [Remedy] Set PNSTROBE input to ON. SYST-025 WARN Teach Pendant is different type [Cause] The type of teach pendant being connected, is different from the one that was disconnected. [Remedy] Connect the same type of teach pendant, as that which was disconnected. SYST-026 System normal power up [Cause] System has executed normal power startup. [Remedy] This is just a notification. You do not have to do anything for this warning message. SYST-027 PAUSE.G HOT start failed (Error:%d) [Cause] HOT start has failed for one of the following reasons: 1 Power failed during system start up. 2 Flash ROM module was changed. 3 A run-time error occurred. 4 System internal error 1. 5 System internal error 2. [Remedy] COLD start is selected automatically. SYST-028 WARN (%s) Program timed out [Cause] $PWR_HOT, $PWR_SEMI program has been aborted by the system due to time out (40sec). [Remedy] Decrease program size so that it can be executed within the time out limit. SYST-029 PAUSE.G Robot was connected (Group:%d) [Cause] The connect/isolate key was turn to the connect side. [Remedy] This is just a notification. You do not have to do anything for this warning message. SYST-030 PAUSE.G Robot was isolated (Group:%d) [Cause] The connect/isolate key was turn to the isolate side [Remedy] This is just a notification. You do not have to do anything for this warning message. SYST-031 SYSTEM F-ROM parity [Cause] A parity error has been detected in the system FROM memory. [Remedy] Reload system software. SYST-032 WARN ENBL signal from UOP is lost [Cause] ENBL input signal from the User Operator Panel is lost. [Remedy] Restore input signal. SYST-033 WARN SFSPD signal from UOP is lost [Cause] SFSPD input signal from User Operator Panel is lost. [Remedy] Restore input signal. - 1077 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SYST-034 WARN HOLD signal from SOP/UOP is lost [Cause] HOLD input signal from System Operator Panel/User Operator Panel is lost. [Remedy] Restore input signal. SYST-035 WARN Low or No Battery Power in PSU. [Cause] Battery power in the PSU board is low. [Remedy] Replace the old battery with a new battery of the same kind. SYST-036 WARN Semi power failure recovery [Cause] System did a semi-hot start. [Remedy] This is just a notification. You do not have to do anything for this warning message. SYST-037 ABORT.G CE Sign key switch broken [Cause] Improper input from CE Sign key switch. [Remedy] Fix the CE Sign key switch. SYST-038 PAUSE.G Operation mode T1 Selected [Cause] Operation mode T1 Selected SYST-039 PAUSE.G Operation mode T2 Selected [Cause] Operation mode T2 Selected SYST-040 PAUSE.G Operation mode AUTO Selected [Cause] Operation mode AUTO Selected SYST-041 Ovrd Select could not ENABLED [Cause] DI index is invalid [Remedy] Please set valid DI index SYST-042 DEADMAN defeated [Cause] The mode switch was changed from T1 or T2 mode to AUTO mode and the DEADMAN was already pressed. The DEADMAN must be released when switching to AUTO mode [Remedy] Release the DEADMAN and press RESET. SYST-043 TP disabled in T1/T2 mode [Cause] The mode selector is in T1 or T2 and the TP ON/OFF switch is in the OFF position [Remedy] Turn the TP ON/OFF switch to ON. Press RESET. SYST-044 (Abnormal) TP disabled in T1/T2 mode [Cause] The mode selector is in T1 or T2 and the TP ON/OFF switch is in the OFF position and SVON is ON. This is an abnormal condition. [Remedy] Call your FANUC technical representative. SYST-045 TP enabled in AUTO mode [Cause] The mode selector is in AUTO and the TP ON/OFF switch is in the ON position [Remedy] Turn the TP ON/OFF switch to OFF. Press RESET."
- 1078 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SYST-046 Control Reliable config mismatch [Cause] Either 1. Control Reliable hardware exists but the option has not been loaded, or 2. The Control Reliable option has been loaded but the hardware is not available. [Remedy] Consult our service representative. SYST-047 Continuing from distant position [Cause] Attempt to continue program from distant position from stopped position. [Remedy] Respond ABORT or CONTINUE in the prompt box on at the teach pendant SYST-048 NECALC couldn't get work memory [Cause] The OS could not allocate work memory to the NUCALC software part. The memory may be insufficient. [Remedy] Increase the controller memory. SYST-049 SFCALC couldn't get work memory [Cause] The OS could not allocate work memory to the SFCALC software part. The memory may be insufficient. [Remedy] Increase the controller memory. SYST-067 Panel HSSB disconnect [Cause] Communication with the panel board is disabled. [Remedy] Check the cable of the panel HSSB. SYST-095 Remote diagnose internal error [Cause] An internal error occurred with the remote diagnosis function. [Remedy] Internal error SYST-096 Designated task is not valid [Cause] A task specified by the PC in remote diagnosis is invalid. [Remedy] Check the remote diagnosis software of the PC. SYST-097 Fail to initialize Modem [Cause] Modem initialization failed. [Remedy] Check if a modem is installed. Check the modem type setting. SYST-098 Card Modem is removed [Cause] The modem card was removed during communication. [Remedy] Reinsert the modem card, then restart the remote diagnosis function. Check if the modem card is inserted into the PCMIA slot correctly. SYST-099 Card Modem is not responded [Cause] There is no response from the modem card. [Remedy] Check if a modem card is inserted correctly. Check the modem card. SYST-100 DSR in Modem OFF [Cause] DSR was turned off during communication. [Remedy] Check the connection between Robot and the modem. If a modem card is used, check if the modem card is not destroyed and if the modem card is inserted correctly.
- 1079 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SYST-101 Connection is stopped [Cause] The line was disconnected. [Remedy] Check the telephone line. SYST-144 Bad DO specfied by %s [Cause] An invalid or unassigned DO was allocated by a system variable. [Remedy] Change the value of the system variable to 0 (for no use) or a valid number. Check that a specified DO is allocated. SYST-148 Dynamic Brake is Disabled [Cause] The dynamic brake release request signal DI[$DYN_BRK.$DI_IDX] was turned on, so that the dynamic brake was released. [Remedy] IMSTP is generated while the dynamic brake release request signal is on. SYST-149 Dynamic Brake is Enabled [Cause] The dynamic brake release request signal was turned off, so that the dynamic brake was actuated. [Remedy] This is not an alarm. SYST-150 Cursor is not on line 1 [Cause] The program was started on a line other than the first line. [Remedy] Reply Yes/No in response to the inquiry displayed on the screen. Then, restart the program. SYST-151 Start again (%s, %d) [Cause] After the program was started on a line other than the first line, Yes was replied to the inquiry displayed on the screen. [Remedy] Restart the program. SYST-152 Cannot force DO's in AUTO mode [Cause] An attempt was made to output a signal in the AUTO mode. [Remedy] Before performing this operation, exit from the AUTO mode. SYST-153 Cannot SIM/UNSIM DO's in AUTO mode [Cause] An attempt was made to simulate signal output in the AUTO mode. [Remedy] Before performing this operation, exit from the AUTO mode. SYST-156 Unknown hard ware [Cause] The PCB does not match the control unit. [Remedy] Replace the PCB with a correct PCB. SYST-157 CE/RIA software does not exist [Cause] The CE/RIA option is not installed. [Remedy] Install the CE/RIA option. SYST-158 Robot cannot move in T2 mode [Cause] The tri-mode switch is set to the T2 mode. In the T2 mode, the robot cannot be moved. [Remedy] Set the switch to the T1 or AUTO mode.
- 1080 -
B-82594EN-4/01
APPENDIX
INTP Error Codes ( ID = 12 ) INTP-000 ABORT.G.G Req has not been processed yet [Cause] Internal system error. [Remedy] Contact our service center serving your locality. INTP-001 PAUSE.G Cannot lock the motion grp [Cause] Internal system error. [Remedy] Contact our service center serving your locality. INTP-002 ABORT.G Program manager internal error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. INTP-003 ABORT.G Invalid request [Cause] Internal system error. [Remedy] Contact our service center serving your locality. INTP-004 PAUSE.G Cannot ATTACH with TP enabled [Cause] The ATTACH statement requires the teach pendant to be disabled. [Remedy] Disable the teach pendant. INTP-005 PAUSE.G Cannot release motion control [Cause] Motion control cannot be released. [Remedy] Abort the running or paused program. INTP-100 to 102 ABORT.L (%s^4, %d^5) Internal error (PXnn) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. INTP-103 ABORT.L (%s^4, %d^5) Program error [Cause] An error occurred while the program was running. [Remedy] Refer to the error cause code. INTP-104 ABORT.L (%s^4, %d^5) Single step failed [Cause] Single step cannot be executed [Remedy] Refer to the error cause code. INTP-105 ABORT.L (%s^4, %d^5) Run request failed [Cause] The program cannot be started. [Remedy] Refer to the error cause code. INTP-106 PAUSE.L (%s^4, %d^5) Continue request failed [Cause] Program cannot be resumed. [Remedy] Refer to the error cause code. INTP-107 ABORT.L (%s^4, %d^5) Pause request failed [Cause] An error occurred when program execution was held. [Remedy] Refer to the error cause code.
- 1081 -
C.ALARM CODES
C.ALARM CODES
APPENDIX
B-82594EN-4/01
INTP-108 ABORT.L (%s^4, %d^5) Abort request failed [Cause] An error occurred when program execution was aborted. [Remedy] Refer to the error cause code. INTP-109 WARN (%s^4, %d^5) BWD motion request failed [Cause] Backward motion cannot be executed. [Remedy] Refer to the error cause code. INTP-110 (%s^4, %d^5) Get task status request failed [Cause] The specified task attribute is not found or is not read accessible. [Remedy] Check the attribute. INTP-111 WARN (%s^4, %d^5) Skip statement request failed [Cause] The currently executing line cannot be changed. [Remedy] Refer to the error cause code. INTP-112 PAUSE.L Cannot call interrupt routine [Cause] The interrupt routine cannot be executed. [Remedy] Refer to the error cause code. [Cause] If this alarm is raised together with the "MEMO-004 WARN SPECIFIED PROGRAM IS IN USE" alarm, the conditions in the condition program are satisfied, and the desired action program is currently being edited, executed, or suspended. [Remedy] Select another program from the program list. Terminate the current action program. [Cause] If this alarm is raised together with the "PROG-020 TASK IS ALREADY ABORTED" alarm, it is possible that the program that executed the monitoring start instruction has already been terminated when the conditions in the condition program are satisfied. [Remedy] When program monitoring is enabled, an action program can run only if the program that executed the monitoring start instruction is running. INTP-113 PAUSE.L (%s^4, %d^5) Stop motion request failed [Cause] An error occurred when motion was stopped. [Remedy] Refer to the error cause code. INTP-114 PAUSE.L (%s^4, %d^5) Cancel motion request failed [Cause] An error occurred when motion was canceled. [Remedy] Refer to the error cause code. INTP-115 PAUSE.L (%s^4, %d^5) Resume motion request failed [Cause] An error occurred when motion was resumed. [Remedy] Refer to the error cause code. INTP-116 PAUSE.L (%s^4, %d^5) Hold motion request failed [Cause] An error occurred when motion was held. [Remedy] Refer to the error cause code. INTP-117 PAUSE.L (%s^4, %d^5) Unhold motion request failed [Cause] An error occurred when motion was unheld. [Remedy] Refer to the error cause code. INTP-118 to 123 PAUSE.L (%s^4, %d^5) System error [Cause] Internal error of software. [Remedy] Refer to the error cause code. - 1082 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
INTP-124 ABORT.L (%s^4, %d^5) Invalid ITR routine [Cause] Internal error of software [Remedy] Refer to the error cause code. INTP-125 ABORT.L Failed to convert position [Cause] The conversion of one position type to another failed. [Remedy] Refer to the error cause code. INTP-126 ABORT.L Vision built-in return failed [Cause] The vision built-in failed to return. [Remedy] Refer to the error cause code. INTP-127 WARN Power fail detected [Cause] Power failure was detected. [Remedy] Resume the program after hot start is complete. INTP-128 PAUSE.L Pos reg is locked [Cause] Pos register is locked. [Remedy] Wait a moment. The error should resolve itself. INTP-129 ABORT.L Cannot use motion group [Cause] You tried to lock the motion group even though this program cannot use motion groups. [Remedy] Clear the motion group mask in the program detail screen. INTP-130 ABORT.L (%s^4, %d^5) Exec status recovery failed [Cause] Failed to recover execution status. [Remedy] Refer to the error cause code. INTP-131 ABORT.L Number of stop exceeds limit [Cause] Too many stop data is created at one time. [Remedy] Decrease the number of stop data. INTP-132 Unlocked groups specified [Cause] The specified motion groups are already unlocked. [Remedy] Change the specify of motion group. INTP-133 Motion is already released [Cause] Some specified motion groups are already unlocked. [Remedy] Change the specify of motion group. Lock the motion group. INTP-134 Over automatic start Max counter [Cause] The automatic start was done the defined times but the alarm was not fixed. [Remedy] Manually fix the alarm. INTP-135 Recovery DO OFF in auto start mode [Cause] The error recovery DO status is OFF in the automatic start feature So the resume program cannot be executed automatically. [Remedy] Please check the condition of error recovery DO status
- 1083 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
INTP-136 Can not use motion group for dry run function [Cause] In $PAUSE_PROG and $RESUME_PROG, a program using a motion group is specified. [Remedy] Specify a program not specifying a motion group. INTP-137 Program specified by $PAUSE_PROG doesn't exist. [Cause] $PAUSE_PROG does not include a specified program. [Remedy] Check $PAUSE_PROG. INTP-138 Program specified by $RESM_DRYPROG doesn't exist. [Cause] $RESUME_PROG does not include a specified program. [Remedy] Check $RESUME_PROG. INTP-139 (%s^4, %d^5) Local variable request failed [Cause] Execution failed. [Remedy] Check the alarm history screen to see if another alarm is output. INTP-200 PAUSE.L (%s^4, %d^5) Unimplemented TP instruction [Cause] This instruction cannot be used. [Remedy] Make sure that the appropriate option is loaded. INTP-201 PAUSE.L (%s^4, %d^5) Untaught element encountered [Cause] The program contains a portion without teaching data. The specified condition program contains an error (statement without teaching data). [Remedy] Teach the instruction. INTP-202 PAUSE.L (%s^4, %d^5) Syntax error [Cause] Instruction syntax error. [Remedy] Reteach the instruction. INTP-203 PAUSE.L (%s^4, %d^5) Variable type mismatch [Cause] The variable type is not correct. [Remedy] Check the variable type. INTP-204 PAUSE.L (%s^4, %d^5) Invalid value for index [Cause] The index value is invalid. [Remedy] Check the index value. INTP-205 PAUSE.L (%s^4, %d^5) Analog port access error [Cause] Analog I/O is not functioning properly. [Remedy] Refer to the error cause code. INTP-206 PAUSE.L (%s^4, %d^5) Digital port access error [Cause] Digital I/O is not functioning properly. [Remedy] Refer to the error cause code. INTP-207 PAUSE.L (%s^4, %d^5) Group I/O port access error [Cause] Group I/O is not functioning properly. [Remedy] Refer to the error cause code. INTP-208 PAUSE.L (%s^4, %d^5) Divide by 0 [Cause] Division by 0 was executed. [Remedy] Check the value. - 1084 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
INTP-209 PAUSE.L (%s^4, %d^5) SELECT is needed [Cause] A CASE instruction was executed before a SELECT instruction. [Remedy] Add a SELECT instruction before the CASE instruction. INTP-212 PAUSE.L (%s^4, %d^5) Invalid value for OVERRIDE [Cause] The indicated value cannot be used for the OVERRIDE instruction. [Remedy] Check the value. INTP-213 PAUSE.L %s^7 (%s^4, %d^5) UALM[%d^9] [Cause] A user alarm occurred. [Remedy] Refer to the user alarm code. INTP-214 PAUSE.L (%s^4, %d^5) Specified group not locked [Cause] The position register or frame setup instructions were executed in a program without a motion group. [Remedy] Set up the motion group in the program DETAIL screen. Refer to the user alarm code. INTP-215 PAUSE.L (%s^4, %d^5) Group mismatch [Cause] The position data is invalid. [Remedy] Check the position data. INTP-216 PAUSE.L (%s^4, %d^5) Invalid value for group number [Cause] The indicated value is invalid for the motion group number. [Remedy] Check the value. INTP-217 PAUSE.L (%s^4, %d^5) SKIP CONDITION needed [Cause] The SKIP instruction was executed before a SKIP CONDITION instruction. [Remedy] Add a SKIP CONDITION instruction. INTP-218 PAUSE.L (%s^4, %d^5) Skip failed [Cause] The SKIP instruction or SKIP CONDITION instruction cannot be executed. [Remedy] Refer to the error cause code. INTP-219 ABORT.L (%s^4, %d^5) Pause task failed [Cause] The pause instruction cannot be executed. [Remedy] Refer to the error cause code. INTP-220 ABORT.L (%s^4, %d^5) Abort task failed [Cause] The ABORT instruction cannot be executed. [Remedy] Refer to the error cause code. INTP-221 PAUSE.L (%s^4, %d^5) Application failed [Cause] The application instruction cannot be executed. [Remedy] Refer to the error cause code. INTP-222 PAUSE.L (%s^4, %d^5) Call program failed [Cause] The program CALL instruction cannot be executed. [Remedy] Refer to the error cause code.
- 1085 -
C.ALARM CODES
APPENDIX
INTP-223 PAUSE.L (%s^4, %d^5) Delay time failed [Cause] The WAIT instruction cannot be executed. [Remedy] Refer to the error cause code. INTP-224 PAUSE.L (%s^4, %d^5) Jump label failed [Cause] The BRANCH instruction cannot be executed. [Remedy] Refer to the error cause code. INTP-225 PAUSE.L (%s^4, %d^5) Motion statement failed [Cause] The MOTION instruction cannot be executed. [Remedy] Refer to the error cause code. INTP-226 PAUSE.L (%s^4, %d^5) Read position register failed [Cause] The position register cannot be read. [Remedy] Refer to the error cause code. INTP-227 PAUSE.L (%s^4, %d^5) Write position register failed [Cause] The position register cannot be written. [Remedy] Refer to the error cause code. INTP-228 PAUSE.L (%s^4, %d^5) Read register failed [Cause] The register cannot be read. [Remedy] Refer to the error cause code. INTP-229 PAUSE.L (%s^4, %d^5) Write register failed [Cause] The register cannot be written. [Remedy] Refer to the error cause code. INTP-230 PAUSE.L (%s^4, %d^5) Wait condition failed [Cause] A condition WAIT instruction cannot be executed. [Remedy] Refer to the error cause code. INTP-231 PAUSE.L (%s^4, %d^5) Read next line failed [Cause] The next line cannot be read. [Remedy] Refer to the error cause code. INTP-232 PAUSE.L (%s^4, %d^5) Invalid frame number [Cause] The frame number is invalid. [Remedy] Check the frame number. INTP-233 PAUSE.L (%s^4, %d^5) Read frame value failed [Cause] The specified frame cannot be read. [Remedy] Refer to the error cause code. INTP-234 PAUSE.L (%s^4, %d^5) Write frame value failed [Cause] The specified frame cannot be written. [Remedy] Refer to the error cause code. INTP-235 PAUSE.L (%s^4, %d^5) Read pos item failed [Cause] The position variable cannot be read. [Remedy] Refer to the error cause code.
- 1086 -
B-82594EN-4/01
B-82594EN-4/01
APPENDIX
C.ALARM CODES
INTP-236 PAUSE.L (%s^4, %d^5) Write pos item failed [Cause] The position variable cannot be written. [Remedy] Refer to the error cause code. INTP-237 WARN (%s^4, %d^5) No more motion for BWD [Cause] Backward execution cannot be executed any further because the current program line is at the top. [Remedy] Stop using backward execution at this point. INTP-238 WARN (%s^4, %d^5) BWD execution completed [Cause] Backward execution was completed. [Remedy] Do not use backward execution from this point. INTP-239 WARN (%s^4, %d^5) Cannot execute backwards [Cause] This instruction cannot be executed backwards. [Remedy] Set the cursor to execute at the next line. INTP-240 PAUSE.L (%s^4, %d^5) Incompatible data type [Cause] The specified data type in the PARAMETER instruction is invalid for the parameter type. [Remedy] Check the data type. INTP-241 PAUSE.L (%s^4, %d^5) Unsupported parameter [Cause] This type of parameter cannot be used. [Remedy] Check the parameter type. INTP-242 PAUSE.L (%s^4, %d^5) Offset value is needed [Cause] An OFFSET instruction was executed before an OFFSET CONDITION instruction. A position register was not taught in the OFFSET PR[] instruction. [Remedy] Add an OFFSET CONDITION instruction before the OFFSET instruction. Teach the position register. INTP-243 ABORT.G (%s^4, %d^5) Def grp is not specified [Cause] This program has no motion group defined. The MOTION instruction cannot be executed. [Remedy] Remove the MOTION instruction or set up the motion group in the program DETAIL screen. INTP-244 PAUSE.L (%s^4, %d^5) Invalid line number [Cause] The input line number is incorrect. [Remedy] Check the line number. INTP-245 PAUSE.L (%s^4, %d^5) RCV stmt failed [Cause] The RECEIVE R[] instruction cannot be executed. [Remedy] Refer to the error cause code. INTP-246 PAUSE.L (%s^4, %d^5) SEMAPHORE stmt failed [Cause] The SEMAPHORE instruction cannot be executed. [Remedy] Refer to the error cause code. INTP-247 PAUSE.L (%s^4, %d^5) Pre exec failed [Cause] Internal error of software. [Remedy] Contact our service center serving your locality.
- 1087 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
INTP-248 PAUSE.L (%s^4, %d^5) MACRO failed [Cause] The MACRO instruction cannot be executed. [Remedy] Refer to the error cause code. INTP-249 PAUSE.L Macro is not set correctly [Cause] The MACRO setup was invalid. [Remedy] Check the MACRO setup. INTP-250 PAUSE.L (%s^4, %d^5) Invalid uframe number [Cause] The user frame number is invalid. [Remedy] Refer to the error cause code. INTP-251 PAUSE.L (%s^4, %d^5) Invalid utool number [Cause] The tool frame number is invalid. [Remedy] Refer to the error cause code. INTP-252 PAUSE.L User frame number mismatch [Cause] The user frame number in the positional data is not the same as the currently selected user frame number. [Remedy] Check the user frame number. INTP-253 PAUSE.L Tool frame number mismatch [Cause] The tool frame number in the positional data is not the same as the currently selected tool frame number. [Remedy] Check the tool frame number. INTP-254 PAUSE.L (%s^4, %d^5) Parameter not found [Cause] The specified parameter name cannot be found. [Remedy] Check the parameter name. INTP-255 PAUSE.L (%s^4, %d^5) CAL_MATRIX failed [Cause] The CAL_MATRIX instruction cannot be executed. [Remedy] Refer to the error cause code. INTP-256 PAUSE.L (%s^4, %d^5) No data for CAL_MATRIX [Cause] The origin 3 points or destination 3 points are not taught. [Remedy] Teach the origin 3 points or destination 3 points. INTP-257 PAUSE.L (%s^4, %d^5) Invalid delay time [Cause] The wait time value is negative or exceeds the maximum value of 2147483.647 sec. [Remedy] Input a correct value. INTP-258 PAUSE.L (%s^4, %d^5) Weld port access error [Cause] The weld is not functioning properly. [Remedy] Refer to the error cause code. INTP-259 PAUSE.L (%s^4, %d^5) Invalid position type [Cause] The data type of the position register was taught using joint type. [Remedy] Change position register data to Cartesian.
- 1088 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
INTP-260 PAUSE.L (%s^4, %d^5) Invalid torque limit value [Cause] The specified torque limit is not in the range of 0.0 to 100.0. [Remedy] Specify a torque limit in the range of 0.0 to 100.0. INTP-261 PAUSE.L (%s^4, %d^5) Array subscript missing [Cause] No array element number is specified. [Remedy] Specify an array element number. INTP-262 PAUSE.L (%s^4, %d^5) Field name missing [Cause] No element name is specified. [Remedy] Specify an element name. INTP-263 PAUSE.L (%s^4, %d^5) Invalid register type [Cause] The register type is not valid. [Remedy] Check the register type. INTP-265 PAUSE.L (%s^4, %d^5) Invalid value for speed value [Cause] The indicated value cannot be used for the AF instruction. [Remedy] Specify a value in the range of 0 to 100. INTP-266 ABORT.L (%s^4, %d^5) Mnemonic in interrupt is failed [Cause] The execution of mnemonic instructions in the KAREL interrupt program failed. [Remedy] insert a CANCEL or STOP instruction before calling an interrupt routine. INTP-267 PAUSE.L (%s^4, %d^5) RUN stmt failed [Cause] Specified program is already running. [Remedy] Abort the specified program. INTP-268 PAUSE.L (%s^4, %d^5) This statement only one in each line [Cause] A single line contains more than one application instruction. Only one of these statements can exist per line. [Remedy] Delete the extra statement. INTP-269 PAUSE.L (%s^4, %d^5) Skip statement only one in each line [Cause] A single line contains more than one skip instruction. Only one Skip statement can exist per line. [Remedy] Delete the extra Skip statement. INTP-270 PAUSE.L (%s^4, %d^5) different group cannot BWD [Cause] During backward execution, a move is encountered that has a different group number from the previous motion statement. [Remedy] Use FWD execution carefully. INTP-271 WARN (%s^4, %d^5) Excessive torque limit value [Cause] The torque limit value was modified to exceed it's maximum value. The torque limit value was clamped at the upper torque limit. [Remedy] Set torque limit value less than or equal to the maximum value. INTP-272 PAUSE.L (%s^4, %d^5) Unsupported operator [Cause] This operator is not supported. [Remedy] Check the operator.
- 1089 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
INTP-274 (%s^4, %d^5) CH program error [Cause] This monitor statement cannot be executed. [Remedy] Refer to the error cause code. Use MENU to display the Alarm Log screen. [Cause] If this alarm is raised together with the "MEMO-004 WARN SPECIFIED PROGRAM IN USE" alarm, the specified condition program is currently being edited. [Remedy] Select another program from the program list. [Cause] If this alarm is raised together with the "INTP-275 PAUSE.L INVALID SUB TYPE OF CH PROGRAM" alarm, the sub type of the specified condition program may not be CH, or that program may not exist. INTP-275 Invalid sub type of CH program [Cause] The sub type of specified ch program cannot be used. [Remedy] Check the sub type of this CH program. INTP-276 (%s^4, %d^5) Invalid combination of motion option [Cause] The motion option instructions (SKIP, TIME BEFORE/AFTER, and application instruction) cannot be taught together [Remedy] Delete the motion option instruction INTP-277 (%s^4, %d^5) Internal MACRO EPT data mismatch [Cause] The EPT index in macro table doesn't point the program name defined in macro table. That is, the EPT index in macro table is incorrect. [Remedy] Please set the correct EPT index for the program name defined in macro table. INTP-278 %s^7 [Cause] The DI monitor alarm for auto error recovery function occurs. [Remedy] This is a user defined alarm. INTP-279 (%s^4, %d^5) Application instruction mismatch [Cause] The application instruction was executed. But this application instruction doesn't match to the application process data of this program. [Remedy] Please change the application process data of this program to the adequate application for this application instruction. INTP-280 (%s^4, %d^5) Application data mismatch [Cause] The application data of called program is different from that of the original program. [Remedy] Please change the structure of the program. INTP0281 No application data [Cause] This program doesn't have the application data. [Remedy] Please define the application data in the program detail screen. INTP-282 (%s^4, %d^5) Fast fault status mismatch [Cause] Internal system error. [Remedy] Contact our service center serving your locality. INTP-283 (%s^4, %d^5) Stack over flow for fast fault recovery [Cause] Stack over flow to record the fast fault recovery nesting data [Remedy] Reduce the nesting of the program
- 1090 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
INTP-284 No detection of fast fault recovery [Cause] The point for the fast fault recover cannot detected [Remedy] Contact our service center serving your locality. INTP-285 Karel program cannot entry in fast fautl recovery [Cause] The fast entry cannot be performed in the karel program. [Remedy] Use the TP program. INTP-286 MAINT program isn't defined in fast fautl recovery [Cause] MAINT program is not defined in fast fault recovery. [Remedy] Set MAINT program. INTP-287 Fail to execute MAINT program [Cause] It failed to execute MAINT program [Remedy] Confirm the MAINT program name is correct or MAINT program exist in actual. INTP-288 (%s^4, %d^5) Parameter does not exist [Cause] The parameter designated by AR register does not exist. [Remedy] Please confirm the index of AR register and the parameter in CALL/MACRO command in main program. INTP-289 Can't save ffast point at program change [Cause] When fast fault is enabled, the program was paused at the part of program change [Remedy] Check whether the CONT termination exists at end of sub-program. If it exist, change it to FINE. This is the limitation of the fast fault recovery function. INTP-290 Fast fault recovery position is not saved [Cause] During fast fault recovery sequence, any alarm occurs. So the fast fault recovery position is not saved. INTP-291 (%s^4, %d^5) Index for AR is not correct [Cause] The AR register number is incorrect. At present, this alarm is not issued. [Remedy] Check the index of the AR register and the argument specified in the call/macro instruction of the main program. INTP-292 more than 6 motion with DB executed [Cause] Six or more advanced execution (distance) motions overlapped each other. [Remedy] Modify the teaching so that six or more advanced execution (distance) motions do not overlap each other. INTP-293 (%s,%d)DB too small(away)(%dmm) [Cause] The condition for advanced execution (distance) is not satisfied. [Remedy] Increase the specified distance value. INTP-294 TPE parameter error [Cause] An incorrect argument is specified for call/macro instruction execution. [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
- 1091 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
INTP-295 (%s,%d)DB too small(away)(%dmm) [Cause] The condition for advanced execution (distance) is not satisfied. [Remedy] Increase the specified distance value. INTP-296 (%s,%d) $SCR_GRP[%d].$M_POS_ENB is FALSE [Cause] Advanced execution (distance) does not function when $SCR_GRP[].$M_POS_ENB is FALSE. [Remedy] Change $SCR_GRP[].$M_POS_ENB to TRUE. INTP-297 (%s,%d)DB too small(done)(%dmm) [Cause] A motion statement ended before the condition for advanced execution (distance) is satisfied. [Remedy] Increase the specified distance value. INTP-300 ABORT.L (%s^4, %d^5) Unimplemented P-code [Cause] KAREL program error. This KAREL statement cannot be executed. [Remedy] Check the KAREL translator software version. INTP-301 ABORT.L (%s^4, %d^5) Stack underflow [Cause] KAREL program error. Execution entered into a FOR loop by the GOTO statement. [Remedy] A GOTO statement cannot be used to enter or exit a FOR loop. Check the label of the GOTO statement. INTP-302 ABORT.L (%s^4, %d^5) Stack overflow [Cause] 1 A recursive program instruction was executed repeatedly without limit. 2 Too many programs are called at one time. [Remedy] 1 Before executing a recursive instruction, perform programming so that a call to the instruction can be cleared at any point of execution. 2 Reduce the number of programs to be called at any one time. For KAREL programs, the stack size can be increased. INTP-303 ABORT.L (%s^4, %d^5) Specified value exceeds limit [Cause] KAREL program error. The specified value exceeds the maximum limit. [Remedy] Check the value. INTP-304 ABORT.L (%s^4, %d^5) Array length mismatch [Cause] KAREL program error. The dimensions of the arrays are not the same. [Remedy] Check the dimensions of the arrays. INTP-305 ABORT.L (%s^4, %d^5) Error related condition handler [Cause] KAREL program error. A condition handler error occurred. [Remedy] Refer to the error cause code. INTP-306 ABORT.L (%s^4, %d^5) Attach request failed [Cause] KAREL program error. The ATTACH statement failed. [Remedy] Refer to the error cause code. INTP-307 ABORT.L (%s^4, %d^5) Detach request failed [Cause] KAREL program error. The DETACH statement failed. [Remedy] Refer to the error cause code.
- 1092 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
INTP-308 ABORT.L (%s^4, %d^5) No case match is encountered [Cause] KAREL program error. The CASE statement does not match any branches. [Remedy] Check the CASE value and branches. INTP-309 ABORT.L (%s^4, %d^5) Undefined WITHCH parameter [Cause] KAREL program error. The specified parameter cannot be used in the with clause of the condition handler. [Remedy] Check the parameter. INTP-310 ABORT.L (%s^4, %d^5) Invalid subscript for array [Cause] KAREL program error. The index of the array is invalid. [Remedy] Check the length of the array and index value. INTP-311 PAUSE.L (%s^4, %d^5) Uninitialized data is used [Cause] KAREL program error. Untaught or uninitialized data was used. [Remedy] Teach or initialize the data before using it. INTP-312 ABORT.L (%s^4, %d^5) Invalid joint number [Cause] KAREL program error. The wrong axis number was used. [Remedy] Check the axis number and the data value. INTP-313 ABORT.L (%s^4, %d^5) Motion statement failed [Cause] KAREL program error. The MOTION statement cannot be executed. [Remedy] Refer to the error cause code. INTP-314 ABORT.L (%s^4, %d^5) Return program failed [Cause] KAREL program error. Execution cannot be returned from the routine. [Remedy] Refer to the error cause code. INTP-315 ABORT.L (%s^4, %d^5) Built-in execution failed [Cause] KAREL program error. A built-in routine error occurred. [Remedy] Refer to the error cause code. INTP-316 ABORT.L (%s^4, %d^5) Call program failed [Cause] KAREL program error. The routine cannot be called. [Remedy] Verify the routine is loaded by referring to the error cause code. INTP-317 ABORT.L (%s^4, %d^5) Invalid condition specified [Cause] KAREL program error. The specified condition was invalid. [Remedy] Check the condition. INTP-318 ABORT.L (%s^4, %d^5) Invalid action specified [Cause] KAREL program error. The specified action was invalid. [Remedy] Check the action. INTP-319 ABORT.L (%s^4, %d^5) Invalid type code [Cause] KAREL program error. The data type was invalid. [Remedy] Check the data type. INTP-320 ABORT.L (%s^4, %d^5) Undefined built-in [Cause] KAREL program error. The built-in routine is not defined. [Remedy] Check the appropriate option is loaded. - 1093 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
INTP-321 ABORT.L (%s^4, %d^5) END stmt of a func rtn [Cause] KAREL program error. The END statement was executed in a function routine instead of a RETURN statement. [Remedy] Add a RETURN statement to the function routine. INTP-322 ABORT.L (%s^4, %d^5) Invalid arg val for builtin [Cause] KAREL program error. The argument value of a built-in routine was wrong. [Remedy] Check the argument value. INTP-323 ABORT.L (%s^4, %d^5) Value overflow [Cause] KAREL program error. The data value for the variable was too large. [Remedy] Check the variable's type and data value. INTP-324 ABORT.L (%s^4, %d^5) Invalid open mode string [Cause] KAREL program error. The usage string in the OPEN FILE statement was invalid. [Remedy] Check the usage string in the OPEN FILE statement. INTP-325 ABORT.L (%s^4, %d^5) Invalid file string [Cause] KAREL program error. The file string in the OPEN FILE statement was invalid. [Remedy] Check the file string. INTP-326 ABORT.L (%s^4, %d^5) File var is already used [Cause] KAREL program error. The FILE variable is already being used. [Remedy] Close the file before reusing the FILE variable or add a new FILE variable. INTP-327 ABORT.L (%s^4, %d^5) Open file failed [Cause] KAREL program error. The file could not be opened. [Remedy] Refer to the error cause code. INTP-328 ABORT.L (%s^4, %d^5) File is not opened [Cause] KAREL program error. The specified file was not opened before operation. [Remedy] Open the file before operation. INTP-329 ABORT.L (%s^4, %d^5) Write variable failed [Cause] KAREL program error. [Remedy] Refer to the error cause code. INTP-330 ABORT.L (%s^4, %d^5) Write file failed [Cause] KAREL program error. Writing to the file failed. [Remedy] Refer to the error cause code. INTP-331 ABORT.L (%s^4, %d^5) Read variable failed [Cause] KAREL program error. Reading the variable failed. [Remedy] Refer to the error cause code. INTP-332 ABORT.L (%s^4, %d^5) Read data is too short [Cause] KAREL program error. Data read from the file is too short. [Remedy] Make sure the data in the file is valid.
- 1094 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
INTP-333 ABORT.L (%s^4, %d^5) Invalid ASCII string for read [Cause] KAREL program error. The string read from the file is wrong. [Remedy] Check the data of the file. INTP-334 ABORT.L (%s^4, %d^5) Read file failed [Cause] KAREL program error. Reading from the file failed. [Remedy] Refer to the error cause code. INTP-335 ABORT.L (%s^4, %d^5) Cannot open pre-defined file [Cause] KAREL program error. A file pre-defined by the system cannot be opened. [Remedy] Use the file defined by the system without opening it. INTP-336 ABORT.L (%s^4, %d^5) Cannot close pre-defined file [Cause] KAREL program error. A file pre-defined by the system cannot be closed. [Remedy] Do not try to close it. INTP-337 ABORT.L (%s^4, %d^5) Invalid routine type [Cause] KAREL program error. This routine cannot be used. [Remedy] Make sure you have the correct routine type and name. INTP-338 ABORT.L (%s^4, %d^5) Close file failed [Cause] KAREL program error. Closing the file failed. [Remedy] Refer to the error cause code. INTP-339 ABORT.L (%s^4, %d^5) Invalid program name [Cause] KAREL program error. The program name is invalid. [Remedy] Make sure you have the correct program name. INTP-340 ABORT.L (%s^4, %d^5) Invalid variable name [Cause] KAREL program error. The variable name is invalid. [Remedy] Make sure you have the correct variable name. INTP-341 ABORT.L (%s^4, %d^5) Variable not found [Cause] KAREL program error. The variable cannot be found. [Remedy] Verify the program name and variable name. INTP-342 ABORT.L (%s^4, %d^5) Incompatible variable [Cause] KAREL program error. The data type defined by the BYNAME function and the variable type are mismatched. [Remedy] Make sure you have the correct data type and variable type. INTP-343 ABORT.L (%s^4, %d^5) Reference stack overflow [Cause] KAREL program error. Too many variables are passed using the BYNAME function. [Remedy] Decrease the number of BYNAME functions. INTP-344 ABORT.L (%s^4, %d^5) Readahead buffer overflow [Cause] KAREL program error. The buffer to read ahead from the device overflowed. [Remedy] Increase the buffer size. INTP-345 ABORT.L (%s^4, %d^5) Pause task failed [Cause] KAREL program error. The PAUSE statement cannot be executed. [Remedy] Refer to the error cause code. - 1095 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
INTP-346 ABORT.L (%s^4, %d^5) Abort task failed [Cause] KAREL program error. The ABORT statement cannot be executed. [Remedy] Refer to the error cause code. INTP-347 ABORT.L (%s^4, %d^5) Read I/O value failed [Cause] KAREL program error. The digital input signal cannot be input. [Remedy] Refer to the error cause code. INTP-348 ABORT.L (%s^4, %d^5) Write I/O value failed [Cause] KAREL program error. The digital output signal cannot be output. [Remedy] Refer to the error cause code. INTP-349 ABORT.L (%s^4, %d^5) Hold motion failed [Cause] KAREL program error. The HOLD statement cannot be executed. [Remedy] Refer to the error cause code. INTP-350 ABORT.L (%s^4, %d^5) Unhold motion failed [Cause] KAREL program error. The UNHOLD statement cannot be executed. [Remedy] Refer to the error cause code. INTP-351 ABORT.L (%s^4, %d^5) Stop motion failed [Cause] KAREL program error. The STOP statement cannot be executed. [Remedy] Refer to the error cause code. INTP-352 ABORT.L (%s^4, %d^5) Cancel motion failed [Cause] KAREL program error. The CANCEL statement cannot be executed. [Remedy] Refer to the error cause code. INTP-353 ABORT.L (%s^4, %d^5) Resume motion failed [Cause] KAREL program error. The RESUME statement cannot be executed. [Remedy] Refer to the error cause code. INTP-354 ABORT.L (%s^4, %d^5) Break point failed [Cause] KAREL program error. The break point function cannot be executed. [Remedy] Refer to the error cause code. INTP-355 ABORT.L (%s^4, %d^5) AMR is not found [Cause] KAREL program error. The AMR operated by the RETURN_AMR built-in routine was not found. [Remedy] Check program operation. INTP-356 ABORT.L (%s^4, %d^5) AMR is not processed yet [Cause] KAREL program error. The RETURN_AMR built-in routine cannot be used for an unoperated AMR. [Remedy] Operate the AMR using the WAIT_AMR built-in routine. INTP-357 ABORT.L (%s^4, %d^5) WAIT_AMR is cancelled [Cause] KAREL program error. The execution of the WAIT_AMR built-in routine was cancelled. [Remedy] The program executing the WAIT_AMR must be restarted.
- 1096 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
INTP-358 ABORT.L (%s^4, %d^5) Timeout at read request [Cause] KAREL program error. The READ statement timed out. [Remedy] Check the device being read. INTP-359 ABORT.L (%s^4, %d^5) Read request is nested [Cause] KAREL program error. Another READ statement was executed while a READ statement was waiting for input. [Remedy] Remove nested reads. INTP-360 ABORT.L (%s^4, %d^5) Vector is 0 [Cause] KAREL program error. The vector value was invalid. [Remedy] Check the vector value. INTP-361 PAUSE.L (%s^4, %d^5) FRAME:P2 is same as P1 [Cause] KAREL program error. The X-axis direction cannot be calculated in the FRAME built-in routine because P1 and P2 are the same point. [Remedy] Teach P1 and P2 as different points. INTP-362 PAUSE.L (%s^4, %d^5) FRAME:P3 is same as P1 [Cause] KAREL program error. The X-Y plane cannot be calculated in the FRAME built-in routine because P1 and P3 are the same point. [Remedy] Teach P1 and P3 as different points. INTP-363 PAUSE.L (%s^4, %d^5) FRAME:P3 exists on line P2-P1 [Cause] KAREL program error. The X-Y plane cannot be calculated in the FRAME built-in routine because P3 is located in the X-axis direction. [Remedy] Teach P3 out of the X-axis direction. INTP-364 ABORT.L (%s^4, %d^5) String too short for data [Cause] KAREL program error. The target string is too short. [Remedy] Increase the target string size. INTP-365 ABORT.L (%s^4, %d^5) Predefined window not opened [Cause] KAREL program error. A FILE pre-defined by the system is not opened. [Remedy] Check the use of this file. INTP-366 ABORT.L (%s^4, %d^5) I/O status is not cleared [Cause] KAREL program error. The last file operation failed. [Remedy] Reset the error using the CLR_IO_STAT built-in routine. INTP-367 ABORT.L (%s^4, %d^5) Bad base in format [Cause] KAREL program error. I/O mode operates only from binary to hexadecimal. [Remedy] Check the specified mode. INTP-368 PAUSE.L (%s^4, %d^5) Cannot use specified program [Cause] KAREL program error. The specified program cannot be used. [Remedy] Refer to the error cause code. INTP-369 ABORT.L (%s^4, %d^5) Timeout at WAIT_AMR [Cause] KAREL program error. The WAIT_AMR built-in routine timed out. [Remedy] If an AMR was expected within the time-out value check logic in the task that should have posted the AMR - 1097 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
INTP-370 ABORT.L (%s^4, %d^5) Vision CPU not plugged in [Cause] KAREL program error. The vision CPU board is not plugged in. [Remedy] Plug in the vision CPU board. INTP-371 ABORT.L (%s^4, %d^5) Vision built-in overflow [Cause] KAREL program error. The operation overflowed in the vision built-in routine. [Remedy] Modify your program so that fewer vision built-ins are executing at the same time. INTP-372 ABORT.L (%s^4, %d^5) Undefined vision built-in [Cause] KAREL program error. The vision built-in routine is not defined. [Remedy] Check the appropriate option is loaded. INTP-373 ABORT.L (%s^4, %d^5) Undefined vision parameter type [Cause] KAREL program error. The parameter to the vision built-in routine is invalid. [Remedy] Check the parameter of the vision built-in routine. INTP-374 ABORT.L (%s^4, %d^5) Undefined vision return type [Cause] KAREL program error. The return value from the vision built-in routine is invalid. [Remedy] Check the return value from the vision built-in routine. INTP-375 (%s^4, %d^5) System var passed using BYNAME [Cause] This alarm is related to the KAREL program. With the BYNAME function, no system variable can be used. Use Pass without BYNAME, GET_VAR, or SET_VAR. INTP-376 ABORT.L (%s^4, %d^5) Motion in interrupt is failed [Cause] There is no CANCEL or STOP instruction. [Remedy] insert a CANCEL or STOP instruction before call a interrupt routine. INTP-377 WARN (%s^4, %d^5) Local COND recovery failed [Cause] This local condition cannot be recovered. [Remedy] Refer to the error cause code. INTP-378 WARN (%s^4, %d^5) Local variable is used [Cause] Local variable or parameter is used for the condition. [Remedy] Use global variable to recover local condition. INTP-379 ABORT.L Bad condition handler number [Cause] An invalid condition handler number was used in either a condition handler definition, or with an ENABLE, DISABLE, or PURGE statement or action. [Remedy] Correct the condition handler number. Condition handler numbers must be in the range of 1-1000. INTP-380 ABORT.L Bad program number [Cause] An invalid program number has been specified. [Remedy] Use a valid program number. Program numbers must be in the range of 1 $SCR,$MAXNUMTASK + 2. INTP-381 (%s^4, %d^5) Invalid Delay Time [Cause] An invalid delay time has been specified in DELAY statement. [Remedy] Use a valid delay time. Delay time must be in the range 0..86400000 . - 1098 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
INTP-382 (%s^4, %d^5) Invalid bit field value [Cause] An invalid value has been specified in bit field [Remedy] Use a valid value for the bit field. INTP-383 (%s^4, %d^5) Path node out of range [Cause] The specified path node is out of range. [Remedy] Check the path node. INTP-400 ABORT.L (%s^4, %d^5) Number of motions exceeded [Cause] Too many motions are executed at the same time. [Remedy] Decrease the number of motions executed at the same time. Execute the next motion after the completion of the last motion. INTP-401 ABORT.L (%s^4, %d^5) Not On Top Of Stack [Cause] Paused motion exists after the motion was resumed. [Remedy] Resume the motion that was previously paused. INTP-420 (%s^4, %d^5) OFIX is not available [Cause] The attitude fix instruction cannot be used. [Remedy] Check the motion format and the motion addition instruction. INTP-421 (%s^4, %d^5) Stitch disable(S/S) [Cause] The single step mode is set. [Remedy] Cancel the single step mode. INTP-422 (%s^4, %d^5) Stitch enable signal off [Cause] The stitch enable signal is set to OFF. [Remedy] Set the stitch enable signal to ON. INTP-423 (%s^4, %d^5) Eq.condition signal error [Cause] The equipment condition signal is incorrect. [Remedy] Check the equipment condition signal. INTP-424 (%s^4, %d^5) Stitch speed error [Cause] The stitch speed value is incorrect. [Remedy] Check the stitch speed value. INTP-425 (%s^4, %d^5) Illegal motion type(J) [Cause] The stitch function cannot be used with joint motion. [Remedy] Make a change to linear motion. INTP-426 (%s^4, %d^5) Another prog is in stitching [Cause] Another program is using the stitch function. [Remedy] Terminate the program that is using the stitch function. INTP-450 (%s^4, %d^5) Cannot call KAREL program [Cause] From the master/slave/single slave program of the robot link, the KAREL program was called. [Remedy] Do not call the KAREL program from the master/slave/single slave program.
- 1099 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
INTP-451 (%s^4, %d^5) Cannot call Motion program [Cause] From the master/slave/single slave program of the robot link, a normal program with a motion group was called. [Remedy] Do not call a normal program with a motion group from the master/slave/single slave program. INTP-452 (%s^4, %d^5) Robot link type mismatch [Cause] From the master/slave/single slave program of the robot link, a program of a different type was called. [Remedy] Do not call a program of a different type from the master/slave/single slave program. INTP-453 (%s^4, %d^5) Not in remote [Cause] The slave program of the robot link can be executed only in the remote mode. [Remedy] Ensure that the remote condition is satisfied. INTP-454 (%s^4, %d^5) Illegal return occurred [Cause] In the robot link, the type of a calling program differs from the type of a called program. [Remedy] Match the type of a calling program with the type of a called program. INTP-455 (%s^4, %d^5) Group mismatch(Link pattern) [Cause] The master program motion group of the robot link does not match the master robot motion group specified with the link pattern. [Remedy] Match the master program motion group with the master robot motion group specified with the link pattern. INTP-456 (%s^4, %d^5) Group mismatch(Slave group) [Cause] The slave program motion group of the robot link does not match the slave robot motion group specified with the slave group. [Remedy] Match the slave program motion group with the slave robot motion group specified with the slave group. INTP-457 (%s^4, %d^5) Master tool number mismatch [Cause] The tool coordinate system number currently selected by the master robot does not match the robot link data master tool coordinate system number of the slave program. [Remedy] Match the tool coordinate system number currently selected by the master robot with the robot link data master tool coordinate system number of the slave program. INTP-458 (%s^4, %d^5) Robot is still moving [Cause] The robots are moving with the robot link, so that the master/slave/single slave cannot establish synchronization. [Remedy] After the robot stops, restart the program. INTP-459 (%s^4, %d^5) Slave cannot JOINT motion [Cause] The motion statement in the slave program of the robot link specifies a joint motion. [Remedy] Change the motion statement of the slave program to orthogonal motion. INTP-460 (%s^4, %d^5) Cannot use JOINT pos for Slave [Cause] The position data format of the slave program of the robot link is the joint format. [Remedy] Change the position data format of the slave program to the orthogonal format.
- 1100 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
INTP-461 (%s^4, %d^5) Master TP is enabled [Cause] The master program of the robot link was activated from the teach pendant. The slave program stops temporarily. [Remedy] The master program was activated from the teach pendant, so that the slave program stops temporarily. INTP-462 (%s^4, %d^5) Cannot start Robot Link [Cause] The setting of the robot link may be incorrect. [Remedy] Check the setting. INTP-463 (%s^4, %d^5) Motion group is Master [Cause] The motion group of a program whose execution was attempted with the robot link is master. [Remedy] Cancel the setting of master, then restart the program. INTP-465 (%s^4, %d^5) Tracking error [Cause] The robot link could not perform synchronous motion. [Remedy] Check the setting of the robot link. INTP-466 (%s^4, %d^5) Robot link not calibrated [Cause] The robot link is not calibrated. [Remedy] Calibrate the robot link. INTP-467 (%s^4, %d^5) Cannot use INC for Slave [Cause] In a motion statement of the slave program of the robot link, an incremental instruction is taught. [Remedy] The incremental instruction cannot be used in a motion statement of the slave program. INTP-468 (%s^4, %d^5) Cannot use OFFSET for Slave [Cause] In a motion statement of the slave program of the robot link, a compensation instruction is taught. [Remedy] The compensation instruction cannot be used in a motion statement of the slave program. INTP-469 (%s^4, %d^5) BWD is failed for Master [Cause] An attempt for BWD synchronization of the mater of the robot link failed. [Remedy] Place the slave in the synchronization wait state. INTP-470 (%s^4, %d^5) Not support BWD for Slav [Cause] BWD synchronization is not supported for the slave program of the robot link. [Remedy] BWD synchronization is supported for the slave program. INTP-471 (%s^4, %d^5) Robot is Master(Manual) [Cause] In the robot link, the robot is placed in the master (manual) state. [Remedy] In the master (manual) state, external activation is disabled. For external activation, set the master (single) state on the manual operation screen. INTP-472 (%s^4, %d^5) Robot is Slave(Manual) [Cause] In the robot link, the robot is placed in the slave (manual) state. [Remedy] In the slave (manual) state, other slaves cannot be executed. Hold the program, and cancel the slave (manual) state.
- 1101 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
INTP-474 (%s^4, %d^5) Synchro ID mismatch [Cause] In the robot link, a program with a synchronous motion ID different from the synchronous motion ID of the currently executed program was executed. [Remedy] Programs with different synchronous motion IDs cannot be executed at the same time. INTP-475 (%s^4, %d^5) Cannot single step [Cause] The slave program of the robot link cannot be executed in the single step mode. [Remedy] Cancel the single step mode. INTP-476 (%s^4, %d^5) BWD is failed [Cause] In the robot link, BWD failed. [Remedy] BWD failed. INTP-477 (%s^4, %d^5) Cannot run Slave directly [Cause] The slave program of the robot link cannot be activated directly. [Remedy] Execute the slave by calling from the normal program. INTP-478 This group can not be MASTER [Cause] This alarm is issued when an attempt is made to specify as a mater a robot not set as a master in the robot link or when an attempt is made to specify as a master a group not set as a master on the manual operation screen. [Remedy] Specify another group as a master, or modify the setting. INTP-479 Bad Hostname or Address(MASTER [Cause] An attempt was made to execute the robot link when a host name not registered is specified or the setting of an IP address is incorrect on the host communication screen or the master setting screen. [Remedy] Check the master in the robot link setting and host communication setting. INTP-480 Bad Hostname or Address(SLAVE) [Cause] An attempt was made to execute the robot link when a host name not registered is specified or the setting of an IP address is incorrect in the host communication setting or link pattern setting. [Remedy] Check the slave in the robot link setting and host communication setting. INTP-481 Bad Synchronization ID [Cause] In the robot link, a program-specified synchronous motion ID is incorrect. [Remedy] Correct the synchronous motion ID on the list screen. INTP-482 Bad Link Pattern Number [Cause] In the robot link, a program-specified link pattern number is incorrect. [Remedy] Correct the link pattern number on the list screen. INTP-483 Bad Master Number [Cause] In the robot link, a program-specified master number is incorrect. [Remedy] Correct the master number on the list screen. INTP-484 Bad Group number (MASTER) [Cause] The group number of the master of the robot link is incorrect. [Remedy] Check the group number of the master.
- 1102 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
INTP-485 Bad Group number (SLAVE) [Cause] The group number of the slave of the robot link is incorrect. [Remedy] Check the group number of the slave. INTP-486 SLAVE is not calibrated [Cause] In the robot link, there is a slave not calibrated. [Remedy] Calibrate the slave robot. INTP-488 RLINK communication timeout [Cause] In the robot link, communication initialization timed out. [Remedy] Increase the value of $RK_SYSCFG.$RMGR_PHTOUT by 100. INTP-489 Bad Hostname or Address, Group [Cause] An attempt was made to execute the robot link when the setting of a host name, IP address, or motion group is incorrect in the host communication setting or robot link setting. [Remedy] Check the robot link setting and host communication setting. INTP-490 Timeout for link start [Cause] An attempt was made to execute the robot link when the setting of a host name, IP address, or motion group is incorrect in the host communication setting or robot link setting or when the robot link program is not executed at the communication destination. So, a synchronization start timeout occurred. [Remedy] Check the robot link setting and host communication setting, and also check the state of the robot at the communication destination. INTP-491 Linked robot or comm stopped [Cause] During robot link execution, the robot at the communication destination stopped program execution, or stopped communication for a cause such as a power failure. [Remedy] Check the state of the robot at the communication destination. INTP-493 Slave program stopped [Cause] During slave program execution, the master program at the communication destination stopped. [Remedy] Check the state of the robot at the communication destination. INTP-493 Slave program stopped [Cause] During robot link execution as the master, the slave program at the communication destination stopped. [Remedy] Check the state of the robot at the communication destination.
JOG Error Codes ( ID = 19 ) JOG-001 WARN Overtravel Violation [Cause] A robot overtravel has occurred. [Remedy] While holding down the shift key, press the alarm clear button to clear the alarm. Then, while holding down the shift key, perform jog feed to move the overtravel axis into the movable range.
- 1103 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
JOG-002 WARN Robot not Calibrated [Cause] Robot has not been calibrated. [Remedy] Apply one the following methods for positioning: 1 Make positioning settings on the positioning screen. 2 Turn the power off and then on again. JOG-003 WARN No Motion Control [Cause] Other program has motion control [Remedy] Abort the program that has motion control by pressing FCTN key then selecting ABORT. JOG-004 WARN Illegal linear jogging [Cause] You cannot do more than one rotational jog at a time. [Remedy] Only press one rotational jog key at a time. JOG-005 WARN Can not clear hold flag [Cause] The hold key or hold button is held down. Or, *HOLD input is off. [Remedy] Release the hold key or hold button. Or, turn on *HOLD input. JOG-006 WARN Subgroup does not exist [Cause] No extended axis exist in this group with which to jog. [Remedy] No action is required. JOG-007 WARN Press SHIFT key to jog [Cause] The SHIFT key is not pressed. [Remedy] You must press the SHIFT key when jogging the robot. Release the JOG key then hold the SHIFT key and press the JOG key to jog. JOG-008 WARN Turn on TP to jog [Cause] Teach pendant is not enabled. [Remedy] Hold the DEADMAN and turn on the teach pendant before jogging the robot. JOG-009 WARN Hold deadman to jog [Cause] The DEADMAN switch is not pressed. [Remedy] Press the DEADMAN switch, then press RESET key to clear the error. JOG-010 WARN Jog pressed before SHIFT [Cause] The JOG key was pressed before the SHIFT key was pressed. [Remedy] Release the JOG key. Then hold down the SHIFT key and press the JOG key. JOG-011 WARN Utool changed while jogging [Cause] The selected tool frame changed while jogging. [Remedy] Release the SHIFT key and the JOG key. The new TOOL frame will take effect automatically. JOG-012 WARN manual brake enabled [Cause] The manual brake enabled. [Remedy] Engage all the brakes by pressing EMERGENCY STOP button, then press the RESET key. JOG-013 WARN Stroke limit (Group:%d Axis:%x Hex) [Cause] Robot axis reaches its specified stroke limit. [Remedy] The robot already reach the stroke limit and cannot jog in the current direction any more. Extend the axis limit if it does not exceed the robot and software specifications. - 1104 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
JOG-014 WARN Vertical fixture position [Cause] Robot reaches its vertical fixture position on the LR-MATE system. [Remedy] To continue jogging, release the JOG key then press it again. JOG-015 WARN Horizontal fixture position [Cause] Robot reaches its horizontal fixture position on the LR-MATE system. [Remedy] To continue jogging, release the JOG key then press it again. JOG-016 SERVO Softfloat time out(Group:%d) [Cause] Follow-up time is over when softfloat is ON. [Remedy] Make the system variable $SFLT_FUPTIM larger. JOG-017 At R-Theta robot posture [Cause] In remote TCP jogging, the robot assumed the R-Theta attitude. [Remedy] To continue jogging, release the jog key, then press the jog key again. JOG-020 Can not PATH JOG now [Cause] PATH JOG has selected, but robot is not currently on a taught path, or tool Z direction is same teaching path, so Y direction can not be determined. Can not PATH JOG [Remedy] Use shift-FWD to execute program path, or specify another jog frame. JOG-021 Multi key is pressed [Cause] Use of multiple jog keys is not supported in PATH JOG [Remedy] Use only one jog key at a time. JOG-022 Disabled in JOINT path [Cause] PATH jog is disabled in JOINT path [Remedy] PATH jog is available in LINEAR and CERCULAR path JOG-023 Available only in PAUSE [Cause] PATH jog is available only in PAUSE status [Remedy] PATH jog is available only in PAUSE status JOG-024 Currently this key is invalid [Cause] This key is currently disabled. [Remedy] Change the jog coordinate system. JOG-025 J4 is not zero [Cause] J4 is not at the 0_ position. [Remedy] To use attitude-fixed jogging, J4 needs to be at the 0_ position. JOG-026 J4 is zero [Cause] J4 is now at the 0_ position. [Remedy] Attitude-fixed jogging is enabled. JOG-027 Reverse direction from J4=0 [Cause] The direction of jogging is opposite to the 0_ direction of J4. [Remedy] Press the jog key for the opposite direction.
- 1105 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
JOG-028 Attitude fix mode limit (TCP) [Cause] A linear motion range limit was reached. [Remedy] Change the target position, or switch to joint motion. A stroke limit in the TCP mode was reached. JOG-029 OFIX jog error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. JOG-030 Can't jog as OFIX [Cause] Attitude-fixed jogging is disabled. An additional alarm is issued. [Remedy] Check the additional alarm on the alarm history screen.
TPIF Error Codes ( ID = 9 ) TPIF-001 to 003 WARN Mnemonic editor error (%s^1) [Cause] Illegal case occurred on software. [Remedy] Contact our service center serving your locality. TPIF-004 WARN Memory write error [Cause] The instruction cannot be used because the corresponding software option is not provided. [Remedy] Install the software option. TPIF-005 WARN Program is not selected [Cause] The program was not selected when the program was displayed at the edit screen. [Remedy] Select a program in the SELECT screen. TPIF-006 WARN SELECT is not taught [Cause] This taught statement needed the SELECT statement before the current line. [Remedy] Teach the SELECT statement before the current line. TPIF-007 WARN Robot is not calibrated [Cause] The calibration was not finished yet [Remedy] Finish the calibration. TPIF-008 WARN Memory protect violation [Cause] The program's write protection is set to on. [Remedy] Release protection on select screen. TPIF-009 WARN Cancel delete by application [Cause] The program cannot be deleted because program deletion is disabled by the application tool software. [Remedy] Enable program deletion on the application setting screen. TPIF-010 WARN Cancel enter by application [Cause] The program cannot be edited because program editing is disabled by the application tool software. [Remedy] Enable program editing on the application setting screen.
- 1106 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
TPIF-011 WARN Item is not found [Cause] Item is not found below this line [Remedy] Try another item or close search function TPIF-012 WARN Kinematics solution is invalid [Cause] Can not translate position data [Remedy] Check the configuration of robot and $MNUTOOL/$MNUFRAM of system variables TPIF-013 WARN Other program is running [Cause] Can not select the program when other is running or pausing. [Remedy] Select program after aborting the program which is running or pausing. TPIF-014 WARN Teach pendant is disabled [Cause] Can not be edit a program when the Teach pendant is disabled. [Remedy] Edit program after Teach pendant is enabled. TPIF-015 WARN Bad position register index [Cause] The specified position register index is invalid. [Remedy] Check the index of the position register. TPIF-016 to 017 WARN Memory access failed (%s^1) [Cause] Illegal case occurred on software. [Remedy] 1 Select a program again. 2 Contact FANUC Robotics. TPIF-018 WARN Unspecified index value [Cause] Specified index value is invalid. [Remedy] Check specified index value. TPIF-019 WARN This item cannot be replaced [Cause] This item can not be replaced. [Remedy] Try another item or close replace function. TPIF-020 NONE Mnaction search error [Cause] Illegal case occurred on software. [Remedy] Contact our service center serving your locality. TPIF-023 WARN WJNT and RTCP are not compatible [Cause] Wjnt and RTCP are not compatible [Remedy] Remove Wjnt or RTCP before add the other TPIF-030 WARN Program name is NULL [Cause] Program name was not entered. [Remedy] Enter program name. TPIF-031 WARN Remove num from top of Program name [Cause] Top of program name is number. [Remedy] Remove number from top of program name. TPIF-032 WARN Remove space from Program name [Cause] A space is included in the program name. [Remedy] Remove space from program name. - 1107 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
TPIF-033 WARN Remove comma from Program name [Cause] A comma is included in the program name. [Remedy] Remove comma from program name. TPIF-034 WARN Remove dot from Program name [Cause] A dot is included in the program name. [Remedy] Remove dot from program name. TPIF-035 WARN Remove minus from Program name [Cause] A minus is included in the program name. [Remedy] Remove minus from program name. TPIF-036 WARN Memory is not enough [Cause] Not enough memory available. [Remedy] Delete unused programs. TPIF-037 WARN Program must be selected by TP [Cause] Only the Teach Pendant default program can be edited on the CRT [Remedy] Please select the program on the Teach Pendant before editing on the CRT TPIF-038 WARN Invalid char in program name [Cause] Invalid character in program name [Remedy] Please remove invalid character from program name TPIF-040 WARN Label is already exist [Cause] Same label No. already exists. [Remedy] Change to different label No. TPIF-041 WARN MNUTOOLNUM number is invalid [Cause] Specified MNUTOOLNUM number is invalid. [Remedy] Check MNUTOOLNUM number in SYSTEM variables. TPIF-042 WARN MNUFRAMENUM number is invalid [Cause] Specified MNUFRAMNUM number is invalid. [Remedy] Check MNUFRAMNUM number in SYSTEM variables. TPIF-043 WARN External change is valid [Cause] Can not change robot (group), because the function that select robot by external DI is valid. [Remedy] Set $MULTI_ROBO.CHANGE_DI in SYSTEM variables to ZERO. TPIF-044 WARN Program is unsuitable for robot [Cause] The group mask of program differs from selected robot (group). [Remedy] Check to select robot (group) or check group mask of program attribute. TPIF-045 WARN Pallet number is over max [Cause] Palletizing instruction can not teach more than 16 in one program. [Remedy] Teach another program. TPIF-046 WARN Motion option is over max [Cause] Too many motion option of default motion [Remedy] Please decrease motion option of default motion - 1108 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
TPIF-047 WARN Invalid program is selected [Cause] The program type is wrong. [Remedy] Select TPE program. TPIF-048 WARN Running program is not found [Cause] The running program does not exist. TPIF-049 WARN Port number is invalid [Cause] Port is not set for outside device. [Remedy] Set port for outside device. TPIF-050 WARN Macro does not exist [Cause] A program is not assigned to this macro command. [Remedy] Assign a program to this macro command. TPIF-051 WARN Program has been selected by PNS [Cause] When a program has been selected by PNS, you can not select program at SELECT screen. [Remedy] You have to turn off the signal of PNSTROBE. TPIF-052 WARN FWD/BWD is disabled [Cause] When the Disabled FWD function has been selected, you can not execute the program by TP [Remedy] Please select the Disabled FWD in the function menu, then you can release it from the Disable FWD function. TPIF-053 WARN Not editing background program [Cause] The program has not been selected by the BACKGROUND editing [Remedy] Please select the BACKGROUND program in the SELECT screen TPIF-054 WARN Could not end editing [Cause] Memory is not enough or background program is invalid [Remedy] Delete any useless programs or confirm the background program TPIF-055 WARN Could not recovery original program [Cause] Failed recovering original program which has been selected by the BACKGROUND [Remedy] End editing by the END_EDIT of [EDCMD] again before executing the origianl program which has been selected by the BACKGROUND TPIF-056 WARN This program is used by the CRT [Cause] The program of BACKGROUND can not be selected by the CRT and TP at the same time [Remedy] End editing by the END_EDIT of [EDCMD] at the CRT TPIF-057 WARN This program is used by the TP [Cause] The program of BACKGROUND can not be selected by the CRT and TP at the same time [Remedy] End editing by the END_EDIT of [EDCMD] at the TP TPIF-060 WARN Can't record on cartesian (Group:%d) [Cause] This current position is in singularity [Remedy] You can record this position on joint type only Please select the function key
- 1109 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
TPIF-061 WARN Group[%s] has not recorded [Cause] This position data has not been changed to displayed groups because you selected the function key which did not record the position, when checking in singularity [Remedy] Check this recorded position again before execution TPIF-062 AND operator was replaced to OR [Cause] All AND operators on this line were replaced with OR operators. [Remedy] You cannot mix AND and OR operator on a the same line. Verify that all logical operators on this line are the same before execution. TPIF-063 OR operator was replaced to AND [Cause] All OR operator on this line were replaced by AND operators. You cannot mix AND OR operator on a the same line [Remedy] Verify all logical operators on this line before execution TPIF-064 Too many AND/OR operator(Max.4) [Cause] Too many AND/OR operators (Max.4 on a single line) [Remedy] Teach the logical operation on another line TPIF-065 Arithmetic operator was unified to +- or */ [Cause] Arithmetic operator on this line was changed to +- or */. Cannot mix arithmetic + and - operators with * and /operators on the same line. [Remedy] Verify all arithmetic operators on this line before execution TPIF-066 Too many arithmetic operator(Max.5) [Cause] Too many arithmetic operators (Max.5 on a single line) [Remedy] Teach the arithmetic operation on another line TPIF-067 Too many arguments (Max.10) [Cause] Too many arguments (Max.10 for a program or a macro) [Remedy] Check arguments of the program/macro TPIF-070 Cannot teach the instruction [Cause] Cannot teach the instruction. [Remedy] Check the sub type of the program. TPIF-071 Cannot change sub type [Cause] Cannot change sub type [Remedy] Check sub type of the program TPIF-072 Cannot change motion group [Cause] Cannot change motion group [Remedy] Check sub type of the program TPIF-090 WARN This program has motion group [Cause] The program specified in $PWR_HOT, $PWR_SEMI and $PWR_NORMAL must not have motion group. [Remedy] Set * to all motion group in program detail screen on TP. TPIF-091 WARN PREG access error [Cause] An error occurred when accessing a position register. [Remedy] Refer to the error cause code. - 1110 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
TPIF-092 Value %d expected %s [Cause] The value_array that was passed to a KAREL built-in was incorrectly specified. [Remedy] Make sure the value_array specifies the correct names for the variables and that the types expected are correct. TPIF-093 USER menu must be selected [Cause] Software internal error. [Remedy] Consult our service representative. TPIF-094 USER2 menu must be selected [Cause] Software internal error. [Remedy] Consult our service representative. TPIF-095 WARN Execution history table error [Cause] Software internal error [Remedy] Please do controlled start( it isn't necessary to re-set the new item) TPIF-097 WARN Running task's history can't display [Cause] The execution history of the executing program can not be displayed [Remedy] Please refer this screen when the program is paused or aborted TPIF-098 WARN %s was not run [Cause] The program of $PWR_HOT, $PWR_SEMI or $PWR_NORMAL is not executed [Remedy] Read the cause code TPIF-099 WARN This program is edited [Cause] The program specified in $PWR_HOT, $PWR_SEMI and $PWR_NORMAL is not executed, when the program is in editing. [Remedy] Select the other program TPIF-100 WARN No vacant table space [Cause] Illegal case occurred on software. [Remedy] Contact our service center serving your locality. TPIF-101 WARN No such menu [Cause] Illegal case occurred on software. [Remedy] Contact our service center serving your locality. TPIF-102 WARN E.STOP is asserted [Cause] FWD execution is selected while, E.STOP is asserted. [Remedy] Turn the E.STOP off. Then select FWD execution TPIF-103 WARN Dead man is released [Cause] When starting the program with the teach pendant, the deadman switch was released. [Remedy] Press and hold the deadman switch and start a program. TPIF-104 WARN Teach Pendant is disabled [Cause] A program was not started because the teach pendant was disabled. [Remedy] After turning on the enable switch of the teach pendant, start a program.
- 1111 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
TPIF-105 WARN Program is not selected [Cause] A program was started without selecting a program. [Remedy] After selecting a program, start the program. TPIF-106 WARN Program is already running [Cause] While a program was running, starting from teach pendant was performed. [Remedy] Start a program after waiting for program's ending or aborting it. TPIF-107 WARN FWD/BWD is disabled [Cause] 1 Starting a program was performed when the starting was prohibited such as entering the value into the message line. 2 A program was not selected. [Remedy] 1 After finishing the procedure of entering the value, start a program. 2 Select a program and then start a program. TPIF-108 WARN Form error, line %d, item %d [Cause] The Form Manager detected an error on the specified line with the specified item. [Remedy] Refer to the cause code for the actual error. TPIF-109 WARN %v not specified correctly [Cause] An internal software error occurred. [Remedy] Contact your FANUC Service Center. TPIF-110 WARN Screen used by other device [Cause] An internal software error occurred. [Remedy] Contact your FANUC Service Center. TPIF-111 op_global does not exist [Cause] Internal system error. [Remedy] Consult our service representative. TPIF-112 op_sel does not exist [Cause] Internal system error. [Remedy] Consult our service representative. TPIF-113 Illegal param in op menu [Cause] Internal system error. [Remedy] Consult our service representative. TPIF-114 Illegal data in op menu [Cause] Internal system error. [Remedy] Consult our service representative. TPIF-115 Data is full [Cause] Internal system error. [Remedy] Consult our service representative. TPIF-116 System variable error: %s [Cause] System variable name is invalid [Remedy] Check the spelling and format of the name.
- 1112 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
TPIF-117 Cannot backup to device: %s [Cause] The default device is not valid for backup [Remedy] Select a valid device and try again TPIF-118 File error for %s [Cause] File error [Remedy] Perform a cold start: 1 Turn off the robot. 2 On the teach pendant, press and hold the SHIFT and RESET keys. 3 While still pressing the SHIFT and RESET keys, turn on the robot. If the error is not cleared, document the events that TPIF-119 File compression failed [Cause] Failed creating compressed file [Remedy] Check backup device TPIF-120 Device failure [Cause] Device failure [Remedy] Check device and try again TPIF-121 Invalid copy. Use MOVE key. [Cause] Cannot COPY a file on a Memory device to the same Memory device. [Remedy] Use the MOVE key and try again TPIF-122 Specified softpart ID is illegal [Cause] Internal system error. [Remedy] Consult our service representative. TPIF-123 No active applications [Cause] Internal system error. [Remedy] Consult our service representative. TPIF-124 Current application is nothing [Cause] Internal system error. [Remedy] Consult our service representative. TPIF-125 Specified softpart ID is nothing [Cause] Internal system error. [Remedy] Consult our service representative. TPIF-126 THKY ASLOAD is failed [Cause] Internal system error. [Remedy] Consult our service representative. TPIF-127 TOPK ASLOAD is failed [Cause] Internal system error. [Remedy] Consult our service representative.
- 1113 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
TPIF-128 Verify logic of pasted line(s) [Cause] The reverse motion copy function does not support the following motion option instruction. 1 Application command 2 Skip, Quick Skip 3 Incremental 4 Continuous turn 5 Ahead execution command [Remedy] Check the above motion option instruction. And modify the copied statement correctly. TPIF-129 Group motion inst. is pasted [Cause] The group motion instruction is copied. The reverse motion copy function does not supported group motion instruction. [Remedy] Check the group motion instruction. And modify the copied statement correctly. TPIF-130 Specified application has no EQ [Cause] Internal system error. [Remedy] Consult our service representative. TPIF-131 Please set application mask data [Cause] This program has no application mask [Remedy] Please set the application mask in the program detail screen TPIF-132 Can't recover this operation [Cause] Because the data for UNDO can not be saved, this operation can not recover by UNDO function [Remedy] Check the cause code. If the memory is full, please delete program or disable UNDO function. TPIF-133 Can't recover this command [Cause] Palletizing command and Compliance control command can not be recovered by UNDO function
MOTN Error Codes ( ID = 15) MOTN-001 to 008 STOP.G Internal error in osmkpkt [Cause] Internal system error. [Remedy] Cycle start the controller MOTN-009 STOP.G Internal error for single step [Cause] The tool stopped at the midpoint of an arc in single step mode. [Remedy] Ignore this alarm. MOTN-010 to 011 STOP.G Internal error in osathpkt [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-012 STOP.G Invalid softpart MIR [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-013 STOP.G Invalid softpart SEG [Cause] Internal system error. [Remedy] Contact our service center serving your locality. - 1114 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
MOTN-017 STOP.G Limit error (Group:%d^2, Axis:%x^3 Hex) [Cause] The specified position falls outside the joint movable range ($PARAM_GROUP.$LOWERLIMS, $PARAM_GROUP.$UPPERLIMS). Axis j is defined in hexadecimal, as shown below. Axis 1: 1, Axis 2: 2, Axis 3: 4, Axis 4: 8, Axis 5: 10, Axis 6: 20, Axis 7: 40, Axis 8: 80, Axis 9: 100 If two or more axes have caused this alarm, the total of their values, shown above, is indicated in hexadecimal. Example Axis 1 + Axis 3 + Axis 4 + Axis 6 + Axis 9 = 12D 1 4 8 20 100 [Remedy] 1 Correct the position so that it falls within the movable range. 2 Change the movable range settings on the joint movable range screen, which is displayed by selecting 6 SYSTEM AXIS LIMITS. MOTN-018 STOP.G Position not reachable [Cause] The position is not reachable or is near a singularity point. [Remedy] Reteach the position that is not reachable. MOTN-019 WARN In singularity [Cause] The position is near a singularity point. [Remedy] Reteach the position that is near a singularity point. MOTN-020 WARN Wristjoint warning [Cause] Wrist joint warning [Cause] Wrist joint warning MOTN-021 STOP.G No kinematics error [Cause] No kinematics. [Remedy] Use joint motion. MOTN-022 STOP.G Invalid limit number [Cause] Invalid limit number. [Remedy] Set limit number correctly. MOTN-023 STOP.G In singularity [Cause] The position is near a singularity point. [Remedy] Reteach the position that is near a singularity point. MOTN-024 STOP.G Kinematics not defined [Cause] Kinematics is not defined. [Remedy] Define Kinematics. MOTN-030 to 046 STOP.G Internal error in MMGR:PEND [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-047 Internal error in MMGR:PRST [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
- 1115 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
MOTN-049 STOP.G Attempt to move w/o calibrated [Cause] Robot not calibrated. [Remedy] Calibrate the robot. MOTN-050 STOP.G Invalid spdlim (Group:%d^2 Axis:%x^3 H) [Cause] An internal software error occurred. The joint speed factor ($PARAM_GROUP.$SPEEDLIMJNT) is invalid. Axis j is defined in hexadecimal, as shown below. Axis 1: 1, Axis 2: 2, Axis 3: 4, Axis 4: 8, Axis 5: 10, Axis 6: 20, Axis 7: 40, Axis 8: 80, Axis 9: 100 If two or more axes have caused this alarm, the total of their values, shown above, is indicated in hexadecimal. Example Axis 1 + Axis 3 + Axis 4 + Axis 6 + Axis 9 = 12D 1 4 8 20 100 [Remedy] Correct the joint speed factor. MOTN-051 to 53 STOP.G Speed out of range (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-054 STOP.G Uninitialized dest pos (Group:%d^2) [Cause] Uninitialized destination position. [Remedy] Teach the destination position. MOTN-055 STOP.G Uninitialized via pos (Group:%d^2) [Cause] Uninitialized via position. [Remedy] Teach the via position. MOTN-056 WARN Speed limits used (Group:%d^2) [Cause] Speed limits used. [Remedy] This is just a notification. You do not have to do anything for this warning message. MOTN-057 to 062 STOP.G Invalid mir (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-063 STOP.G Position config change (Group:%d^2) [Cause] For path-controlled operation (linear or circular operation), different position data formats are set for the start point and end point. [Remedy] 1 Set the same position data format for the start point and end point. 2 Specify joint operation mode. 3 Specify a wrist joint operation instruction (operation addition instruction). MOTN-064 and 065 STOP.G Rs orientation error (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality.
- 1116 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
MOTN-066 STOP.G Degenerate circle (Group:%d^2) [Cause] For circular operation, the position data for the start point, passing point, and end point is invalid. a Two of the start, passing, and end points overlap one another. b All of the start, passing, and end points are arranged in a straight line. [Remedy] Specify appropriate start, passing, and end points for circular operation. MOTN-067 to 072 STOP.G Ata2 error in circle (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-073 STOP.G Error in orientype (Group:%d^2) [Cause] Internal error: planner received invalid orientype. [Remedy] Contact our service center serving your locality. MOTN-074 to 079 STOP.G Error in speed (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-080 STOP.G Via position required (Group:%d^2) [Cause] Missing via position for circular motion. [Remedy] Teach via position. MOTN-081 STOP.G Extended position error (Group:%d^2) [Cause] No value is set for the additional axis. [Remedy] Set a value for the additional axis. MOTN-082 to 087 STOP.G (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-088 STOP.G Not cartesian move (Group:%d^2) [Cause] Motype is not cartesian. [Remedy] Must set motype to cartesian. MOTN-089 to 091 STOP.G (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-092 STOP.G Extended not supported (Group:%d^2) [Cause] Extended axes not supported [Remedy] Do not use extended axes. MOTN-093 and 094 STOP.G Internal (Group:%d^2) [Cause] Internal plan error [Remedy] Contact our service center serving your locality. MOTN-095 WARN Can't blend corner line:%d^5 [Cause] Under acceleration vector control, the specified operation instruction results in an inconstant robot path. [Remedy] 1 Turn off acceleration vector control. 2 Correct the operation instruction so that it can be executed normally. - 1117 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
MOTN-096 STOP.G Cart rate not equal(Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-097 WARN INTR overrun %d^3 (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-098 to 109 STOP.G INTR (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-110 STOP.G Use FINE in last L (Group:%d^2) [Cause] During the execution of the specified operation instruction, joint operation could not be performed. [Remedy] Correct the operation instruction, according to the desired path-controlled operation. MOTN-111 WARN Can't switch filter(Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-112 Increment move turn Mismatch [Cause] Incremental motion causes turn number mismatch [Remedy] Change position to absolute position MOTN-113 WARN Robot not calibrated [Cause] Robot not calibrated. [Remedy] Calibrate the robot. MOTN-114 WARN Servo is on (Group:%d^2) [Cause] Servo in still on. [Remedy] Turn off servo. MOTN-115 WARN Invalid brake mask (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-116 WARN Invalid solution (Group:%d^2) [Cause] Invalid kinematics solution. [Remedy] Reteach position. MOTN-117 WARN Robot not mastered (Group:%d^2) [Cause] Robot not mastered. [Remedy] Master the robot. MOTN-118 WARN Robot in over travel (Group:%d^2) [Cause] Robot in overtravel. [Remedy] Reset over travel jog the robot outside of the overtravel position.
- 1118 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
MOTN-119 WARN Servo is off (Group:%d^2) [Cause] Robot servo is on. [Remedy] Turn off servo power. MOTN-120 to 121 WARN Invalid reference position (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-122 STOP.G Dfilter not empty (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-123 WARN Not enough node (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-124 to 127 STOP.G INTR:Bad Mirpkt req_code(Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-128 STOP.G Group mtn not supported(Group:%d^2) [Cause] Group motion not supported. [Remedy] Document the events that led to the error and contact our service center serving your locality. MOTN-129 and 130 STOP.G Local cond ptr conflict(Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-131 STOP.G In singularity [Cause] Position near by a singularity point. [Remedy] a. Move the target point well away from the singular point. b. Use joint coordinates to specify the target point in joint operation mode. MOTN-132 STOP.G Group circ not supported(Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-133 WARN Time after limit used(Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-134 STOP.G Can not move path backward (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-135 STOP.G Last motype can't be circular (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-136 STOP.G Illegal filter switch line:%d^5 [Cause] Internal system error. [Remedy] Contact our service center serving your locality. - 1119 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
MOTN-137 STOP.G No circular softpart (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-138 STOP.G No joint short motion SP (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-139 STOP.G No cart short motion SP (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-140 STOP.G No KAREL motion softpart (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-141 STOP.G No KAREL motion func. ptr (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-142 STOP.G No Group Motion SP (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-143 STOP.G No Motion Resume SP (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-144 STOP.G No joint Turbo Move SP (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-145 STOP.G No cart Turbo Move SP (Group:%d^2) [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MOTN-146 STOP.G INTR can't replan major axis(Group:%d^2) [Cause] Mismatch in major axis turn number. [Remedy] Reteach position. MOTN-147 WARN L->J replan joint slowdown (Group:%d^2) [Cause] Linear motions ignore turn numbers. Therefore, when a joint motion follows several linear motions, the turn number might be mismatched, causing the robot to slow down [Remedy] Change the current motion's motype to linear or change the previous motion's motype to joint. If the problem persists, re-teach the path. MOTN-148 SWARN Can't move concurrently (Group:%d^2) [Cause] Two motion groups cannot synchronize with each other due to replanning of one group. This will cause slow down on both groups. [Remedy] If slow down is not acceptable, re-teach the path.
- 1120 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
MOTN-149 STOP.G CF:rotspeedlim exceeded line:%d^5 [Cause] CF:rotspeedlim exceeded. [Remedy] 1 Set system variable $cf_paramgp[].$cf_framenum to 1 or 2. Turn the power off and then on again. 2 Reduce the speed. 3 Specify positioning as the previous operation. MOTN-161 (%s^4 L:%d^5) Can't look ahead [Cause] With the shortest time control function, program lines cannot be read in advance. The following situations can be considered: - The position register is used without locking. - The if/selection instruction is used. - Another program is called. [Remedy] - Use the lock position register instruction. - Remove the if/selection instruction. - Integrate the programs into one. MOTN-171 Overload [Cause] An overload is imposed. [Remedy] Reduce the load. MOTN-172 Another robot is re-linked [Cause] The robot at a link destination was relinked, so that operation stopped. [Remedy] Stop all linked robots once, then restart the robots. MOTN-173 Robot link configuration error [Cause] The robot link setting is incorrect. [Remedy] Check the host name and IP address in the host communication setting, and also check the robot link setting. MOTN-174 No motion control [Cause] This alarm is issued, for example, when an operation for master or slave setting such as manual operation screen manipulation or program execution is performed while the robot is moving according to a program or jog operation. [Remedy] Perform an operation after the robot stops. MOTN-175 Failed to be MASTER [Cause] At the time of switching to the master state by program execution or manual operation, robot motion is not completed, or the setting is incorrect. [Remedy] Modify the program, or check the robot link setting. MOTN-176 Failed to be SLAVE [Cause] At the time of switching to the master state by program execution or manual operation, robot motion is not completed, or the setting is incorrect. [Remedy] Modify the program, or check the robot link setting. MOTN-177 Failed to end sync motion [Cause] If the master and slave have not stopped or the setting is incorrect, synchronous motion cannot be completed. [Remedy] Check the motion instruction of the program, and the robot link setting.
- 1121 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
MOTN-178 Link robot is HELD [Cause] After start of synchronous motion, it was detected that the robot at the communication destination lost synchronism for a cause such as program termination. [Remedy] The programs temporarily stop. Restart the programs of the master and slave. MOTN-179 Robot link internal error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. MOTN-180 Robot link Calib-data not found [Cause] Calibration data cannot be found. [Remedy] Calibrate the robot link. MOTN-181 Robot link Version mismatch [Cause] The robot link software differs between the master robot and slave robot. [Remedy] Match the software version of the master robot with that of the slave robot. MOTN-182 Failed to get data from master [Cause] Communication data is not sent from the master robot. [Remedy] Check the Ethernet cable, cable connection, hub, main board, and robot link setting. MOTN-184 Invalid MNUTOOL data array [Cause] The value of the system variable $MNUTOOL is invalid. [Remedy] Check the value of the system variable $MNUTOOL. MOTN-185 Protect of ACK BF to be sent [Cause] The memory in the slave robot for communication from the slave robot to the master robot is protected. [Remedy] No particular action is required. MOTN-186 Protect of BCST BF to be sent [Cause] The memory in the master robot for communication from the master robot to the slave robot is protected. [Remedy] No particular action is required. MOTN-187 Protect of ACK BF to be read [Cause] The memory in the master robot for communication from the slave robot to the master robot is protected. [Remedy] No particular action is required. MOTN-188 Protect of BCST BF to be read [Cause] The memory in the slave robot for communication from the master robot to the slave robot is protected. [Remedy] No particular action is required. MOTN-189 Slave motion remained [Cause] In the slave robot, the amount of travel of the previous motion remains before the slave program is started. [Remedy] Restart after the previous motion is completed.
- 1122 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
MOTN-190 Slave cannot use JOINT pos [Cause] The motion instruction data of the slave robot is in the joint format. [Remedy] Change the data to the orthogonal format. MOTN-191 Slave cannot JOINT motion [Cause] The slave program cannot make a joint motion. [Remedy] Change the instruction to an orthogonal motion instruction. MOTN-192 UT of MASTER was changed [Cause] In the master state, the tool coordinate system of the master robot was changed. [Remedy] Do not change the tool coordinate system in the master state. MOTN-193 UT of SLAVE was changed [Cause] In the slave state, the tool coordinate system of the slave robot was changed. [Remedy] Do no change the tool coordinate system in the slave state. MOTN-194 Machine Lock is ENABLED [Cause] In the master lock state, synchronous motion is disabled. [Remedy] Cancel the machine lock state. MOTN-195 RLINK internal error %d^5 [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. MOTN-198 CRC Start-Via too close(L:%d^5) [Cause] The start point and center point of an arc are too close to each other. [Remedy] Reteach the robot. The taught points of an arc must be on the same plane. Otherwise, a minor modification to the teaching can cause a major change in motion. MOTN-199 CRC Via-Dest too close(L:%d^5) [Cause] The intermediate point and end point of an arc are too close to each other. [Remedy] Reteach the robot. The taught points of an arc must be on the same plane. Otherwise, a minor modification to the teaching can cause a major change in motion. MOTN-200 (%s^4, %d^5) Too long anticipate time [Cause] The value of advanced processing time (Timebefore) is too large. [Remedy] - Reteach the previous taught point to increase the distance of motion. - Decrease the advanced processing time. MOTN-230 T1 rotspeed limit (G:%d^2) [Cause] The attitude change speed in the T1 mode was clamped. [Remedy] Decrease the speed of teaching. Alternatively, use a motion instruction in deg/sec or sec. MOTN-231 T1 Speed restriction (G:%d^2) [Cause] When the taught speed is 250 mm/sec or less in the T1 mode, speed restriction processing was performed. [Remedy] The speed of the flange section exceeded 250 mm/sec because of a change in the tool attitude. This alarm is a warning, and does not represent a failure. However, the actual motion of this portion needs to be checked in the T2 mode.
- 1123 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
MOTN-240 J4 is not zero [Cause] The J4-axis is not at the 0_ position. [Remedy] Make a motion so that the J4-axis is at the 0_ position. MOTN-241 OFIX stroke limit [Cause] In attitude-fixed motion, a stroke limit was detected. [Remedy] Check the motion range, and reteach the robot so that the motion does not exceed the range. MOTN-242 OFIX is disabled [Cause] The attitude-fixed motion instruction is disabled. [Remedy] Check if the robot supports attitude-fixed motion. MOTN-243 OFIX error [Cause] The attitude-fixed motion instruction cannot be executed for another cause. [Remedy] Check the alarm history to see if other alarms are issued. MOTN-244 OFIX Detect J4 is not 0 [Cause] J4 at the motion start position or target position is not at the 0_ position. [Remedy] Check the value of J4 at each position, and make modifications. MOTN-245 OFIX Wrist config mismatch [Cause] The configuration differs between the motion start position and target position. [Remedy] Check the attitude and make modifications. If motion is still unsuccessful, use joint motion. MOTN-246 OFIX Invalid rail vector [Cause] The attitude-fixed motion instruction is disabled. [Remedy] Check if the robot supports attitude-fixed motion. MOTN-247 E-Effector is not vertical to rail [Cause] The flange surface is not parallel with the J1-axis. [Remedy] Cause the robot to assume such an attitude that the flange surface is parallel with the J1-axis. MOTN-248 OFIX Too large tool rotation [Cause] In attitude-fixed motion, the rotation angle of the flange between the start point and end point exceeded the range allowable in one motion. [Remedy] Split the motion, and teach each split part of the motion. MOTN-249 OFIX Too large tool spin [Cause] In attitude-fixed motion, the rotation angle of J6 between the start point and end point exceeded the range allowable in one motion. [Remedy] Split the motion, and teach each split part of the motion. MOTN-250 Use CNT0/FINE for L/C before OFIX [Cause] A circular motion or a linear motion other than attitude-fixed motion continues to an attitude-fixed motion through a smooth motion. [Remedy] Change the positioning mode of the circular motion or linear motion to smooth 0 or positioning. MOTN-251 Can't use OFIX with this motion [Cause] A motion statement, such as an incremental motion instruction or remote TCP, which cannot be used at the same time with the attitude fix instruction, is specified. [Remedy] Modify the instruction. - 1124 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
MOTN-252 OFIX: No plan data [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. MOTN-253 OFIX: Motion type mismatch [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. MOTN-254 OFIX: Detect large spin [Cause] The tool attitude change per motion is too large. [Remedy] Split the motion, and teach each split part of the motion. MOTN-255 OFIX: Detect J4 is not 0 [Cause] During motion, it was detected that J4 is not at the 0_ position. This alarm is issued because J4 is slightly shifted from the 0_ position at the start point or end point of motion, or the angular change of the flange per motion is too large. [Remedy] Check the values of the start point and end point of J4. If this alarm is issued even when J4 is taught to assume exactly the 0_ position at both points, split the motion statement. MOTN-256 OFIX: TCP config limit [Cause] A linear motion range limit was reached. [Remedy] Change the target position, or switch to joint motion. MOTN-257 Wrist start angle mismatch [Cause] The motion start angle of the wrist axis does not match the internal calculation for attitude-fixed motion. [Remedy] Modify the teaching only so that the J4-axis moves completely with 0 degree. Moreover, check if an application such as for tracking that compensates for a motion is used and check also if a motion addition instruction such as for compensating for a track is used. MOTN-258 Not reached to dest rotation [Cause] At the end of attitude-fixed motion, the tool arrival attitude does not match the internal calculation for attitude-fixed motion. [Remedy] Modify the teaching only so that the J4-axis moves completely with 0 degree. Moreover, check if an application such as for tracking that compensates for a motion is used and check also if a motion addition instruction such as for compensating for a track is used. MOTN-259 Not reached to dest spin [Cause] At the end of attitude-fixed motion, the tool arrival attitude does not match the internal calculation for attitude-fixed motion. [Remedy] Modify the teaching only so that the J4-axis moves completely with 0 degree. Moreover, check if an application such as for tracking that compensates for a motion is used and check also if a motion addition instruction such as for compensating for a track is used. MOTN-300 CD not support:Use CNT L:%d^5 [Cause] Term type CD is not supported. [Remedy] Change termtype FINE or CNT.
- 1125 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
MOTN-301 Path to resume is changed(G:%d^2) [Cause] Can't resume motion. [Remedy] Abort and run program. MOTN-302 Corner speed slowdown L:%d^5 [Cause] Corner speed slows down automatically because of robot constraint. [Remedy] If slow down is not acceptable, re-teach the path. MOTN-303 Can't maintain CDist L:%d^5 [Cause] Can't maintain corner distance because path is short or speed is high. [Remedy] Lengthen path or reduce speed. MOTN-304 CS:Prog speed achieved L:%d^5 [Cause] SPD value does not affect corner speed anymore. [Remedy] This is just a notification. You do not have to do anything for this warning messsage. MOTN-305 Can't maintain speed L:%d^5 [Cause] Can't maintain program speed on the path because of robot constraint. [Remedy] This is just a notification. You do not have to do anything for this warning messsage. MOTN-306 Can't replan (G:%d^2, A:%x^3 Hex) [Cause] Resume motion cannot reach stop position Can't resume original path. [Remedy] Abort program and rerun MOTN-307 Mismatch MMR (G:%d^2) [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. MOTN-308 FINE termtype used L:%d^5 [Cause] Can't generate corner between two motion because of motion instruction. And CNT or CD is ignored. [Remedy] Use LOCK PREG instruction when PR[] is used for position or OFFSET instruction is used. MOTN-309 Circular speed reduced L:%d^5 [Cause] Circular speed is reduced because of robot constraint [Remedy] Reduce program speed not to display. MOTN-310 Pos. Cfg. change 2 (G:%d^2) [Cause] Configuration mismatch [Remedy] string matches the start position's configuration string. MOTN-311 Path to resume is changed(G:%d^2) [Cause] Can't resume motion on the original path. [Remedy] Abort and run program. Then, the resumed motion may not be on the original path. MOTN-312 Can't resume in single step CJ [Cause] Can't resume motion in single step mode. [Remedy] Abort program and rerun.
- 1126 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
MOTN-313 Can't resume motion CJ(2) [Cause] Can't resume motion on the original path. [Remedy] Abort and run program. Then, the resumed motion may not be on the original path. MOTN-314 Can't resume motion CJ(3) [Cause] Can't resume motion on the original path due to motion condition. [Remedy] Abort and run program. Then, the resumed motion may not be on the original path. MOTN-315 Command speed is changed CJ [Cause] Can't resume motion on the original path due to command speed change. [Remedy] Modify back the command speed, or abort program MOTN-316 Override change not allowed [Cause] An override change was made when CJP was disabled and the program was being restarted. [Remedy] Make an override change before restarting the program. Do not make an override change immediately after the program is restarted. MOTN-319 CRC large orient change (G:%d^2) [Cause] The small circle causes a large attitude change. [Remedy] Reteach the robot. MOTN-320 Adj out of limit at line %s [Cause] During a fine adjustment check, a position that cannot be reached was detected. [Remedy] From the alarm message, identify the line that generated the alarm. Use CLR_Adj to clear the adjustment value. MOTN-321 Posn unreachable at line %s [Cause] During a fine adjustment check, a position that cannot be reached was detected. [Remedy] From the alarm message, identify the line that generated the alarm. Use CLR_Adj to clear the adjustment value. MOTN-340 Fast fault recovery [Cause] This is notification for application process enabled in the fast fault recovery when the alarm position is found. [Remedy] N/A MOTN-341 NO Z offset for INC motion [Cause] A Z offset value cannot be applied to an incremental motion. [Remedy] Do not use an incremental motion. MOTN-342 Override change not allowed [Cause] Change in teach pendant override setting while the program is running. [Remedy] Set Teach Pendant's override to the desired value and resume the program
PALT Error Codes ( ID = 26 ) PALT-001 ABORT.G Inadequate register value [Cause] Column/row/layer number is illegal. [Remedy] Please confirm palletizing register. - 1127 -
C.ALARM CODES
APPENDIX
PALT-002 ABORT.G Computing shift vector [Cause] The position data of specified column/row/layer can not be calculated. [Remedy] Teach an appropriate stack point. PALT-003 ABORT.G Computing rotation matrix [Cause] The position data of specified column/row/layer can not be calculated. [Remedy] Teach an appropriate stack point. PALT-004 ABORT.G Increment value is ill [Cause] Increment value of parettaizing config screen is illegal. [Remedy] Please correct increment value PALT-005 ABORT.G Application item unfound [Cause] Software internal error [Remedy] Teach a pallet instruction again. PALT-006 ABORT.G Amr number is differnet [Cause] Software internal error [Remedy] Teach a pallet instruction again. PALT-007 ABORT.G Configulation not decided [Cause] The array of column/row/layer of palletizing initial data is mistakes. [Remedy] Set the array of column/row/layer again. PALT-008 ABORT.G Route pattern duplicated [Cause] Condition setting of the route pattern overlaps. [Remedy] Set the condition in the route pattern again. PALT-009 ABORT.G Bottom point unfound [Cause] The corresponding stack point does not exist. [Remedy] Teach the stack point again. PALT-010 ABORT.G Route pattern unfound [Cause] Route pattern unfound. [Remedy] Check route pattern in palletizing route pattern screen. PALT-011 ABORT.G Route point unfound [Cause] The corresponding route point does not exist. [Remedy] Teach the route point again. PALT-012 ABORT.G Route Bottom point unfound [Cause] The stack point of a present route pattern is not found. [Remedy] Teach the stack point of a present route pattern. PALT-013 ABORT.G Memory id error [Cause] Setting of palletizing data is imcomplete. [Remedy] Contact our service center serving your locality. PALT-014 ABORT.G Illegal bottom number [Cause] Software internal error [Remedy] Contact our service center serving your locality.
- 1128 -
B-82594EN-4/01
B-82594EN-4/01
APPENDIX
PALT-015 ABORT.G Illegal pattern number [Cause] Software internal error [Remedy] Contact our service center serving your locality. PALT-016 ABORT.G Illegal rout number [Cause] Software internal error [Remedy] Contact our service center serving your locality. PALT-017 ABORT.G Illegal current number [Cause] Software internal error [Remedy] Contact our service center serving your locality. PALT-018 ABORT.G Illegal key input [Cause] Software internal error [Remedy] Contact our service center serving your locality. PALT-019 ABORT.G Illegal point data [Cause] Software internal error [Remedy] Contact our service center serving your locality. PALT-020 ABORT.G Function code unfound [Cause] Software internal error [Remedy] Contact our service center serving your locality. PALT-021 ABORT.G Register index ill value [Cause] Software internal error [Remedy] Contact our service center serving your locality. PALT-022 ABORT.G Item code cannot be found [Cause] Software internal error [Remedy] Contact our service center serving your locality. PALT-023 ABORT.G Illegal element value [Cause] Software internal error [Remedy] Contact our service center serving your locality. PALT-024 ABORT.G Calculation error occured [Cause] Palletizing data is imcomplete. [Remedy] Teach bottom point all ? Teach rout point all ? PALT-025 ABORT.G OS error occured [Cause] Software internal error PALT-026 ABORT.G Cannot read/write to PL[] [Cause] Software internal error. [Remedy] Check palletizing register index PALT-027 ABORT.G Failed program close [Cause] Software internal error
- 1129 -
C.ALARM CODES
C.ALARM CODES
APPENDIX
B-82594EN-4/01
PALT-028 ABORT.G Failed program open [Cause] Software internal error PALT-029 ABORT.G Not exist application data [Cause] Software internal error PALT-030 WARN Pallet number is over max [Cause] Don't teach palletizing instruction over 16 [Remedy] palletizing instruction don't teach more than 16 in this program, Please teach another program. PALT-031 WARN Can not be set FREE or INTER [Cause] In FREE configuration, can not be set INTER over two directions [Remedy] In FREE configuration, can be set INTER only one direction (ROW, COLUMN or LAYER) PALT-033 This speed type isn't supported [Cause] Palletizing option doesn't support this speed type [Remedy] Please select the other motion statement.
PROG Error Codes PROG-001 to 004 ABORT.L Invalid pointer is specified [Cause] System internal error. [Remedy] Contact our service center serving your locality. PROG-005 WARN Program is not found [Cause] The specified program cannot be found. [Remedy] Check the program name. PROG-006 WARN Line is not found [Cause] The specified line number cannot be found. [Remedy] Check the line number. PROG-007 WARN Program is already running [Cause] The specified program is already being executed. [Remedy] Check the program name. PROG-008 WARN In a rtn when creating a task [Cause] Execution cannot be started in sub-routine program. [Remedy] Check the line number. PROG-009 WARN Line not same rtn as paused at [Cause] The program attempted to resume at a line different from the paused line. [Remedy] Check the line number. PROG-010 WARN Not same prg as paused [Cause] A program, different from the paused program, attempted to resume. [Remedy] Check the program name.
- 1130 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
PROG-011 PAUSE.L Cannot get the motion control [Cause] Motion control cannot be obtained. [Remedy] Check the teach pendant enable switch and other running programs to determine who has motion control. PROG-012 WARN All groups not on the top [Cause] The program attempted to resume at a motion different from the paused motion. [Remedy] Resume the motion paused the last time. PROG-013 WARN Motion is stopped by program [Cause] This motion was paused by the MOTION PAUSE instruction. Only the RESUME MOTION program instruction can resume the motion. [Remedy] Use the RESUME MOTION instruction in the program. PROG-014 WARN Max task number exceed [Cause] The number of programs you attempted to start exceeded the maximum number allowed. [Remedy] Abort any unnecessary programs. PROG-015 WARN Cannot execute backwards [Cause] Backward execution cannot be used. [Remedy] Do not use backward execution at this point. PROG-016 WARN Task is not found [Cause] The specified task is not running or paused. [Remedy] Check the task name. PROG-017 WARN Task is not running [Cause] The specified task is not running. [Remedy] Check the task name. PROG-018 ABORTG Motion stack overflowed [Cause] Too many programs are paused. [Remedy] Resume or abort some programs. PROG-019 WARN Ignore pause request [Cause] The request to pause the program was ignored. PROG-020 WARN Task is already aborted [Cause] The specified program was already aborted. [Remedy] Check the program name. PROG-021 WARN Ignore abort request [Cause] The request to abort the program was ignored. PROG-022 WARN Invalid request type [Cause] Internal error [Remedy] Contact our service center serving your locality. PROG-023 WARN Task is not paused [Cause] The specified program is not paused. [Remedy] Pause the program.
- 1131 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
PROG-024 WARN Not have motion history [Cause] The motion path record is lost. [Remedy] Do not attempt backwards execution at this time. PROG-025 WARN Cannot execute backwards [Cause] Backward execution cannot be used. [Remedy] Do not use backwards execution here. PROG-026 WARN No more motion history [Cause] Backward execution cannot be used any more. The current line is on top of the memorized path. PROG-027 to 033 WARN Invalid task number [Cause] Internal system error. [Remedy] Contact our service center serving your locality. PROG-034 WARN Routine not found [Cause] The specified routine cannot be found. [Remedy] Check the routine name and verify it is loaded. PROG-035 WARN Not locked the specified group [Cause] Motion control for the specified group cannot be locked. [Remedy] Check the teach pendant enable switch and other running programs to determine who has motion control. PROG-036 WARN The length of trace array is 0 [Cause] Either there is not enough memory available, or the task attribute is set incorrectly. [Remedy] Set the trace buffer length using the KCL SET TASK TRACELEN command. PROG-037 WARN No data in the trace array [Cause] There is no execution record in memory. [Remedy] Turn on tracing using the KCL SET TRACE ON command. PROG-038 Inconsistency in task status [Cause] Internal system error. [Remedy] Consult our service representative. PROG-039 WARN locked, but not get mctl [Cause] Motion control for the specified group was reserved, but it cannot be obtained. [Remedy] Check the teach pendant enable switch and other running programs to determine who has motion control. PROG-040 PAUSE.L Already locked by other task [Cause] Motion control for the specified group was already reserved by another program. [Remedy] Check the other running programs to determine who has motion control. PROG-041 WARN mctl denied because released [Cause] Motion control is released. The teach pendant currently has motion control. The robot cannot be started until motion control is obtained. [Remedy] Disable the teach pendant.
- 1132 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
PROG-042 WARN Already released [Cause] Motion control was already released. [Remedy] If you had expected that the task may have already released the group, this may not be an error. Otherwise, check UNLOCK_GROUP usage. PROG-043 WARN Already released by you [Cause] Motion control was already released by request of this program. [Remedy] If you had expected that the task may have already released the group, this may not be an error. Otherwise, check UNLOCK_GROUP usage. PROG-044 WARN Arm has not been released yet [Cause] Motion control was not released yet. [Remedy] If you had expected that the task may have already locked the group, this may not be an error. Otherwise, check LOCK_GROUP usage. PROG-045 WARN Other than requestor released [Cause] Motion control was already released by the request of another program. [Remedy] If you had expected that another task may have already released the group, this may not be an error. Otherwise, check UNLOCK_GROUP usage. PROG-046 PAUSE.L TP is enabled while running (%s^7) [Cause] The teach pendant was enabled while the program was executing. [Remedy] Disable the teach pendant and resume the program. PROG-047 PAUSE.L TP is disabled while running (%s^7) [Cause] The teach pendant was disabled while the program was executing. [Remedy] Enable the teach pendant and use shift-FWD to resume execution. PROG-048 PAUSE.L Shift released while running (%s^7) [Cause] The shift key was released while the program was executing. [Remedy] Hold the shift key and press the FWD key to resume execution. PROG-049 WARN Cannot release, robot moving [Cause] Motion control cannot be released because the robot is moving. [Remedy] Check the status of robot motion. PROG-050 WARN Abort still in progress [Cause] The program is in the process of being aborted. [Remedy] Wait a few seconds. PROG-051 WARN Cannot skip the return stmt [Cause] The specified lines to which a move was attempted exceed the number of lines in the program. [Remedy] Check the line number. PROG-052 ABORT.L Process is aborted while executing [Cause] The user application task was forced to abort while the application was executing. [Remedy] This requires no special action for the user. PROG-053 ABORT.L User AX is not running [Cause] The user application task was not executed. [Remedy] Start the user application task before executing the application. - 1133 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
PROG-054 FWD released while running (%s^7) [Cause] FWD key was released while the program is executing. [Remedy] Hold the FWD key with shift key to resume execution. PROG-055 BWD released while running (%s^7) [Cause] BWD key was released while the program is executing. [Remedy] Hold the BWD key with shift key to resume execution. PROG-056 Motion data out is enable [Cause] The machine lock function is disabled, and the motion data output function is enabled. [Remedy] On the test execution screen, disable the motion data output function.
MACR Error Codes ( ID = 57 ) MACR-001 WARN Can't assign to MACRO command [Cause] The conditions for assigning macros are not correct. 1 The allocation definition is duplicated. 2 The index is beyond the set range. [Remedy] Modify the device allocation. MACR-003 WARN Can't assign motn_prog to UK [Cause] It is not possible to assign a program with MOTION lock group to the User Key(UK) button. [Remedy] Remove the motion lock group from the program. MACR-004 WARN Can't execute motn_prog by UK [Cause] It is not possible to execute a program with MOTION lock group with the User Key(UK) button. [Remedy] 1 Remove all the motion groups from the group mask for detailed program information. 2 Allocate the program to other devices (SU, SP, and MF). MACR-005 WARN Please enable teach pendant [Cause] It is not possible to execute a program when the teach pendant is disabled. [Remedy] Enable the teach pendant. MACR-006 WARN Please disable teach pendant [Cause] It is not possible to execute a program when the teach pendant is enabled. [Remedy] Disable the teach pendant. MACR-007 WARN The same macro type exists [Cause] The macro assign type already exists. [Remedy] Change the assign type. MACR-008 WARN Remote-cond isn't satisfied [Cause] This assign type is only enabled at a REMOTE condition. [Remedy] Create a REMOTE condition. MACR-009 WARN The index is out of range [Cause] This assign index is out of range. [Remedy] Change the assign index so that it is within the valid range.
- 1134 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
MACR-010 WARN This SOP button is disabled [Cause] This SOP button is disable for macro execution. [Remedy] Change the value of the $MACRSOPENBL system variable. MACR-011 WARN This UOP button is disabled [Cause] This UOP signal is disabled for macro execution. [Remedy] Change the value of the $MACRUOPENBL system variable. MACR-012 WARN Number of DI+RI is over [Cause] The number of RI+DI is over the maximum number. [Remedy] First deassign the other RI or DI assignments. Then assign the new macro as RI or DI. MACR-013 WARN MACRO execution failed [Cause] Cannot execute this MACRO. [Remedy] Refer to the error cause code. MACR-016 WARN The macro is not completed [Cause] The macro aborted while executing. [Remedy] The macro will begin executing from the first line at the next execution.
MEMO Error Codes ( ID = 7 ) MEMO-001 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-002 WARN Specified program is in use [Cause] The specified program is editing or executing. [Remedy] Either abort the specified program or select it once more after selecting another program. MEMO-003 WARN Specified program is in use [Cause] The specified program is editing or executing. [Remedy] Either abort the specified program or select it once more after selecting another program. MEMO-004 WARN Specified program is in use [Cause] The specified program is editing or executing. [Remedy] Either abort the specified program or select it once more after selecting another program. MEMO-006 WARN Protection error occurred [Cause] The specified program is protected by a user. [Remedy] Cancel the protection of the specified program. MEMO-007 WARN Invalid break number [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-008 WARN Specified line no. not exist [Cause] Internal system error. [Remedy] Contact our service center serving your locality.
- 1135 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
MEMO-009 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-010 WARN Program name error [Cause] The specified program name is different from the one in the P-code file. [Remedy] Specify the same program name. MEMO-011 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-012 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-013 WARN Program type is different [Cause] The specified program type is different from that of the object being processed. [Remedy] Specify the same program type. MEMO-014 WARN Specified label already exists [Cause] The specified label id already exists in the program. [Remedy] Specify another label number. MEMO-015 WARN Program already exists [Cause] The specified program already exists in the system. [Remedy] Either specify another program name or delete the registered program. MEMO-019 WARN Too many programs [Cause] The number of the programs and routines exceeded the maximum allowed (3200). [Remedy] Delete unnecessary programs and routines. MEMO-020 to 024 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-025 WARN Label does not exist [Cause] Specified label does not exist. [Remedy] Set the index to an existing label. MEMO-026 WARN Line data is full [Cause] The number of line data exceeded the maximum possible line number (65535). [Remedy] Delete unnecessary line data. MEMO-027 WARN Specified line does not exist [Cause] The specified line data does not exist. [Remedy] Specify another line number. MEMO-028 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality.
- 1136 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
MEMO-029 WARN The line data can't be changed [Cause] The specified line data cannot be changed. The size of modified data is different from that of original data when replacing it. [Remedy] Specify another line number or data of the same size. MEMO-030 and 031 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-032 WARN Specified program is in use [Cause] The specified program is editing or executing. [Remedy] Either abort the specified program or select it once more after selecting another program. MEMO-034 WARN The item can't be changed [Cause] The specified item is locked to change by system. [Remedy] Specify another item. MEMO-035 to 037 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-038 WARN Too many programs [Cause] The number of programs exceeded the maximum allowed. [Remedy] Delete unnecessary programs. MEMO-039 to 047 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-048 WARN Break point data doesn't exist [Cause] The specified break point data does not exist. [Remedy] Specify another break point. MEMO-049 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-050 WARN Program does not exist [Cause] The specified program does not exist in the system. [Remedy] Specify another program or create the new program first. MEMO-051 to 055 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-056 WARN Program does not exist [Cause] The specified program does not exist in the system. [Remedy] Specify another program or create the new program first. MEMO-057 to 064 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. - 1137 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
MEMO-065 WARN Too many opened programs [Cause] Too many CALL instructions being used. The number of opened programs exceeded the maximum allowed ( 100 ). [Remedy] Abort any unnecessary programs or remove unnecessary CALL instructions. MEMO-066 and 067 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-068 WARN Specified program is in use [Cause] 1 The specified program is editing or executing. 2 The specified program is tied to a MACRO. [Remedy] 1 Either abort the specified program or select it once more after selecting another program. 2 Remove the program from the MACRO entry. MEMO-069 and 070 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-071 WARN Position does not exist [Cause] The specified position data does not exist. [Remedy] Specify another position. MEMO-072 WARN Position data already exists [Cause] Position data already exists in the position you specified to move. [Remedy] Specify another position or delete the data in the specified position. MEMO-073 WARN Program does not exist [Cause] The specified program does not exist in the system. [Remedy] Specify another program or create the new program first. MEMO-074 WARN Program type is not TPE [Cause] The operation can be applied only to teach pendant programs. [Remedy] Select a teach pendant program. MEMO-075 WARN Program can't be used [Cause] The program must be opened before attempting read or write operations. [Remedy] Open the program before reading or writing. MEMO-076 to 077 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-078 WARN Program can't be used [Cause] The specified operation is not supported for program type. [Remedy] Specify a program whose program type matches the operation. MEMO-079 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. - 1138 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
MEMO-080 WARN Protection error occurred [Cause] The specified program is protected by a user. [Remedy] Cancel the protection of the specified program. MEMO-081 WARN Specified program is in use [Cause] The specified program is editing or executing. [Remedy] Abort the specified program or select it once more after selecting another program. MEMO-082 to 087 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-088 WARN Program does not exist [Cause] The specified position data does not exist. [Remedy] Specify another position. MEMO-089 to 092 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-093 WARN Specified program is in use [Cause] The specified program is editing or executing. [Remedy] Abort the specified program or select it once more after selecting another program. MEMO-094 to 097 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-098 WARN EOF occurs in file access [Cause] EOF occurs in file access. When the P-code file was scanned, EOF occurs. [Remedy] The P-code data may be broken. Translate the specified KAREL program again. Then reload the P-code. MEMO-099 WARN Program name is wrong [Cause] The length of the program name is different from that of the P-code data. [Remedy] Check the name of the specified program. MEMO-100 to 102 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-103 WARN Check sum error occurred [Cause] The specified data was broken. This is the internal error. [Remedy] Contact our service center serving your locality. MEMO-104 WARN Program already exists [Cause] The specified program already exists in the system. [Remedy] Specify another program name or delete the registered program.
- 1139 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
MEMO-105 to 111 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-112 WARN Break data already exists [Cause] The specified break point data already exists in the program. [Remedy] Specify another break point. MEMO-113 WARN File access error [Cause] The port that has the program you want to load is not connected. [Remedy] Check the port setting and the connected device. MEMO-114 WARN Break point can't be removed [Cause] The break point data can not be overwritten because the program is protected by a user or is executing. [Remedy] Cancel the protection of the program or abort the program. MEMO-115 WARN Break point can't be removed [Cause] The break point data can not be removed because the program is protected by a user or is executing. [Remedy] Cancel the protection of the program or abort the program. MEMO-116 to 118 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-119 WARN Application data doesn't exist [Cause] The specified application data does not exist because the program does not correspond to the specified application. [Remedy] Specify another application data. Then create the program in the current system. MEMO-120 WARN Application data doesn't exist [Cause] The specified application data does not exist because the program does not correspond to the specified application. [Remedy] Specify another application data. Create the program in the current system. MEMO-121 to 122 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-123 WARN Application data doesn't exist [Cause] The specified application data does not exist because the program does not correspond to the specified application. [Remedy] Specify another application data. Then create the program in the current system. MEMO-124 WARN Program version is too new [Cause] KAREL program version number is newer than that of the system. [Remedy] Translate the program with an older version of the Translator. MEMO-125 WARN Program version is too old [Cause] KAREL program version number is older than that of the system. [Remedy] Translate the program with a newer version of the Translator. - 1140 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
MEMO-126 WARN No more available memory [Cause] Lack of the memory which can be used. [Remedy] Delete unnecessary programs. MEMO-127 WARN Pos reference over 255 times [Cause] Reference of the same position exceeded the maximum count (256). [Remedy] Set new position ID for the referenced position. MEMO-128 WARN %s parameters are different [Cause] A routine exists in memory with a different parameter definition than the routine in the PC file being loaded. [Remedy] Update the calling convention in the KAREL program being loaded or delete the obsolete routine from system memory. MEMO-129 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-130 SYSTEM Please power up again [Cause] System data in CMOS has been broken. [Remedy] Turn power off and then back on. MEMO-131 SYSTEM Please power up again [Cause] System data in CMOS has been broken. [Remedy] Turn power off and then back on. MEMO-132 WARN %s has been broken [Cause] Program data has been broken at the power fail recover. [Remedy] Delete the program and create it again. Contact our service center serving your locality. MEMO-133 SYSTEM Please power up again [Cause] System data in CMOS has been broken. [Remedy] Turn power off and then back on. MEMO-134 WARN TPE program %s already exists [Cause] A teach pendant (TP) program with the same name already exists. [Remedy] Delete the teach pendant (TP) program. Then load the specified KAREL program again. MEMO-135 WARN Cannot create TPE program here [Cause] The teach pendant (TP) program cannot be created in this start mode. [Remedy] On the auxiliary menu, switch the start mode to cold start or control start 2. MEMO-136 WARN Cannot load P-code here [Cause] The KAREL program cannot be loaded in this start mode. [Remedy] Select the function menu to change the start mode, or power on again. MEMO-137 WARN Load at Control Start Only [Cause] Specified KAREL program cannot be loaded in this mode. Because the same name program has already been loaded at controlled start. [Remedy] Load the program at controlled start.
- 1141 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
MEMO-138 WARN Delete at Control Start Only [Cause] Specified program has already been loaded at controlled start. Because of this, you can only delete the program at controlled start. [Remedy] Delete the program at controlled start. MEMO-139 to 143 WARN System error [Cause] Internal system error. [Remedy] Contact our service center serving your locality. MEMO-144 WARN Header size too big [Cause] The teach pendant (TP) header size specified is too big. Must be less than 256. [Remedy] Change size to range of 1-256. If necessary, use multiple header records. MEMO-145 TPE cannot have KAREL routine [Cause] A KAREL program with the same name already exists, so that a program with the specified name cannot be created. [Remedy] Change the name to a different one. MEMO-146 Invalid variable is used [Cause] A KAREL program includes an invalid variable. [Remedy] Check the variable of the KAREL program. MEMO-147 Flash File access error(write) [Cause] An attempt to write to the F-ROM failed. Program data may be destroyed. [Remedy] The F-ROM may be faulty. MEMO-148 Flash File access error(read) [Cause] An attempt to read from the F-ROM failed. Program data may be destroyed. [Remedy] The F-ROM may be faulty. MEMO-149 Specified program is broken [Cause] Program data is destroyed. [Remedy] Check the contents of the program. MEMO-151 No more available memory(TEMP) [Cause] Temporary memory is insufficient. [Remedy] Delete unnecessary programs.
CMND Error Codes CMND-001 WARN Directory not found [Cause] The specified directory can not be found. [Remedy] Check the device and path that you entered. CMND-002 WARN File not found [Cause] The specified file could not be found. [Remedy] Check to make sure the file has been spelled correctly and that it exists. Also verify the device and path name are correct.
- 1142 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
CMND-003 WARN File already exists [Cause] The file already exists and could not be overwritten. [Remedy] Make sure the overwrite option has been specified. CMND-006 WARN Self copy not allowed [Cause] A file cannot be copied to itself. [Remedy] Change the name of the destination file so it is different from the source file. CMND-009 WARN Position types are the same [Cause] Internal error. CMND-010 WARN Source type code is invalid [Cause] Internal error. CMND-011 WARN Destination type code is invalid [Cause] Internal error. CMND-012 WARN Type codes do not match [Cause] Internal error. CMND-013 WARN Representation mismatch [Cause] Internal error. CMND-014 WARN Positions are not the same [Cause] Internal error. CMND-015 WARN Both arguments are zero [Cause] Internal error. CMND-016 WARN Division by zero [Cause] Internal error. CMND-017 WARN Angle is out of range [Cause] Internal error. [Remedy] Make sure that the rotational angle is no greater than 100 times PI, or about 314.15926######. CMND-018 WARN Invalid device or path [Cause] You have specified an invalid device or path. [Remedy] Check the device and path that you entered. CMND-019 WARN Operation cancelled [Cause] The operation was cancelled because CTRL-C or CTRL-Y was pressed. [Remedy] Repeat the operation. CMND-020 WARN End of directory [Cause] The directory listing is finished. [Remedy] This is a notification. You do not have to do anything for this warning message.
- 1143 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
CMND-021 WARN Cannot rename file [Cause] The destination file name contained both alphanumeric characters and the global character '*'. [Remedy] Use only alphanumeric characters or a single global character when renaming a file. CMND-022 STOP.G Time motion with dist before [Cause] A time-based motion was specified along with distance before. [Remedy] Do not use these options in combinations.
COND Error Codes COND-001 WARN Condition does not exist [Cause] The number of a monitor to be enabled, disabled, or deleted is specified, but it is not found. [Remedy] Check the existing monitor numbers and specify one of them. COND-002 WARN Condition handler superseded [Cause] The specified condition number already exists in the system, and has been superseded by the new condition. [Remedy] This is a notification. You do not have to do anything for this warning message. COND-003 WARN Already enabled, no change [Cause] The specified condition is already enabled. No change has been made. [Remedy] This is just a notification, and you do not have to do anything for this warning massage. COND-004 WARN Already disabled, no change [Cause] The specified condition is already disabled. No change has been made. [Remedy] This is just a notification, and you do not have to do anything for this warning message. COND-009 WARN Break point encountered [Cause] Break point has been encountered. [Remedy] No action is required. COND-010 WARN Cond exists, not superseded [Cause] The specified condition already exists. Condition was not superseded. [Remedy] Either renumber the condition handler or avoid re-defining the same condition handler. COND-011 ABORT.G Scan time took too long [Cause] There are too many conditions defined. It took too long to scan them all. [Remedy] Reduce the number of conditions defined.
DICT Error Codes DICT-001 WARN Dictionary already loaded [Cause] A dictionary cannot be reloaded if it was loaded into FROM. [Remedy] Load into a different language and use KCL SET LANG to set the language. DICT-002 WARN Not enough memory to load dict [Cause] There is no more permanent memory available in the system to load another dictionary. [Remedy] Clear all unnecessary programs, dictionaries, or variables.
- 1144 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
DICT-003 WARN No dict found for language [Cause] There are no dictionaries loaded for the specified language. [Remedy] Use the DEFAULT language or a language in which a dictionary has been loaded. DICT-004 WARN Dictionary not found [Cause] The specified dictionary was not found. [Remedy] Use KCL LOAD DICT to load the dictionary into the DEFAULT language or the current language. DICT-005 WARN Dictionary element not found [Cause] The dictionary element was not found. [Remedy] Check the dictionary or element number to be sure it is specified correctly. DICT-006 WARN Nested level too deep [Cause] Only five levels of dictionary elements can be nested. [Remedy] Fix the dictionary text file to include fewer nested levels. DICT-007 WARN Dictionary not opened by task [Cause] The dictionary was never opened. [Remedy] Remove the close operation. DICT-008 WARN Dictionary element truncated [Cause] The dictionary element was truncated because the KAREL string array is not large enough to hold all the data. [Remedy] Increase either the size of the string or the number of strings in the array. DICT-009 WARN End of language list [Cause] The language list has completed. [Remedy] This is a notification. You do not have to do anything for this warning message. DICT-010 WARN End of dictionary list [Cause] The dictionary list has completed. [Remedy] This is a notification. You do not have to do anything for this warning message. DICT-011 WARN Dict opened by too many tasks [Cause] Only five dictionaries can be open by one task at one time. [Remedy] Load the dictionary files into F-ROM or C-MOS memory, where file open processing is not required. Close any unused dictionary files. DICT-012 WARN Low on FROM, loaded to memory [Cause] Not enough memory exists in FROM so the dictionary was loaded to CMOS. [Remedy] Store the dictionaries into C-MOS memory. DICT-013 WARN Cannot open dictionary file [Cause] The dictionary file does not exist on the specified device or in the specified directory. [Remedy] Select the proper device/directory and try again. DICT-014 WARN Expecting $ in dictionary file [Cause] The dictionary text incorrectly specifies an element without a $. [Remedy] Make sure all dictionary elements begin with a $.
- 1145 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
DICT-015 WARN Reserved word not recognized [Cause] A reserved word was not recognized in the dictionary text. [Remedy] Check for misspellings or look up the correct word in the KAREL Reference Manual. DICT-016 WARN Ending quote expected [Cause] The dictionary text incorrectly specifies an element without using quotes. [Remedy] Make sure all dictionary text is surrounded by double quotes. Use a backslash if you want an actual quote to appear in the text. For example, ¥"This is an example¥" will produce "This is an example" DICT-017 WARN Expecting element name or num [Cause] A reference to another element is expected. [Remedy] Use the element number to reference the element. DICT-018 WARN Invalid cursor position [Cause] The cursor position is specified incorrectly or the values are outside the limits. [Remedy] Make sure the cursor position is valid. For example, use @1,1 for the first row and col respectively. DICT-019 WARN ASCII character code expected [Cause] A series of digits are expected after the # to specify an ASCII character code. [Remedy] Remove the # or look up the ASCII character code in the KAREL Reference Manual. DICT-020 WARN Reserved word expected [Cause] An identifier is expected after the & to specify a reserved word. [Remedy] Remove the & or look up the reserved word in the KAREL Reference Manual. DICT-021 WARN Invalid character [Cause] An unexpected character was found in the dictionary text file. [Remedy] Make sure all dictionary text is correct. DICT-022 WARN Dict already opened by task [Cause] The dictionary is already open by the task. [Remedy] This is a notification. You do not have to do anything for this warning message. DICT-023 WARN Dict does not need to be opened [Cause] Dictionaries loaded to memory do not need to be opened. [Remedy] Do not try to open the dictionary file. DICT-024 WARN Cannot remove dictionary file [Cause] Dictionaries loaded to FROM cannot be removed or a dictionary cannot be removed if another task has it opened. [Remedy] Do not try to remove a dictionary loaded to FROM. Remove the dictionary from the same task which loaded it. DICT-025 Invalid state - internal error [Cause] Incorrect scanning. [Remedy] Correct the text of the dictionary. DICT-028 WARN No FROM write, loaded to memory [Cause] Not enough memory exists in FROM so the dictionary was loaded to CMOS for R-J. [Remedy] This is a notification. You do not have to do anything for this warning message. - 1146 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
DICT-029 WARN Help element not found [Cause] The help dictionary element was not found. [Remedy] Check the dictionary to be sure the help dictionary element was specified correctly. The help dictionary element must be specified with a question mark (?) followed by the element number. DICT-030 WARN Function key element not found [Cause] The function key dictionary element was not found. [Remedy] Check the dictionary to be sure the function key element was specified correctly. The function key element must be specified with a caret (^) followed by the element number.
LANG Error Codes LANG-004 WARN File is not open [Cause] 1 A file having the same name already exists. 2 The specified file has already been opened. 3 The file is write-protected. 4 When a floppy disk is used, it has no free space. [Remedy] 1 Delete any unnecessary files, or rename the file. 2 Close the file. 3 Cancel write protection. 4 Use a new floppy disk. Or, delete any unnecessary files from the existing floppy disk to create sufficient free space to save the file. LANG-005 WARN Program type is different [Cause] Only able to process teach pendant programs. [Remedy] Please select a teach pendant program. LANG-006 Invalid or corrupted TP file [Cause] The data of a program file cannot be read correctly. [Remedy] Check the port setting. Check the Handy File setting. Check the floppy or memory card connection. If the checks above cannot correct the error, the data of the file may be destroyed. LANG-007 System Error [Cause] The data of a program file cannot be read correctly. [Remedy] Check the port setting. Check the Handy File setting. Check the floppy or memory card connection. If the checks above cannot correct the error, the data of the file may be destroyed. LANG-014 WARN Program already exists [Cause] The program that is about to load, already exists in the system. [Remedy] Before you load it, delete the program already in the system. LANG-015 WARN Can not write file [Cause] 1 The file is write-protected. 2 Data of the specified size could not be written. [Remedy] 1 Cancel write protection. 2 The disk may be faulty. Replace the disk. - 1147 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
LANG-016 WARN Can not read file [Cause] Data of the specified size could not be read. Data communication failed. [Remedy] Check the connection of the device. LANG-017 WARN File format is incorrect [Cause] The data you are trying to save to a file is either abnormal or broken, therefore the file cannot be loaded. [Remedy] The file cannot be loaded with the data as it is. The data must be normal to load the file. LANG-018 WARN Group mask value is incorrect [Cause] When printing the program, there was an illegal position that did not match the group mask of the program. [Remedy] Reteach the position data so that the group number matches the group mask of the program. LANG-050 WARN %s contains %s, program/file names must match [Cause] The file name and the program name are not same. Their names must match. [Remedy] Rename the file name to be same as the program name. LANG-094 WARN File already exists [Cause] The specified file already exists on the floppy. [Remedy] Before you write the new file to the floppy, delete the file that already exists on the floppy. LANG-095 WARN File does not exist [Cause] The specified file does not exist on the floppy. [Remedy] Check the file name or content of the floppy. LANG-096 WARN Disk is full [Cause] The floppy disk has reached its limit and is full. [Remedy] Either use a new floppy disk or delete an necessary file in order to make room for saving to the floppy. LANG-098 WARN Disk timeout [Cause] Could not access the disk. [Remedy] Check if the correct device is set to port and if it turns on. LANG-099 WARN Write protection violation [Cause] The disk has write protection. [Remedy] Cancel the write protection. LANG-100 WARN Device error [Cause] Could not access the device. [Remedy] Connect the correct device to the correct port.
MCTL Error Codes MCTL-001 NONE TP is enabled [Cause] The teach pendant is enabled, and the motion control was not granted. [Remedy] Disable the teach pendant and try the operation again.
- 1148 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
MCTL-002 NONE TP is disabled [Cause] The teach pendant is disabled, and the motion control was not granted. [Remedy] Enable the teach pendant and try the operation again. MCTL-003 NONE system is in error status [Cause] The motion control was not granted because the system is in error status. [Remedy] Clear the error, and try the operation again. MCTL-004 NONE motion is in progress [Cause] The motion is still in progress, and the motion control was not granted. [Remedy] Wait until the robot comes to a complete stop. MCTL-005 NONE not in control of motion [Cause] The motion control was not granted because of some unknown reason. [Remedy] Clear the reason, and try the operation again. MCTL-006 NONE TP has motion control [Cause] The motion control was not granted because the teach pendant currently has motion control. [Remedy] Disable the teach pendant, and try the same operation again. MCTL-007 NONE PROG has motion control [Cause] The motion control was not granted because the program has motion control [Remedy] Pause or abort the program, and try the operation again. MCTL-008 NONE Operator panel has motion control [Cause] The motion control was not granted because the operator panel has the motion control. [Remedy] Set the $RMT_MASTER system variable correctly, and try the operation again. MCTL-009 NONE Other has motion control [Cause] Another device has motion control, and the motion control was not granted. [Remedy] Set the $RMT_MASTER system variable correctly, and try the operation again. MCTL-010 Other than msrc is rel'ing [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. MCTL-011 Due to error processing [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. MCTL-012 subsystem code unknown [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. MCTL-013 NONE ENBL input is off [Cause] ENBL input on the UOP is off. [Remedy] Set ENBL input ON.
- 1149 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
MCTL-014 NONE Waiting for Servo ready [Cause] The motion control was not granted because servo was not up. [Remedy] Wait for a few seconds until servo is up and ready. MCTL-015 NONE Manual brake enabled [Cause] The motion control was not granted because manual brake control is enabled. [Remedy] Disable the manual brake control.
PRIO Error Codes PRIO-001 WARN Illegal iotype [Cause] Port type specified is invalid. [Remedy] Use one of the port types defined in IOSETUP.KL. PRIO-002 WARN Illegal index [Cause] Port number is invalid or not presently assigned. [Remedy] Correct the port number. PRIO-003 SYST No memory available [Cause] The memory required for this operation is not available. [Remedy] Delete KAREL programs and/or variables to free memory. PRIO-004 WARN Too few ports on mod too few ports on mod [Cause] There are not enough ports on the specified board or module to make the specified assignments [Remedy] Correct either the first port number or the number of ports. PRIO-005 WARN bad logical port no [Cause] The specified port number in an assignment is invalid. It must be in the range of 1 - 32767. [Remedy] Correct the logical port number, so that it is within the valid range. PRIO-006 WARN bad log port number in asgt [Cause] The specified port number in an assignment is invalid. It must be in the range of 1 - 32767. [Remedy] Correct the logical port number, so that it is within the valid range. PRIO-007 WARN no match in deassign call [Cause] Port being deassigned is not presently assigned. [Remedy] Correct the port number. PRIO-008 WARN phys ports not found [Cause] Physical port being assigned to, does not exist. [Remedy] Correct the rack number, slot number, or port number. PRIO-009 WARN n_ports invalid [Cause] The number of ports in an assignment is invalid. It must be in the range of 1 - 128. [Remedy] Correct the number of ports, so that it is within the valid range. PRIO-010 WARN bad phys port number is asgt [Cause] Invalid physical port number in assignment request. It must be greater than 1. [Remedy] Correct the physical port number, so that it is greater than 1.
- 1150 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
PRIO-011 WARN asgt overlaps existing asgt [Cause] The logical port numbers being assigned overlap existing assignments. [Remedy] Correct the first port number or number of ports. PRIO-012 WARN bad board num [Cause] The specified rack and/or slot number is invalid or refers to an unused rack/slot number. [Remedy] Correct the rack and/or slot number. PRIO-013 WARN no aiseq for bd [Cause] An attempt was made to delete an analog input sequence which has not been defined. [Remedy] Check the rack and/or slot number. PRIO-014 WARN ai seq too long [Cause] The specified analog input sequence is too long. The sequence has from 1 to 15 port numbers. [Remedy] Supply a sequence of an appropriate length. PRIO-016 WARN log port already asgnd [Cause] The specified logic number is already in use. [Remedy] Use another logic number. PRIO-017 WARN I/O point not sim I/O point not sim [Cause] You attempted to set an input port that was not simulated. [Remedy] Use the I/O menu to set the port simulated or avoid setting the port. PRIO-020 SYST SLC communications error %d %d %d %d [Cause] An unrecoverable error is detected in communication with a process I/O board. [Remedy] Check the cable between the main CPU board and the I/O unit. Check the SLC2 mounted on the main CPU board or I/O unit. PRIO-021 Unknown I/O hardware [Cause] An unknown device is connected to the I/O Link connector. [Remedy] Replace the device with a device that is compatible with the current software or install a version of software that recognizes the device. PRIO-022 Too much I/O data on I/O link [Cause] The devices connected to the I/O Link exceed the I/O link capacity. [Remedy] Disconnect some devices. PRIO-023 WARN no ports of this type [Cause] There are no ports of the specified type. [Remedy] Change the port type, or define ports (e.g., GIN or GOUT) of the specified type. PRIO-032 WARN too many DIO modules [Cause] More than 31 I/O units are connected through an I/O link. [Remedy] Disconnect some of the I/O units so that no more than 31 are connected.
- 1151 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
PRIO-063 WARN Bad IO asg: rack% d^1 slot %d^2 [Cause] The I/O unit to which a signal is allocated is not found. There is no I/O unit corresponding to the rack and slot numbers subsequent to the alarm message. Possible causes are as follows: (1) The I/O unit has been replaced with another type of I/O unit. (2) The I/O unit fuse has blown. (3) Power is not supplied to the I/O unit. (4) The I/O link cable is either disconnected or not securely connected. (5) The I/O link cable is broken. (6) The I/O unit is faulty. [Remedy] (1) If the I/O unit has been replaced, apply the following procedure to clear the I/O allocation. 1 Press MENU and select I/O. Then, press F1 (TYPE) and select I/O LINK to display the I/O link screen. 2 Press F5 (INTER CONNECT). 3 In response to the prompt "RECOVER ALL," press F4 (YES). 4 Turn the power off and then back on. In this case, even when power restoration is enabled, all output signals are turned off. (2) Replace the I/O unit fuse. (3) Check the power supply to the I/O unit. (4) Ensure that the I/O link cable is connected securely. (5) Replace the I/O link cable. (6) Replace the I/O unit. PRIO-072 WARN Pulse output is full [Cause] Max of pulse output is 255 at the same time. [Remedy] Check the count of pulse output. PRIO-081 I/O is not initialized [Cause] This indicates that an severe error has occurred during I/O initialization at controller power-up. [Remedy] Check other error messages displayed on the TP alarm screen. PRIO-083 Digital I/O is not recovered [Cause] Digital output port states are not recovered when semi-hot start is enabled because I/O device configuration or assignments have changed. [Remedy] Initialize I/O. PRIO-085 BUSY in SLC2 does not turn off [Cause] BUSY bit in SLC2 does not turn off. [Remedy] Check SLC2 on Main CPU board or I/O device and I/O link cable. PRIO-100 Model B comm fault %srack:%d slot:%d [Cause] Communication between the Model B interface unit and DI/DO units, or between DI/DO units, is lost. [Remedy] Check the power and cabling from Model B interface unit and DI/DO unit, or between DI/DO units. PRIO-119 Too many DIGITAL I/O ports [Cause] There are too many DIGITAL I/O ports. [Remedy] Disconnect some DIGITAL I/O devices.
- 1152 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
PRIO-125 SLC2 initialization error [Cause] The SLC2 is in an error state at the end of initialization. [Remedy] Check SYSFAIL of the other PCB. Also check the main PCB.
ROUT Error Codes ROUT-022 PAUSE.G Bad index in ORD [Cause] Internal error of software. [Remedy] Contact our service center serving your locality. ROUT-023 PAUSE.G Bad index in SUBSTR [Cause] Internal error of software. [Remedy] Contact our service center serving your locality. ROUT-024 PAUSE.G SUBSTR length less than 0 [Cause] Internal error of software. [Remedy] Contact our service center serving your locality. ROUT-025 ABORT.G Illegal semaphore number [Cause] Incorrect number is specified for semaphore id. [Remedy] Specify a number between 1 to 255. ROUT-026 WARN Illegal group number [Cause] Invalid group number is specified. [Remedy] Specify existing group number. ROUT-027 WARN String size not big enough [Cause] Specified string variable does not have enough room to hold the return data. [Remedy] Specify a larger size string variable. ROUT-028 ABORT.G Illegal file attribute number [Cause] Incorrect file attribute id was specified. [Remedy] Specify a correct file attribute id. ROUT-029 ABORT.G Illegal file attribute value [Cause] Incorrect file attribute value was specified. [Remedy] Specify a correct attribute value. ROUT-030 WARN Non existent register number [Cause] A register number, that does not exist, is specified. [Remedy] Specify a correct register number. ROUT-031 WARN Illegal register type [Cause] Incorrect register type is specified. [Remedy] Specify the correct register type for the attempted operation. ROUT-032 ABORT.G Position type mismach [Cause] Position type is not correct for the operation. [Remedy] Specify correct position type.
- 1153 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
ROUT-033 ABORT.G Illegal attribute type [Cause] Illegal attribute id was specified. [Remedy] Specify correct attribute id. ROUT-034 WARN Not a TPE program [Cause] A non-teach pendant program is specified. [Remedy] Specify a program name other than a KAREL program. ROUT-035 WARN Value is out of range [Cause] Internal error of software. [Remedy] Contact our service center serving your locality. ROUT-037 ABORT.G Bad TPE header size [Cause] Value used in SET_HEAD_TPE for bfr_size is invalid. [Remedy] Use buffer size in the range 1-255. ROUT-038 PAUSE.G Uninitialized TPE position [Cause] It indicates that the position data in the specified line of the specified TP program has not been recorded. [Remedy] Confirm the contents of position data. ROUT-039 WARN Executing motion exists [Cause] Cannot unlock group while motion is executing. [Remedy] Wait until executing motion has completed. ROUT-040 WARN Stopped motion exists [Cause] Cannot unlock group while stopped motion exists. [Remedy] Resume stopped motion and wait until motion has completed or cancel stopped motion. ROUT-041 Dym. disp. var. not static [Cause] Internal system error. [Remedy] Consult our service representative. ROUT-042 TPE parameters do not exist [Cause] The parameter designated by param_no does not exist. [Remedy] Confirm the param_no and the parameter in CALL/MACRO command in main TPE program.
SCIO Error Codes SCIO-001 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-002 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
- 1154 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SCIO-003 out buffer size is not enough [Cause] Internal system error. [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-004 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-005 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-006 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-007 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-008 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-009 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-010 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-011 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-012 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
- 1155 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SCIO-013 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-014 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-015 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-016 WARN This option does not exist [Cause] This option does not exist [Remedy] Confirm the bought option. SCIO-017 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-018 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-019 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-020 WARN LBL[%d] exists in line %d: [Cause] This label number exists in another line. [Remedy] Select another label number. SCIO-021 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-022 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-023 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. - 1156 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SCIO-024 System Error [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of an alarm message displayed. SCIO-030 JOINT motion in slave program [Cause] The single slave execution program and slave program of the robot link cannot use a joint motion instruction. [Remedy] For teaching, use a linear or circular motion instruction. SCIO-031 JOINT position in slave program [Cause] The single slave execution program and slave program of the robot link cannot use the joint position format for motion instruction position data. [Remedy] Use the orthogonal position format. SCIO-032 Master UT mismatch [Cause] The current tool coordinate system number of the master robot does not match the tool coordinate system number specified on the program detail screen. [Remedy] Modify the tool coordinate system number of the master robot. Alternatively, modify the tool coordinate system number of the master robot on the program detail screen. SCIO-033 Slave can have ony one motion line [Cause] The robot link slave program allows only one line of motion instructions to be taught. [Remedy] Ensure that the slave program contains only one line of motion instructions.
SRIO Error Codes SRIO-002 SERIAL PORT NOT OPEN [Cause] Serial port is not opened. [Remedy] Open serial port before using it. SRIO-003 SERIAL PORT ALREADY OPEN [Cause] Serial port has already been opened, and it was tried to be opened again. [Remedy] Do not try to open the serial port which has already be opened. SRIO-004 SERIAL PORT NOT INITIALIZE [Cause] Serial port is not initialized. [Remedy] Initialize the serial port before using it. SRIO-005 SERIAL PORT DSR OFF [Cause] Serial port DSR is off. [Remedy] Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller. Check target device status. SRIO-006 SERIAL PORT PARITY ERROR [Cause] Serial port parity error occurred. [Remedy] Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller.
- 1157 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SRIO-007 SERIAL PORT OVERRUN ERROR [Cause] Serial port overrun error occurred. [Remedy] Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller. SRIO-008 SERIAL PORT FRAME ERROR [Cause] Serial port frame error occurred. [Remedy] Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller. SRIO-009 S. PORT PARITY & OVERRUN [Cause] Serial port parity error and overrun error occurred. [Remedy] Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller. SRIO-010 S. PORT PARITY & FRAME [Cause] Serial port parity error and frame error occurred [Remedy] Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller. SRIO-011 S. PORT OVERRUN & FRAME [Cause] Serial port overrun error and frame error occurred. [Remedy] Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller. SRIO-012 S. PORT PRTY & OVRRN & FRM [Cause] Serial port parity error, overrun error, and frame error occurred. [Remedy] Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller. SRIO-013 S. PORT DSR OFF & HARDWARE ERR [Cause] Serial port DSR is off and hardware error occurred. [Remedy] Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller. Check target device status. Check the hardware.
FLPY Error Codes FLPY-001 End of directory reached [Cause] Your listing has reached the end of the directory. [Remedy] This is a notification. You do not have to do anything for this warning message. FLPY-002 File already exists [Cause] The file name you are trying to create already exists on this device. [Remedy] Delete the file of this name or choose a different file name. FLPY-003 File does not exist [Cause] The file you are trying to open does not exist on this device. [Remedy] Open a file that does exist on the device.
- 1158 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
FLPY-004 Unsupported command [Cause] Operation is not supported on floppy disk. [Remedy] Use only operations supported on floppy disk. FLPY-005 Disk is full [Cause] The disk file capacity has been reached. [Remedy] Delete some unneeded files or use a disk with sufficient free space. FLPY-006 End of file reached [Cause] The end of the file was reached while reading. [Remedy] Do not attempt to read beyond the end of a file. FLPY-008 Only one file may be opened [Cause] An attempt was made to open more than one file. [Remedy] Do not attempt to open more than one file at a time. FLPY-009 Communications error [Cause] The protocol format was invalid. [Remedy] Retry the operation. FLPY-015 Write protection violation [Cause] The disk has write protection enabled. [Remedy] Remove write protection from the disk or use a disk that is not write protected. FLPY-100 Directory read error [Cause] The directory information is corrupted and unreadable. [Remedy] Try another disk or reformat the disk. FLPY-101 Block check error [Cause] The checksum data is bad. Data is corrupted on disk and can not be read. [Remedy] Try another disk, or reformat the disk FLPY-103 Seek error [Cause] There is a bad sector or track on the disk. [Remedy] Clean the disk drive, try another disk, or reformat the disk. FLPY-104 Disk timeout [Cause] The drive did not respond to a command. [Remedy] Check the cable to the drive and make sure drive power is on. FLP-105 Write protection violation [Cause] The disk has write protection enabled. [Remedy] Remove write protection from the disk or use a disk that is not write protected. FLPY-106 Memory Card hardware error [Cause] Memory Card hardware error is detected. [Remedy] Check Memory Card I/F unit connection or battery of the card. FLPY-107 Not formatted card [Cause] The Memory Card is not formatted. [Remedy] Format the card with UTILITY menu on FILE screen. - 1159 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
FILE Error Codes FILE-001 Device not ready [Cause] Specified file device is not ready. [Remedy] Check if the device is mounted and ready to use. FILE-002 Device is Full [Cause] Device is full. There is no more space to store data on the device. [Remedy] Delete any unnecessary files or change to a new device. FILE-003 Device is protected [Cause] Device is protected. So, you cannot write to the device. [Remedy] Release the device protection. FILE-005 Device not mounted [Cause] Device is not mounted. You should mount the device before using it. [Remedy] Mount the correct file device. FILE-006 Device is already mounted [Cause] You tried to mount the device which had been already mounted. [Remedy] Mount device only once. FILE-008 Illegal device name [Cause] Device name contains an illegal character. [Remedy] Check spelling and validity of device name. FILE-009 Illegal logical unit number [Cause] Illegal LUN is used. [Remedy] This is an internal error. Check the validity of the logical unit number. FILE-010 Directory not found [Cause] Specified directory does not exist [Remedy] Check validity of directory name. FILE-011 Directory full [Cause] Directory is full. You tried to create a file in the root directory which execeeded the maximum number of files allowed on the device. [Remedy] Delete unnecessary files in the root directory. FILE-012 Directory is protected [Cause] You tried to write to a write protected directory. [Remedy] Release the protection to the directory. FILE-013 Illegal directory name [Cause] Directory name contains an illegal character. [Remedy] Check spelling of directory name. FILE-014 File not found [Cause] The specified file was not found. [Remedy] Check that the file exists and that the file name was spelled correctly. - 1160 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
FILE-015 File is protected [Cause] You tried to access a protected file. [Remedy] Release the protection from file. FILE-017 File not open [Cause] You tried to access a file which is not open. [Remedy] Open the file before accessing. FILE-018 File is already opened [Cause] You tried to create/delete/rename a file which is already opened. [Remedy] Close file before such operations. FILE-019 File is locked [Cause] You tried to access a file which is locked. [Remedy] Release the lock. FILE-020 Illegal file size [Cause] File size is invalid. [Remedy] Change file size to be correct. FILE-021 End of file [Cause] End of file was detected. FILE-022 Illegal file name [Cause] File name contains an illegal character. [Remedy] Check spelling of file name. FILE-023 Illegal file number [Cause] File number is illegal. [Remedy] Use a valid file number which is the ID returned from an open request. FILE-024 Illegal file type [Cause] File type contains an illegal character. [Remedy] Check the spelling and validity of the file type. FILE-025 Illegal protection code [Cause] File protection code is illegal. [Remedy] Check if the protection code is correct. FILE-026 Illegal access mode [Cause] File access mode is illegal. [Remedy] Check if the access mode is correct. FILE-027 Illegal attribute [Cause] File attribute in the SET_ATTRIBUTE request is illegal. [Remedy] Check that attribute specified is valid. FILE-028 Illegal data block [Cause] Data block is broken which is used in FIND_NEXT request. [Remedy] You should keep the data block which is returned from the previous FIND_FIRST or FIND_NEXT request. - 1161 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
FILE-029 Command is not supported [Cause] Illegal request command is specified. [Remedy] Check if the request code is correct. FILE-030 Device lun table is full [Cause] Device management table is full. [Remedy] Dismount any unnecessary devices. FILE-031 Illegal path name [Cause] Path name contains an illegal character. [Remedy] Check if the path name is correct. FILE-032 Illegal parameter [Cause] Illegal parameter is detected. [Remedy] Check that all parameters for the request are valid. FILE-033 System file buffer full [Cause] File management buffer is full. [Remedy] Close unnecessary files. FILE-034 Illegal file position [Cause] Illegal file position is specified. [Remedy] Check that the file position parameter from SEEK request is positive and not beyond the end of file. FILE-035 Device not formatted [Cause] You tried to access a unformatted device. [Remedy] Format the device before using it. FILE-036 File already exist [Cause] You tried to rename a file to an already existing file name. [Remedy] Change the new file name to be unique or delete the existing file. FILE-037 Directory not empty [Cause] You tried to remove a subdirectory which contains some files or directories. [Remedy] Remove all files and directories in the subdirectory before removing subdirectory. FILE-038 File locked by too many tasks [Cause] There are too many lock requests to same file. [Remedy] Unlock any unnecessary file lock requests. FILE-039 Directory already exists [Cause] You tried to create a sub-directory that already exists. [Remedy] Use a unique name for new sub-directory FILE-040 Illegal file access mode [Cause] You tried to read from a write only opened file or tried to write to a read only opened file. [Remedy] Open a file with correct access mode.
- 1162 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
FILE-041 File not locked [Cause] You tried to unlock file which you had not locked. [Remedy] Don't unlock a file that is not locked. You can only unlock files which YOU have locked.
SSPC Error Codes SSPC-001 Waiting until space gets clear [Cause] Special checking space is not clear. [Remedy] No remedy SSPC-002 Occer dead lock condition [Cause] The priority of space is invalid [Remedy] Set the priority valid SSPC-003 AccuPath not allowed [Cause] Space Check function is not compatible with AccuPath. AccuPath is not allowed. [Remedy] Not use AccuPath or disable space check function SSPC-004 CTV option not allowed [Cause] Space Check function is not compatible with Continuous Turn CTV option. The CTV motion option is not allowed. [Remedy] Remove CTV option or disable space check function SSPC-011 APDT error (i) [Cause] Internal error [Remedy] Contact your FANUC customer service representative, and inform the representative of the character string indicated in (i) of the message. SSPC-012 Invalid element (s:i j) [Cause] The setting of model elements is incorrect. Example of display: "Invalid element (G:1 6)" The sixth model element of group1 is set incorrectly. "Invalid element (H:2 1)"The first model element of hand 2 is set incorrectly. [Remedy] Check the setting of model elements. Check that the setting of a link number and link type is correct. SSPC-013 Invalid hand num (G:i UT:j) [Cause] The hand number assigned to tool coordinate system number (UT:j) of group (G:i) is invalid. [Remedy] On the model setting screen, check the hand number assignment. SSPC-014 Common frame setting (G:i) [Cause] The inter-robot calibration of group (G:i) is not completed. [Remedy] Perform inter-robot calibration. SSPC-015 Not calibrated (G:i) [Cause] The calibration of group (G:i) is not completed. [Remedy] Perform calibration.
- 1163 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SSPC-016 Invalid comb type (C:i s) [Cause] The model type on the (s) side (L [left], R[right]) of combination setting (C:i) is invalid. [Remedy] On the model combination setting screen, check the model type. SSPC-017 Invalid comb index (C:i s) [Cause] The model number on the (s) side (L[left], R[right]) of combination setting (C:i) is invalid. [Remedy] On the model combination setting screen, check the model number. SSPC-018 APDT is not supported (G:i) [Cause] The robot of group (G:i) does not support the proximity stop function. [Remedy] On the model combination setting screen, check the model type and model number. SSPC-019 (G:i) is close to target [Cause] An interference was detected. [Remedy] The alarm can be released by an ordinary reset operation. SSPC-020 Invalid fixture obj (F:i) [Cause] The teach group number of jig model (F:i) is invalid. [Remedy] On the jig model setting screen, check the teach group number. SSPC-021 Too many settings [Cause] There are an excessive number of model settings or combination settings. [Remedy] Reduce the number of settings. SSPC-101 (G:i) is close to target [Cause] Proximity was detected. ( i: Group number) [Remedy] The alarm can be released by an ordinary reset operation. SSPC-101 SSPC-102 (G:i) is close to target(qstop) [Cause] Proximity was detected. ( i: Group number) [Remedy] The alarm can be released by an ordinary reset operation. SSPC-103 (G:i) is near to target [Cause] A gradual stop occurred. ( i: Group number) [Remedy] The alarm can be released by an ordinary reset operation. SSPC-104 APDT error (i) [Cause] Internal error ( i: Error number) [Remedy] This alarm is not issued usually. Inform your FANUC customer service representative of the numeric value indicated in (i) of the message. SSPC-105 Too many settings [Cause] There are an excessive number of model settings or combination settings. [Remedy] Reduce the number of settings. SSPC-106 Failed to get dist (j,C:i) [Cause] The distance between model elements could not be calculated. [Remedy] SSPC-111. This alarm is not issued usually. Inform your FANUC customer service representative of the numeric value indicated in (j,C:i) of the message.
- 1164 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SSPC-111 Invalid comb type (ST,C:i,s) [Cause] The model type on the (s) side (L[left], R[right]) of combination number (C:i) in the proximity stop combination setting is invalid. [Remedy] On the proximity stop combination setting screen, check the model type. SSPC-112 Invalid comb index(ST,C:i,s) [Cause] The model number on the (s) side (L[left], R[right]) of combination number (C:i) in the proximity stop combination setting is invalid. [Remedy] On the proximity stop model combination setting screen, check the model number. SSPC-113 APDT isn't supported (ST,G:i) [Cause] The robot of group (G:i) does not support the proximity stop function. [Remedy] On the proximity stop combination setting screen, check the model type and model number. SSPC-114 Not calibrated (ST,G:i) [Cause] The calibration of group (G:i) is not completed. [Remedy] Perform calibration. SSPC-115 Invalid utool number (ST,G:i) [Cause] The tool coordinate system number of group (G:i) is invalid. [Remedy] Check the tool coordinate system number. SSPC-116 Invalid hand num(ST,G:i,UT:j) [Cause] The hand number assigned to tool coordinate system number (UT:j) of group (G:i) is invalid. [Remedy] On the model setting screen, check the hand number assignment. SSPC-117 Common frame setting (ST,G:i) [Cause] The inter-robot calibration of group (G:i) is not completed. [Remedy] SSPC-111. Perform inter-robot calibration. SSPC-118 Invalid element (ST,s:i,j) [Cause] The setting of model elements is incorrect. Example of display: "Invalid element (ST,G:1 6) "The sixth model element of group1 is set incorrectly. "Invalid element (ST ,H:2 1)"The first model element of hand 2 is set incorrectly. [Remedy] Check the setting of model elements. Check that the setting of a link number and link type is correct. SSPC-119 Can't get elem pos(ST,G:i,j) [Cause] The current position of a model element could not be calculated. [Remedy] This alarm is not issued usually. Inform your FANUC customer service representative of the numeric value indicated in (ST,G:i, j) of the message. SSPC-120 Invalid fixture obj (ST,F:i) [Cause] The teach group number of jig model (F:i) is invalid. [Remedy] On the jig model setting screen, check the teach group number. SSPC-131 Invalid comb type (WT,C:i,s) [Cause] The model type on the (s) side (L[left], R[right]) of combination number (C:i) in the proximity wait combination setting is invalid. [Remedy] On the proximity wait combination setting screen, check the model type.
- 1165 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SSPC-132 Invalid comb index(WT,C: i,s) [Cause] The model number on the (s) side (L[left], R[right]) of combination number (C:i) in the proximity wait combination setting is invalid. [Remedy] On the proximity wait combination setting screen, check the model number. SSPC-133 APDT isn't supported (WT,G:i) [Cause] The robot of group (G:i) does not support the proximity wait function. [Remedy] On the proximity wait combination setting screen, check the model type and number. SSPC-134 Not calibrated (WT,G:i) [Cause] The calibration of group (G:i) is not completed. [Remedy] Perform calibration. SSPC-135 Invalid utool number (WT,G:i) [Cause] The tool coordinate system number of group (G:i) is invalid. [Remedy] Check the tool coordinate system number. SSPC-136 Invalid hand num(WT,G:i,UT:j) [Cause] The hand number assigned to tool coordinate system number (UT:j) of group (G:i) is invalid. [Remedy] On the model setting screen, check the hand number assignment. SSPC-137 Common frame setting (WT,G:i) [Cause] The inter-robot calibration of group (G:i) is not completed. [Remedy] Perform inter-robot calibration. SSPC-138 Invalid element (WT,s:i,j) [Cause] The setting of model elements is incorrect. Example of display: "Invalid element (WT,G:1 6)"The sixth model element of group1 is set incorrectly. "Invalid element (WT,H:2 1)"The first model element of hand 2 is set incorrectly. [Remedy] Check the setting of model elements. Check that the setting of a link number and link type is correct. SSPC-139 Can't get elem pos(WT,G:i,j) [Cause] The current position of a model element could not be calculated. [Remedy] This alarm is not issued usually. Contact your FANUC customer service representative of the numeric value indicated in (WT,G:i, j) of the message. SSPC-140 Invalid fixture obj (WT,F:i) [Cause] The teach group number of jig model (F:i) is invalid. [Remedy] On the jig model setting screen, check the teach group number. SSPC-151 App_STOP (ST,C:i) is disabled [Cause] An attempt was made to temporarily disable invalid proximity stop combination (C:i) on the setting screen with a program instruction. [Remedy] Enable the proximity stop combination on the setting screen before using it. SSPC-152 App_STOP (ST,C:i) is disabled [Cause] An attempt was made to temporarily disable invalid proximity stop combination (C:i) on the setting screen with a program instruction. [Remedy] Enable the proximity stop combination on the setting screen before using it.
- 1166 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SSPC-153 (WT,C:i) is enabled by other [Cause] An attempt was made to enable/disable proximity wait condition number (C:i) already enabled by another task. [Remedy] The proximity wait condition number is currently used by another program. Use it after it is freed. SSPC-154 (ST,C:i) is disabled by other [Cause] The proximity stop instruction was used for proximity stop condition number (C:i) being used by another task. [Remedy] The proximity stop condition number is currently used by another program. Use it after it is freed. SSPC-155 Invalid host name (ST,C:i) [Cause] In a specified proximity stop combination, an invalid host name is set. [Remedy] On the host communication screen of the setting screen, check the host name. Set a correct host name. SSPC-156 Invalid host name (WT,C:i) [Cause] In a specified proximity wait combination (C:i), an invalid host name is set. [Remedy] On the host communication screen of the setting screen, check the host name. Set a correct host name. SSPC-157 Intrupt signal (WT,C:i) [Cause] In the proximity wait state, the proximity wait halt signal was input. [Remedy] If the halt is unexpected, check the setting of the proximity wait halt signal. Moreover, check if the same signal is used for another purpose. SSPC-158 App_WAIT timeout (WT,C:i) [Cause] In the proximity wait state, the time set in time-out has elapsed. [Remedy] Adjust the wait time. To wait infinitely, set 0 in "time-out" on the proximity wait combination setting screen. SSPC-159 App_WAIT can't be used(WT,G:i) [Cause] In the following operations, automatic stop/restart based on the proximity wait function cannot be performed: • When slave robot follow-up operation is being performed based on robot link synchronization • When the continuous rotation function is being used [Remedy] Do not use any of the two functions above at the time of automatic stop/restart operation. SSPC-160 App_STOP is TMP_DISed(ST,C:i) [Cause] This message is output for confirmation when combination (C:i) is temporarily disabled by the proximity stop instruction. [Remedy]
- 1167 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SSPC-161 App_STOP is enabled (ST,C:i) [Cause] This alarm is issued in the following cases: • Case where the program is temporarily stopped with combination (C:i) temporarily disabled by the proximity stop instruction, then is restarted by changing the line • Case where the program is temporarily stopped with combination (C:i) temporarily disabled by the proximity stop instruction, then is executed after retraction After this alarm is issued, the combination is not temporarily disabled even if the program is restarted. [Remedy] When the program is restarted by changing the line, reply NO in response to the confirmation message to prevent execution from being disabled. SSPC-162 App_WAIT is enabled (WT,C:i) [Cause] This message is issued for confirmation when combination (C:i) is enabled by the proximity wait instruction. [Remedy] SSPC-163 App_WAIT is disabled (WT,C:i) [Cause] This alarm is issued in the following cases: • Case where the program is temporarily stopped with combination (C:i) enabled by the proximity wait instruction, then is restarted by changing the line • Case where the program is temporarily stopped with combination (C:i) enabled by the proximity wait instruction, then is executed after retraction After this alarm is issued, the proximity wait function is disabled even if the program is restarted. [Remedy] When the program is restarted by changing the line, reply NO in response to the confirmation message to prevent execution from being disabled. SSPC-168 (s,i) invalid group number [Cause] An invalid group number is specified with the proximity stop sensitivity instruction. [Remedy] Specify a correct group number. (s: Program name, i: Line number) SSPC-169 PAUSE.G (s, i) invalid rate value" [Cause] An invalid sensitivity is specified with the proximity stop sensitivity instruction. Program name, i: Line number) [Remedy] Enter a correct value (0 to 100).
(s:
SSPC-181 Comm init error i s [Cause] An error occurred at communication initialization time. (i: Error cause number, s: Control unit name) [Remedy] For the control unit name indicated by the error message, check the address setting, host name, and communication line state. SSPC-182 Invalid hostname (s) [Cause] After the setting of a new control unit name with a proximity stop or proximity wait combination, an attempt was made to enable the setting before the power is turned off then back on. Alternatively, an invalid control unit name is specified. (s: Control unit name) [Remedy] When a new control unit name is specified, the power must be turned off then back on for the setting to become effective. Moreover, check the control unit name on the host communication setting screen.
- 1168 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SSPC-183 Invalid address (s) [Cause] For the control unit name for which this alarm is issued, the communication address setting is incorrect. (s: Control unit name) [Remedy] The control unit name and its address must be checked and modified as required. Next, the power must be turned off then back on for the setting to become effective. SSPC-184 Number of host exceed limit [Cause] The number of control units specifiable for proximity stop setting and proximity wait setting on one control unit exceeded the limit. [Remedy] Delete unused control units, if any, from the proximity stop setting screen and the proximity wait setting screen. Alternatively, reduce the number of control units specified. SSPC-185 Number of element exceed limit [Cause] The number of elements whose settings can be enabled on one control unit exceeded the limit. [Remedy] Check the settings of elements, and disable the settings of those elements that may not be used. Alternatively, reduce the number of elements whose settings are enabled. SSPC-186 Invalid element (s,i,j) [Cause] The setting of an element of the control unit indicated by the control unit name in this alarm message is invalid. (s: Control unit name, i: Element type, j: Element number) Element type 1 represents the robot, element type 2 represents the hand, and element type 3 represents the jig. [Remedy] Check and modify the setting of the element. SSPC-187 Receive invalid data i s [Cause] Data received from another control unit contains an error. [Remedy] Check if an error has occurred on the source control unit or hub. SSPC-188 Invalid data for send i [Cause] Data to be sent to another control unit contains an error. [Remedy] SSPC-111. Open the element setting screen, then check if the settings are correct and also check if all data is displayed correctly. If this alarm is issued even when all elements are set correctly, contact your FANUC customer service representative. SSPC-189 Timeout element (s,i,j) [Cause] The position data of a remote element received from another control unit is obsolete. Communication with the control unit may have been disconnected. (s: Control unit name, i: Element type, j: Element number) [Remedy] If communication is disconnected, the no-response alarm is usually issued. Turn off the power, then turn on the power.
- 1169 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SSPC-190 No communication (s) [Cause] This alarm is issued when no response is received from another control unit. (s: Control unit name) This function does not communicate with a control unit not specified as a proximity stop or proximity wait target. So, this alarm is issued also when the control unit indicated in the alarm does not have a proximity stop or proximity wait setting made for the target control unit. [Remedy] Check the communication line cabling, and the address, host name, and hub settings. Moreover, on the remote control unit as well, make a proximity stop or proximity wait setting for the target control unit. SSPC-191 Target elem not exist(ST,C:i,s) [Cause] The element on the (s) side (L[left], AR[right]) of proximity stop combination (C:i) contains an error. There may be one of the following errors: • A nonexistent element type or number is specified. • A nonexistent group is specified. • All elements of the target $IA_GRP.$ROBOT, $IA_HAND, or $IA_FOBJ are disabled. • The communication destination control unit does not have a target set correctly for a cause indicated above or because of nonexecution of calibration. [Remedy] Check the items listed above. SSPC-192 Target elem not exist(PA,C:i,s) [Cause] The element on the (s) side (L[left], AR[right]) of proximity wait combination (C:i) contains an error. There may be one of the following errors: • A nonexistent element type or number is specified. • A nonexistent group is specified. • All elements of the target $IA_GRP.$ROBOT, $IA_HAND, or $IA_FOBJ are disabled. • The communication destination control unit does not have a target set correctly for a cause indicated above or because of nonexecution of calibration. [Remedy] Check the items listed above. SSPC-193 IAL detect overload (i) [Cause] The operation, communication processing, proximity stop processing, and proximity wait processing in the control unit are causing an overload. For the current robot setting, the interpolation period may be is too short. [Remedy] This alarm is not issued usually. Contact your FANUC customer service representative.
CNTR Error Codes CNTR-004 WARN No cnir pointer [Cause] Internal software error. [Remedy] Contact your FANUC service center. CNTR-005 WARN Wrong CN Axis/N1 or N2 (G:i) [Cause] The number of the continuous rotation axis is invalid. [Remedy] Set a valid axis number. CNTR-006 WARN Unable to Allocate Memory [Cause] Internal software error. [Remedy] Contact your FANUC service center.
- 1170 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
CNTR-007 STOP.G Serious Internal error (G:i) [Cause] Internal software error. [Remedy] Contact your FANUC service center. CNTR-008 STOP.G Invalid dest.angle (G:i) [Cause] An operation option that cannot be used with the continuous rotation function is specified. [Remedy] Check the operation option. CNTR-009 WARN Warn-Cont Vel too high (G:i) [Cause] The continuous rotation speed is relatively high. [Remedy] This does not present any problem. Ignore this message. CNTR-010 STOP.G Ind.EV option not allowed [Cause] Both an additional axis speed instruction and continuous rotation instruction are used. [Remedy] Delete either instruction. CNTR-011 STOP.G Axis speed exceeds lim (G:i) [Cause] The continuous rotation speed exceeds the upper limit. [Remedy] Decrease the continuous rotation speed. CNTR-012 STOP.G Ending Cont Rot on Rel Motion [Cause] The continuous rotation speed instruction ended with a relative operation. [Remedy] Check the operation add instruction used together with the continuous rotation instruction.
RTCP Error Codes RTCP-001 Wrist Joint is not allow [Cause] Wrist Joint is used on the resume motion. [Remedy] RTCP does not coexist with Wrist Joint. Normally, Wrist Joint is used with the resume motion, so this error always occurs. Change the setting about the resume motion and do not use wrist joint.
APSH Error Codes APSH-000 WARN %s [Cause] General status messages. [Remedy] N/A APSH-001 WARN %s missing [Cause] A MACRO was called without a parameter that must be entered. [Remedy] Check the MACRO call in the TP program. APSH-002 WARN %s Illegal type [Cause] A MACRO was called with a parameter that is illegal. The parameter has the wrong data type. [Remedy] Check the MACRO call in the TP program. APSH-003 WARN %s Illegal zone number [Cause] An zone number less that 1 or greater than $IZONEIO.$NO_ZONES was used. [Remedy] Use an event number from 1 to $IZONEIO.$NO_ZONES. - 1171 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
APSH-004 WARN Waiting for interf. zone %s [Cause] The robot has requested an interference zone, but has not been given permission to enter by the cell controller. [Remedy] If the cell controller does not give control of an interference zone to the robot when it should, check the cell controller’s interference zone programming. APSH-005 WARN Entering interf. zone %s [Cause] The robot has received permission to enter the interference zone. [Remedy] Used to clear the waiting for interference zone message only. APSH-006 WARN PERM memory is low [Cause] This warning indicates that the amount of free memory in the CMOS memory partition has gotten dangerously low. If the PERM memory runs out, you will experience strange MEMO errors and possibly robot lock-ups or register dumps. [Remedy] Warning only. Delete any unneeded data. Contact your FANUC representative with this error. You will probably have to adjust the memory configuration in your robot controller. APSH-007 WARN TEMP DRAM memory is low [Cause] This warning indicates that the amount of free memory in the TEMP memory partition has gotten dangerously low. If the TEMP memory runs out, you will experience strange MEMO errors and possibly robot lock-ups or register dumps. [Remedy] Warning only. Delete any unneeded data. Contact your FANUC representative with this error. You will probably have to adjust the memory configuration in your robot controller. APSH-008 WARN FAULT must be reset [Cause] A fault has occurred, so the operation requested cannot be performed. [Remedy] Clear the source of the fault, and press FAULT RESET. APSH-009 WARN Program already running [Cause] The shell detected a start signal but a program is already running. [Remedy] Re-issue start request when current program is paused or aborted. APSH-010 WARN %s aborted [Cause] A UOP CYCLE START or DI[Initiate Style] was detected when a non-production (i.e. test cycle) program was paused. This paused program was aborted for safety reasons. [Remedy] None is required. The next production start signal will start the current style. APSH-012 WARN REMOTE switch must be on LOCAL [Cause] The robot’s REMOTE condition is TRUE, so the remote operating device (PLC) currently has motion control over the robot. [Remedy] Disable the REMOTE condition by turning the REMOTE key switch on the SOP to LOCAL. APSH-013 WARN Place robot into REMOTE state [Cause] The REMOTE condition is currently false, so the robot is not under the control of the remote operating device (PLC). [Remedy] Verify that the following conditions are true in order to put the robot into the REMOTE condition: 1. UOP inputs #1 (IMSTP), #3 (SFTYSPD), and #8 (ENBL) are all HIGH. 2. SOP REMOTE/LOCAL key switch is set to REMOTE. 3. Teach pendant is disabled. 4. Robot Auto/Bypass mode input is HIGH (if so assigned). 5. Make sure a user program is not setting $RMT_MASTER = 1
- 1172 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
APSH-014 WARN RESET Failure [Cause] There is an active fault, which prevents the reset request from executing [Remedy] Clear the source of the fault (usually en external E-Stop) and press FAULT RESET. APSH-015 WARN Step mode must be disabled [Cause] Step mode is enabled, which prevents the run request from executing [Remedy] Disable step mode by pressing the STEP hardkey. APSH-016 WARN Robot is not under PLC control [Cause] The UOP is not the master device, which prevents the run request from executing [Remedy] Turn SOP REMOTE/LOCAL key switch to REMOTE. Make sure all UOP signals are correct for execution. Set $RMT_MASTER to 0. APSH-017 WARN Running with process disabled [Cause] This is a warning to notify the user that a production job is running with the sealant disabled. [Remedy] None needed. APSH-018 WARN WARNING - Machine lock is on [Cause] This is a warning to notify the user that a production job is running with machine lock on. [Remedy] None needed. APSH-019 WARN Job queue is full [Cause] The job queue cannot accept the next job because it is full. [Remedy] Manually edit the job queue to delete any unneeded jobs or increase queue size. APSH-020 WARN Job queue is empty [Cause] A request to run the next job in the queue came in, but the queue is empty. [Remedy] Check the external device to make sure that a job number was correctly sent to the controller, or manually edit the job queue to CREATE a job. APSH-021 WARN Raise UOP ENBL input [Cause] Robot motion and/or program execution cannot occur unless UOP input 8 is ON. [Remedy] Check UOP I/O setup. UOP input 8 (ENBL) must be ON. APSH-022 WARN Safety fence is open [Cause] The safety fence input is LOW. [Remedy] The safety fence input must be ON to resume normal robot operation. Raise the safety fence input. APSH-024 WARN Program %s not loaded [Cause] The program name that the shell was requested to run is not loaded on the controller. [Remedy] Check PLC->Robot style communication. Verify that specified JOB name was requested by PLC. Load or create the specified JOB program. APSH-025 WARN WARNING - Running at < 100%% [Cause] This is a warning to notify the user that a production job is running at less than 100% speed. override. [Remedy] None needed. Dispense tool can increase the override speed to 100% if you require it. Go to the Cell Setup menu to access this option.
- 1173 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
APSH-027 WARN Press FAULT RESET button [Cause] In order to resume normal production operation, Dispense tool requires that you perform this action. [Remedy] Perform the action stated in the error message when you are ready to resume normal operation. APSH-028 WARN Increasing speed to 100%% [Cause] This is a warning to notify the user that Dispensetool in increasing the genoverride (speed override) to 100%. [Remedy] None needed. To disable this feature, you may change this option on the Cell Setup menu. APSH-029 WARN Robot must be at home [Cause] The robot must be at the HOME position in order to perform the requested operation. This error is usually posted when the PLC sends a cycle start and the robot is not at home. [Remedy] Move the robot to the home position. APSH-030 WARN Style code %s is invalid [Cause] The GIN[style_in] is set to an invalid number. [Remedy] Check the GIN[style_in] value as well as the Group input configuration. APSH-031 WARN %s [Cause] Place holder error, used to keep documentation for errors from Drastically changing. [Remedy] Check the GIN[style_in] value as well as the Group input configuration. APSH-032 WARN Robot Servos Disabled [Cause] Dispensetool has detected that the robot servos have been disabled manually. [Remedy] This is a status message to make sure the user is aware that the robot cannot move. The servos must be re-enabled to resume normal production operations. APSH-033 WARN PLC comm error - timeout [Cause] A communication sequence took too long to complete. [Remedy] Increase communication timeout value in PNS Cell Communication setup menu or disable communication timeout checking. APSH-034 WARN No UOP output defined [Cause] The User Operator Panel output group has not been defined. [Remedy] Set up the UOP Outputs in the UOP I/O menu and restart the robot controller. APSH-035 WARN Robot is in Bypass mode [Cause] The MODE input is low, forcing the robot into BYPASS mode. The robot will now ignore all PLC style initiation. [Remedy] Set the MODE switch to ON. The robot will then re-enter AUTOMATIC mode and again accept PLC signals. APSH-036 WARN User JOB has been paused [Cause] The current JOB has been paused. This often happens if the HOLD input is turned ON or the UOP ENBL signal is set to OFF. [Remedy] If the REMOTE condition is TRUE, the fault recovery menu will appear and give the user the appropriate recovery options. If the REMOTE condition is not TRUE, recovery is up to the user. If all else fails, select FCTN (Function hardkey) then ABORT ALL.
- 1174 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
APSH-037 WARN No UOP input defined [Cause] The User Operator Panel input group has not been defined. [Remedy] Set up the UOP Inputs in the UOP I/O menu. APSH-038 WARN No style input group defined [Cause] The group which carry the style code in to the controller has not been defined. [Remedy] Set up a STYLE SELECT group in the Cell I/O and GROUP I/O input menus and restart the robot. APSH-039 WARN No style ack strobe defined [Cause] The style acknowlege strobe, which is needed with the current communication configuration, has not been defined. [Remedy] Set up a Style Ack Strobe in the Cell Output I/O menu and restart the robot. APSH-040 WARN No backup input group defined [Cause] The backup input group, which is needed with the current communication configuration, has not been defined. [Remedy] Set up a Backup Style Select group in the Cell output I/O and GROUP I/O menus and restart the robot. APSH-041 WARN No style input strobe defined [Cause] The style strobe, which is needed with the current communication configuration (queue enabled), has not been defined. [Remedy] Set up a PNS Strobe in the Cell Input I/O menu and restart the robot. APSH-042 WARN %s [Cause] Place holder error, used to keep documentation for errors from Drastically changing. [Remedy] Set up a PNS Strobe in the Cell Input I/O menu and restart the robot. APSH-043 WARN No style ack group defined [Cause] The style acknowlege group, which is needed with the current communication configuration, has not been defined. [Remedy] Set up a Style Ack Group in the Cell output I/O and GROUP I/O menus and restart the robot. APSH-044 WARN A user program is HELD [Cause] The current job has been held by pressing the HOLD button or setting the UOP HOLD input LOW. [Remedy] Release the HOLD button and raise the UOP HOLD input. APSH-045 WARN No program setup for style %s [Cause] No program number has been set up for this RSR input. [Remedy] Enter a program number for this RSR input in the RSR Cell Setup menu. APSH-046 WARN Robot is in Automatic mode [Cause] This is a notice that the robot is leaving BYPASS mode and entering AUTOMATIC mode, where it can respond to PLC inputs [Remedy] None needed.
- 1175 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
APSH-047 WARN Shell will not run without UOPs [Cause] This is a warning, telling the user that the UOPs have not yet been set up, so the shell will wait for the UOPs to be defined before resuming. [Remedy] The shell requires the UOPs to run. Once the UOPs have been set up, the shell will continue its initialization sequence. APSH-048 WARN PLC comm error - invert check [Cause] The backup style group is not the 1’s complement (inverse) of the style input group. [Remedy] Verify that the PLC is sending the correct invert style to the correct group. Disable invert checking in the PNS Cell Setup menu. APSH-049 WARN %s [Cause] Place holder error, used to keep documentation for errors from Drastically changing. [Remedy] Verify that the PLC is sending the correct invert style to the correct group. Disable invert checking in the PNS Cell Setup menu. APSH-050 WARN Cell IO setup is invalid [Cause] Signals which are required for this cell IO configuration have not been configured. [Remedy] Check the messages posted previous to the in the error log for the names of the incorrect signals. Fix the IO setup of these signals and cold start the controller. APSH-050 WARN Cell IO setup is invalid [Cause] Signals which are required for this cell IO configuration have not been configured. [Remedy] Check the messages posted previous to the in the error log for the names of the incorrect signals. Fix the IO setup of these signals and cold start the controller. APSH-051 WARN Connect or deassign UOP inputs [Cause] The robot cannot move while the UOP inputs are in this state. [Remedy] You must either wire UOP inputs #1, #2, #3, and #8 high or deassign the UOP inputs and restart the controller. APSH-052 WARN Critical UOP inputs are LOW [Cause] UOP inputs #1 (IMSTP), #2 (HOLD), #3(SFTYFNC), #8 (ENBL) are all LOW. These must all be HIGH for normal production operation. [Remedy] See [Remedy] for APSH-051, Connect or deassign UOP inputs. APSH-054 PAUSE Release SOP E-STOP [Cause] In order to resume normal production operation, Dispensetool requires that you perform this action. [Remedy] Perform the action stated in the error message when you are ready to resume normal operation. APSH-055 PAUSE Raise UOP IMSTP input [Cause] In order to resume normal production operation, Dispensetool requires that you perform this action. [Remedy] Perform the action stated in the error message when you are ready to resume normal operation.
- 1176 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
APSH-056 PAUSE Release SOP E-STOP [Cause] In order to resume normal production operation, Dispensetool requires that you perform this action. [Remedy] Perform the action stated in the error message when you are ready to resume normal operation. APSH-057 PAUSE Release TP E-STOP [Cause] In order to resume normal production operation, Dispensetool requires that you perform this action. [Remedy] Perform the action stated in the error message when you are ready to resume normal operation. APSH-058 PAUSE Pause forced by shell [Cause] This error is posted to simulate a PAUSE error. [Remedy] This error is posted by Dispensetool during normal operation, but should not be visible to the user. If you see this error, report it to you FANUC representative. APSH-059 PAUSE Abort forced by shell [Cause] This error is posted to simulate a ABORT error. [Remedy] This error is posted by Dispensetool during normal operation, but should not be visible to the user. If you see this error, report it to you FANUC representative. APSH-060 WARN Cycle start ignored-not in AUTO [Cause] This is not a fault. This error is posted when the robot is sent a cycle start from the cell controller, but the robot is either in BYPASS mode (set from Soft Panel menu) or in MANUAL mode, but no manual cycle start has been initiated. Is is also possible that the robot is in the MANUAL mode and a MANUAL CYCLE was requested, but the style sent by the PLC does not match the one specified on the SOFT PANEL. [Remedy] In most cases, this fault can be ignored. This fault was put in to assist in debugging problems with the soft panel in Dispensetool. If you are trying to initiate a MANUAL CYCLE, make sure the MANUAL CYCLE STYLE inputted into the Soft Panel menu is the same as what the PLC is sending. APSH-061 WARN %s [Cause] Place holder error, used to keep documentation for errors from Drastically changing. [Remedy] In most cases, this fault can be ignored. This fault was put in to assist in debugging problems with the soft panel in Dispensetool. If you are trying to initiate a MANUAL CYCLE, make sure the MANUAL CYCLE STYLE inputted into the Soft Panel menu is the same as what the PLC is sending. APSH-062 WARN %s [Cause] Place holder error, used to keep documentation for errors from Drastically changing. [Remedy] In most cases, this fault can be ignored. This fault was put in to assist in debugging problems with the soft panel in Dispensetool. If you are trying to initiate a MANUAL CYCLE, make sure the MANUAL CYCLE STYLE inputted into the Soft Panel menu is the same as what the PLC is sending. APSH-063 PAUSE A HOLD input is active [Cause] The current job has been paused by pressing the HOLD button or setting the UOP HOLD input LOW. [Remedy] Release the HOLD button and raise the UOP HOLD input.
- 1177 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
APSH-064 PAUSE %s [Cause] Place holder error, used to keep documentation for errors from Drastically changing. [Remedy] Release the HOLD button and raise the UOP HOLD input. APSH-065 PAUSE %s [Cause] Place holder error, used to keep documentation for errors from Drastically changing. [Remedy] Release the HOLD button and raise the UOP HOLD input. APSH-066 WARN %s [Cause] Place holder error, used to keep documentation for errors from Drastically changing. [Remedy] Release the HOLD button and raise the UOP HOLD input. APSH-070 PAUSE Failed to continue %s [Cause] The error handler was unable to continue the task named when the user requested that all tasks be continued This is probably due to one of the E-Stops or HOLD buttons being active. [Remedy] Disable all E-Stops and release HOLD buttons. If it is not desired that the task named be continued, abort it. APSH-071 PAUSE Failed to pause robot task [Cause] A Karel PAUSE_TASK() command failed to pause a task which the error handler believes should be paused. [Remedy] The task which the error handler tried to pause was probably a system utility, and is not allowed to be paused. You can probably ignore this fault without any problems. APSH-072 PAUSE Failed to abort robot task [Cause] A Karel ABORT_TASK() command failed. [Remedy] Cold start the robot controller, then manually restore production status. APSH-073 WARN Servos Locked-out, enable servos [Cause] Robot servos are locked out. [Remedy] Enable robot servos. APSH-074 WARN Disable Teach Pendant [Cause] In order to resume normal production operation, Dispensetool requires that you perform this action. [Remedy] Perform the action stated in the error message when you are ready to resume normal operation. APSH-075 WARN Error in accessing TPE:%s [Cause] The following error occurred when a the data associated with a TPE program was accessed. [Remedy] Verify that this TPE program exists. Go into the DETAIL pages under the SELECT menu and hit NEXT key until robot allows this mode to END. APSH-076 WARN Shell could not run:%s [Cause] The shell tried to execute a program, but was stopped by the operating system. [Remedy] Make sure the program exists and it is not already running or paused. Use the PROGRAM STATUS display to make sure you have not exceeded the maximum number of tasks. Abort all programs which do not need to be running.
- 1178 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
APSH-077 WARN No positions in %s [Cause] This TPE did not contain a position to represent HOME, SERVICE, or PURGE. [Remedy] If you need to use the AT PERCH, AT PURGE, or AT SERVICE outputs, teach the positions you need in the appropriate TPEs. If you do not need these outputs to be updated ignore this warning. APSH-078 WARN Shell could not run program [Cause] The shell tried to execute a program, but was stopped by the operating system. [Remedy] Make sure the program exists and it is not already running or paused. Use the PROGRAM STATUS display to make sure you have not exceeded the maximum number of tasks. Abort all programs which do not need to be running. APSH-079 WARN No DIN for Auto/Bypass [Cause] No Auto/Bypass input has been defined, but one was expected. [Remedy] Set a Auto/Bypass input in the Cell I/O Input menu and restart the robot. APSH-080 WARN Waiting for Cancel/Continue [Cause] The robot is currently waiting for Cancel or continue (Wet or Dry) or a HOME input from the PLC. [Remedy] This is a warning to inform the person at the teach pendant that the PLC has been given exclusive control over how the robot will recover from the current error. APSH-081 WARN Waiting for Cancel [Cause] The robot is currently waiting for a cancel input from the PLC. The current JOB has had a fault so severe that it cannot recover and must be aborted or receive the HOME UOP input [Remedy] This is a warning to inform the person at the teach pendant that the PLC has been given exclusive control over how the robot will recover from the current error. APSH-082 WARN No $ERROR_PROG defined [Cause] No $ERROR_PROG has been defined for this JOB. This fault will only appear if the Karel variable [SLERROR]POST_NO_ERRP is set to TRUE (default = FALSE). [Remedy] Use the TPE ERROR_PROG command, under Program Control, to set up a Error Program for this JOB. This will allow the robot to move out of the work area when an error occurs. APSH-083 WARN No $RESUME_PROG defined [Cause] No $RESUME_PROG has been defined for this JOB. [Remedy] Use the TPE RESUME_PROG command, under Program Control, to set up a Resume Program for this JOB. This will allow the JOB to resume the interrupted program. APSH-084 WARN WARNING - simulated I/O [Cause] The robot is running a style program with one or more I/O ports simulated. Unexpected motions and actions may occur. [Remedy] Verify that all simulated I/O points should be simulated. Un-simulate all I/O ports which should not be simulated. APSH-090 WARN %s [Cause] Place holder error, used to keep documentation for errors from Drastically changing. [Remedy] Verify that all simulated I/O points should be simulated. Un-simulate all I/O ports which should not be simulated.
- 1179 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
APSH-091 WARN %s [Cause] Place holder error, used to keep documentation for errors from Drastically changing. [Remedy] Verify that all simulated I/O points should be simulated. Un-simulate all I/O ports which should not be simulated. APSH-092 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. APSH-093 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. APSH-094 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. APSH-095 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. APSH-096 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. APSH-097 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. APSH-098 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. APSH-099 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. APSH-100 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. APSH-110 WARN READ IO parm %s missing [Cause] The READ IO MACRO was called without a parameter that must be entered. READ IO(signal name string, integer register number) [Remedy] Check the MACRO call in the TP program. APSH-111 WARN READ IO parm %s is wrong type [Cause] The READ IO MACRO was called with illegal parameters. READ IO(signal name string, integer register number) [Remedy] Check the MACRO call in the TP program.
- 1180 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
APSH-112 WARN signal %s does not exist [Cause] The READ IO MACRO was called but the signal could not be found. READ IO(signal name string, integer register number) [Remedy] Check the MACRO call in the TP program. APSH-113 WARN can’t fetch signal type [Cause] The READ IO MACRO was called but the signal could not be found. READ IO(signal name string, integer register number) [Remedy] Check the MACRO call in the TP program. APSH-114 WARN can’t fetch signal number [Cause] The READ IO MACRO was called but the signal could not be found. READ IO(signal name string, integer register number) [Remedy] Check the MACRO call in the TP program. APSH-115 WARN can’t read signal %s [Cause] The READ IO MACRO was called but the signal could not be found. READ IO(signal name string, integer register number) [Remedy] Check the MACRO call in the TP program. APSH-116 WARN Reg %s could not be set [Cause] Register operation failed [Remedy] Check if the register is defined, if it is between 1-64 and if it has the right value. Must ABORT ALL and retry APSH-117 WARN Register not defined %s [Cause] This is just a debug message [Remedy] N/A APSH-118 WARN WRITE IO parm %s missing [Cause] The WRITE IO MACRO was called without a parameter that must be entered. WRITE IO(signal name string, integer value to write) [Remedy] Check the MACRO call in the TP program. APSH-119 WARN WRITE IO parm %s is wrong type [Cause] The WRITE IO MACRO was called with illegal parameters. WRITE IO(signal name string, integer value to write) [Remedy] Check the MACRO call in the TP program. APSH-120 WARN signal %s does not exist [Cause] The WRITE IO MACRO was called but the signal could not be found. WRITE IO(signal name string, integer register number) [Remedy] Check the MACRO call in the TP program. APSH-121 WARN can’t write signal %s [Cause] The WRITE IO MACRO was called but the signal could not be found. WRITE IO(signal name string, integer register number) [Remedy] Check the MACRO call in the TP program.
- 1181 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
APSH-122 WARN GET IO PORT parm %s missing [Cause] The GET IO MACRO was called without a parameter that must be entered. GET IO(signal name string, integer port number) [Remedy] Check the MACRO call in the TP program. APSH-123 WARN GET IO PORT parm %s is wrong type [Cause] The GET IO MACRO was called with illegal parameters. GET IO(signal name string, integer port number) [Remedy] Check the MACRO call in the TP program. APSH-124 WARN signal %s does not exist [Cause] The GET IO MACRO was called but the signal could not be found. GET IO(signal name string, integer port number) [Remedy] Check the MACRO call in the TP program. APSH-125 WARN Forcing Process Enabled [Cause] It was detected that the Process was DISABLED at the start of this production program. A choice (or setup selection) has indicated that the Process should be FORCED to the enabled state. [Remedy] - Don’t choose to FORCE the process enable. - Change Prog Select-Production Check Process ready setup to NOT Force Condition. - Ensure that Process Enabled input is on at the start of the next production cycle. APSH-126 PAUSE %s [Cause] Robot is paused [Remedy] Status message APSH-127 WARN Repower to activate change. [Cause] The joint velocity limit has changed. This parameter change requires you to cycle controller power in order to take effect. [Remedy] Turn off the controller, then turn it on again. APSH-130 WARN Cannot access FR: %s *.DT files [Cause] Error occurred while accessing the FR: device. No .dt files found. [Remedy] DT files must exist on the FR: device. APSH-131 WARN I/O data error: %s [Cause] I/O port defined wrong: Illegal type, Default data is used. [Remedy] DT file on the FR: device must be corrected. APSH-132 WARN Selected Prog %s not loaded [Cause] The program name that the shell was requested to run is not loaded on the controller. [Remedy] Check PLC->Robot style communication. Verify that specified Program name was requested by PLC. Load or create the specified Program program. APSH-133 WARN Not in safe starting position [Cause] The robot has been jogged away from the position where the teach pendant was enabled. [Remedy] Move the robot back to the position where the teach pendant was enabled, abort the program, or continue (in linear motion) from position where the robot is currently positioned.
- 1182 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
APSH-141 PAUSE %s [Cause] The robot has been jogged away from the position where the teach pendant was enabled. [Remedy] Move the robot back to the position where the teach pendant was enabled, abort the program, or continue (in linear motion) from position where the robot is currently positioned. APSH-142 WARN WARNING - System is in dry run [Cause] This is a warning to notify you that a production job is running with the process disabled. [Remedy] None is required. APSH-143 WARN Robot motion is not enabled [Cause] Robot motion and/or program execution cannot occur unless UOP input 8 is ON. [Remedy] Check UOP I/O setup. UOP input 8 must be ON. APSH-144 WARN WARNING - Process Complete manually turned on at end of %s [Cause] A ’Force Process Complete’ was performed from the Soft Panel [Remedy] This is just a warning to let the operator know that Process Complete was manually turned on. APSH-150 WARN Gun operation is NOSTROKE [Cause] This is a warning to notify you that a production job is running with gun set to NOSTROKE. None is required. [Remedy] N/A APSH-151 WARN Weld operation is NOWELD [Cause] This is a warning to notify you that a production job is running with weld set to NOWELD. None is required. [Remedy] N/A APSH-152 WARN Robot mode must be AUTO [Cause] The robot must be in full automatic mode with the PLC before production operation can occur. [Remedy] Go to the SOFT PANEL menu and set Robot mode=AUTO. APSH-153 WARN Must press SHIFT key too [Cause] The shift key must be pressed when accessing this teach pendant hardkey. [Remedy] Press the shift key. APSH-154 WARN Only one gun defined [Cause] Because the system is currently configured for one equipment with a single gun, there is no need to set the equipment that that GUN and BACKUP hardkeys will operate on; they will always operate on the one gun. [Remedy] None is required APSH-155 WARN HOME position not recorded [Cause] The HOME position hasn’t been recorded yet. The HOME position is contained in Reference Position menu. [Remedy] Go to the SETUP menu, select Reference Position from the [TYPE] menu. Jog the robot to the HOME position. Record your reference position, then specify it is a Valid Home. NOTE : HOME_IO program will be started when the robot reaches the HOME position. You have to edit the HOME_IO program correctly if you use the HOME_IO. If you do not need HOME_IO, delete all contents (all program lines) in the HOME_IO program. - 1183 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
APSH-156 WARN Specify Home in Ref Pos Menu [Cause] This is only the message of remedy for ASPH-155. [Remedy] N/A APSH-157 WARN Teach pendant must be enabled [Cause] The teach pendant must be enabled when accessing this teach pendant hardkey. [Remedy] Enable the teach pendant. APSH-158 WARN No group output for weld sched [Cause] The group output that contains the weld schedule has not been configured yet. [Remedy] Go to the Weld Intface Output menu, and edit the index of the Weld Schedule I/O point. Make sure the group output has been properly configured from the Group Output menu. You must cold start the controller when changing this index, or redefining the group output. APSH-159 WARN Servos are not ready [Cause] The servos are not ready, so operation requested cannot be performed. [Remedy] When resetting a fault, wait for the servos to click on before attempting to execute a program. APSH-160 WARN Robot not at POUNCE position [Cause] The robot is not at the POUNCE position, so the operation requested cannot be performed. [Remedy] Re-issue this request when the robot is AT POUNCE. APSH-161 WARN No production program is running [Cause] The robot is not currently running a production style, so the operation requested cannot be performed. [Remedy] Re-issue the request when the robot is running a production style. APSH-162 WARN No group output for multi-pressure [Cause] The group output that contains the setting for the multi-pressure valving has not been configured yet. [Remedy] Go to the Spot Equipment Intface Output menu, and edit the index of the Valve pressure I/O point. Make sure the group output has been properly configured from the Group Output menu. You must cold start the controller when changing this index, or redefining the group output. APSH-163 WARN No motion allowed--gun closed [Cause] No motion can occur because the gun is closed. This prevents the user from jogging or running a program while the gun is closed, and damaging parts and/or tooling. [Remedy] Open the gun. APSH-164 WARN Home I/O program %s not loaded [Cause] The HOME I/O program as specified from the Cell Setup menu does not exist and was not run. [Remedy] Go to the Cell Setup menu and either check the name of the HOME I/O macro name menu item. Make sure the file specified exists on the controller. Either create a program by that name or change this menu item to a program that already exists on the controller.
- 1184 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
APSH-165 WARN Invalid Studgun Selection [Cause] There I/O configuration for the proper studwelding gun has not been initialized. [Remedy] Proceed to the Spot Equipment I/O setup screen and configure the digital inputs Gun Present = On/Off, Gun in Nest = On/Off for the 2 stud guns. Proper configuration if gun 1 is on the robot is for Gun 1 (Gun Present = ON, Gun in Nest = OFF and for Gun 2 (Gun Present = OFF, Gun in Nest = ON. Proper configuration if gun 2 is on the robot is for Gun 1 (Gun Present = OFF, Gun in Nest = ON and for Gun 2 (Gun Present = ON, Gun in Nest = OFF. APSH-166 WARN Studgun Change Unsuccessful [Cause] The robot was aborted or interrupted during the studgun change sequence. [Remedy] Manually change the stud guns and move the robot to the home position. Press cycle start to run production. APSH-167 WARN Move robot home & cycle start [Cause] The stud gun change program was interrupted. [Remedy] To resume production the robot must be manually returned home and cycle start must be pressed to continue. APSH-168 WARN No GO for EQP pressure [Cause] The group output that contains the setting for the equalization pressure has not been configured yet. [Remedy] Go to the Spot Equipment Intface Output menu, and edit the index of the Equal pressure I/O point. Make sure the group output has been properly configured from the Group Output menu. You must cold start the controller when changing this index, or redefining the group output. APSH-169 WARN Uninitialized Stud Macros [Cause] A macro program to dropoff or pickup studgun 1 or 2 has not been initialized. [Remedy] Proceed to Spot Equipment Menu under MENUS-SETUP and initialize the studwelding macros which will only appear if STUD BACKUP is ENABLED at CONTROLLED START. APSH-170 WARN Check Nest/Changer Inputs [Cause] A macro program to dropoff or pickup studgun 1 or 2 has not been initialized. [Remedy] Proceed to Spot Equipment Menu under MENUS-SETUP and initialize the studwelding macros which will only appear if STUD BACKUP is ENABLED at CONTROLLED START. APSH-174 WARN SCR overtemp detected [Cause] An SCR overtemp signal has been received. [Remedy] Check the SCR for overheating. APSH-175 WARN Req. Press. Not mapped for WC:%s [Cause] The Request Pressure digital input is not mapped. [Remedy] Map request pressure input on Weld Interface Menu. APSH-176 WARN GIN For Weld Press. Not mapped for WC:%s [Cause] The GIN for Weld Pressure is not mapped. [Remedy] Map Weld Pressure input on Weld Interface Menu.
- 1185 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
APSH-177 WARN Read Press. Not mapped for WC:%s [Cause] Read pressure input is not mapped on weld interface Menu. [Remedy] Map read pressure input on Weld Interface Menu. APSH-178 WARN Map I/O in Weld Interface Menu [Cause] There is not [Cause], this is a help code [Remedy] No remedy required. APSH-179 WARN Upd. Press. timeout WC:%s [Cause] The weld controller did not set Read Pressure input in time. [Remedy] Check if weld controller is functioning correctly, or increase Weld Pres time-out at CTRL start menu. APSH-180 WARN Could not communicate to WC. [Cause] Could not read any I/O from the Weld controller. Device may be offline. [Remedy] Check if weld controller is functioning correctly, or powered on. APSH-201 WARN ColRecBegin Automatic Collision Recovery [Cause] Automatic Collision recovery is beginning. [Remedy] None. Just a WARN message. APSH-202 WARN RecPrgNotFnd Recovery Program not found [Cause] Automatic Collision recovery was attempting to run the recovery program. [Remedy] Make sure the program is loaded. APSH-203 WARN ErrRunTask Error running %s [Cause] Could not run or continue the task. [Remedy] Check the associated error message for the task error and follow the recovery procedure. APSH-204WARN RunRecProg Running recovery prog %s [Cause] Automatic Collision recovery is about to run the recovery program [Remedy] None. Just a WARN message. APSH-205WARN RunOrigProg Running original prog %s [Cause] Automatic Collision recovery is about to run the original program. [Remedy] None. Just a WARN message. APSH-206 WARN Invalid Group Specified [Cause] The group specified to get_home does not exist. [Remedy] Verify that the specified group number exists. APSH-207WARN Invalid Ref Pos Specified [Cause] The reference position specified to get_home. [Remedy] Verify specified Reference position exists. APSH-208WARN Failed to check %s [Cause] This error is related to production setup check screen. This item should not be checked on the present configuration. [Remedy] Press F6,REDO and cycle power to update items.
- 1186 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
CPMO Error Codes CPMO-001 ABORT.G internal PLAN error (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-002 ABORT.G Internal INTR error (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-003 SERVO2 Internal CP error (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-004 ABORT.G Feature not Supported(G:%d^2) [Cause] An unsupported function was used. [Remedy] Disable the function and retry.
- 1187 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
CPMO-010 SERVO2 Cycle power: JBF size (G: %d^2) [Cause] The data structure is not sufficiently large for JBF or Ext JBF. [Remedy] Turn off the power and back on. CPMO-011 SERVO2 JBF INTR_T < Ts (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-012 SERVO2 JBF Len<0 (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-013 SERVO2 JBF Len=0 (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1188 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
CPMO-014 SERVO2 JBF NULL PTR (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-015 SERVO2 JBF Ts>itp (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-016 SERVO2 JBF Ts != 0 (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1189 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
CPMO-017 SERVO2 JBF INTR_T != itp (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-018 SERVO2 JBF nitp_time < 1 (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-019 SERVO2 JBF INTR_T > itp (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1190 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
CPMO-020 ABORT.G JBF MEMORY ALLOC ERROR [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-021 SERVO2 JBF Index < 0 (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-022 SERVO2 JBF Ptout > Ptin (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1191 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
CPMO-023 SERVO2 JBF Ptout != Ptin (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-024 SERVO2 JBF (Ptin-Ptout)>itp (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-025 SERVO2 JBF Ts < 0 (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1192 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
CPMO-026 SERVO2 JBF Ts != 0 (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-027 SERVO2 JBF Ts > itp [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-028 SERVO2 JBF TS, Ptin & Ptout mismatch [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1193 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
CPMO-029 SERVO2 JBF Index > 1 (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-030 SERVO2 JBF Ptout > npts (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-031 SERVO2 JBF Len <= 0 (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1194 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
CPMO-032 SERVO2 JBF Set not empty (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-033 SERVO2 JBF not empty (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-034 SERVO2 JBF len mismatch (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1195 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
CPMO-035 SERVO2 JBF set not main (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-036 SERVO2 JBF set not valid (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-037 SERVO2 JBF not valid (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1196 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
CPMO-038 SERVO2 NonZero JBF Remainder(G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-039 SERVO2 NonZero Chn Remainder(G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-040 ABORT.G GTF not empty (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1197 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
CPMO-041 ABORT.G GTF no main filter (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-042 ABORT.G GTF fout too big (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-043 ABORT.G GTF num_tf != 1 (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-044 SYSTEM Cycle power: GTFsize (G: %d^2) [Cause] The time filter size is too small. [Remedy] Turn off the power and back on.
- 1198 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
CPMO-050 ABORT.G No System Variables (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-051 ABORT.G No Data Structure (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-052 ABORT.G Stack Underflow (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1199 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
CPMO-053 ABORT.G No Stack(G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-054 ABORT.G Stack Overflow (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-055 ABORT.G Stack Not Full (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1200 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
CPMO-056 ABORT.G Corrupt data (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-057 ABORT.G Wrong MT or OT (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-058 SYSTEM Cycle power: CHNs (G: %d^2) [Cause] There are not enough channels to continue operation. [Remedy] Turn off the power and back on. CPMO-059 SYSTEM Cycle power: JBFSETs (G: %d^2) [Cause] There are not enough JBFSETs to continue operation. [Remedy] Turn off the power and back on. CPMO-060 SYSTEM Cycle power: JBFs (G: %d^2) [Cause] There are not enough JBFs to continue operation. [Remedy] Turn off the power and back on. CPMO-061 SYSTEM Cycle power: TFs (G: %d^2) [Cause] There are not enough time filters to continue operation. [Remedy] Turn off the power and back on. CPMO-062 SYSTEM Cycle power: RSINFOs (G: %d^2) [Cause] There are not enough RSINFOs to continue operation. [Remedy] Turn off the power and back on.
- 1201 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
CPMO-063 SYSTEM MAINCHN is NULL (G: %d^2) [Cause] Internal error. The main channel is NULL. [Remedy] Report this problem to our service center serving your locality. Turn off the power and back on. CPMO-064 SYSTEM MAINCHN is Unknown (G: %d^2) [Cause] Internal error. The main channel is neither JBF nor JF. [Remedy] Report this problem to our service center serving your locality. Turn off the power and back on. CPMO-065 ABORT.G MultiGrp RSM STOPPOS MisSyn [Cause] Internal error. Groups are not synchronized in a stoppage during resume operation. [Remedy] Report this problem to our service center serving your locality. Reset the alarm and resume. CPMO-066 ABORT.G MultiGrp RsmType MisSyn [Cause] Internal error. The resume operation types of the groups differ. [Remedy] Report this problem to our service center serving your locality. resume. CPMO-067 ABORT.G MultiGrp RsmInfo Mismatch [Cause] Internal error. The number of rsinfo items of the groups differ. [Remedy] Report this problem to our service center serving your locality. resume.
Reset the alarm and
Reset the alarm and
CPMO-069 STOP Step mode enabled (G: %d^2) [Cause] In step operation, resume operation cannot be performed. [Remedy] No action available. CPMO-070 ABORT.G Channel not empty(G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1202 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
CPMO-071 ABORT.G Channel not main (G: %d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-072 ABORT.G Can't resume same path(G: %d^2) [Cause] The resume operation cannot continue a constant path. [Remedy] Reset the alarm and retry. At this time, the path may differ from a normal one. CPMO-073 ABORT.G Can't resume same path(G: %d^2) [Cause] The resume operation cannot continue a constant path. [Remedy] Reset the alarm and retry. At this time, the path may differ from a normal one. CPMO-074 WARN Can't resume blend path(G: %d^2) [Cause] If different filter types exist, it is not possible to perform pause and resume on a constant path. [Remedy] Use filters of the jerk blending (JBF) type in all operation segments. CPMO-075 WARN %s [Cause] Warning. [Remedy] Check the status and the settings carefully. CPMO-076 WARN Can't resume same path(G: %d^2) [Cause] The resume operation cannot continue a constant path. [Remedy] Reset the alarm and retry. At this time, the path may differ from a normal one. CPMO-077 WARN Can't resume same path(G: %d^2) [Cause] The resume operation cannot continue a constant path. [Remedy] Reset the alarm and retry. At this time, the path may differ from a normal one. CPMO-078 WARN Seg Overrun (G: %d^2) [Cause] The next segment is ready, but cannot be used. The path may differ from a normal one. [Remedy] Reset the alarm and retry. At this time, the path may differ from a normal one. CPMO-079 WARN Preplan fail (G: %d^2) [Cause] The next segment is ready, but the operation plan has been canceled. [Remedy] Reset the alarm and retry. At this time, the path may differ from a normal one.
- 1203 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
CPMO-080 SERVO2 EXTChannel not empty(G:%d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-081 SERVO2 EXT JBFSet not empty(G:%d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-082 SERVO2 EXT JBF not empty(G:%d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality.
- 1204 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
CPMO-083 SERVO2 EXT JBF len mismatch(G:%d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-084 SERVO2 EXT JBFSET NULL PTR (G:%d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-085 SERVO2 EXT JBF NULL PTR (G:%d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-086 SYSTEM Cycle power: EXT JBFs(G:%d^2) [Cause] The data structure is not large enough for EXTJBFs. [Remedy] Turn off the power and back on.
- 1205 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
CPMO-087 ABORT.G EXT pt.valid.ext=0(G:%d^2) [Cause] Internal error of software. [Remedy] The system may have been destroyed. Possible actions include: (1) Turn off the power and back on. (2) Perform an initial start and reconfigure the robot. (3) Check to see if any optional or additional software differs in edition from original software. If the original software is distributed in multiple media, check to see if the editions of all software match. In addition, check to see if the software installation manual matches the edition of the software to be installed. If any edition does not match, it is necessary to re-install correct software. (4) Check to see if options that are exclusive to each other and incompatible are loaded. (5) Re-load all software. (6) If the error persists, record the operation procedure used until the error occurred, and contact our service center serving your locality. CPMO-090 ABORT.G Invalid MainChn ID (G: %d^2) [Cause] Internal error. The main channel ID is inappropriate. This alarm should not be issued. [Remedy] Cancel program execution and retry. Report this problem to our service center serving your locality. CPMO-091 ABORT.G Invalid JBF MainChn ID (G: %d) [Cause] Internal error. The JBF main channel ID is inappropriate. This alarm should not be issued. [Remedy] Cancel the program and retry. Report this problem to our service center serving your locality. CPMO-092 ABORT.G JF NewLastAng Mismatch (G: %d^2) [Cause] Internal error. In JF, misalignment occurred. [Remedy] Report this problem to our service center serving your locality. CPMO-093 ABORT.G JB NewLastAng Mismatch (G: %d^2) [Cause] Internal error. In JB, misalignment occurred. [Remedy] Report this problem to our service center serving your locality. CPMO-094 ABORT.G Invalid JBF New ChnId (G: %d^2) [Cause] Internal error. The JBF new main channel is inappropriate. [Remedy] Cancel program execution and retry. Report this problem to our service center serving your locality. CPMO-095 SERVO Too Large Jnt Cmd (G:%d A:%d) [Cause] Internal error. The axis move command is too large. [Remedy] Cancel program execution and retry. Report this problem to our service center serving your locality. CPMO-096 SERVO Error: ChnNewAng (G: %d^2) [Cause] Internal error. The axis move command is too large. [Remedy] Cancel program execution and retry. Report this problem to our service center serving your locality.
- 1206 -
APPENDIX
B-82594EN-4/01
SEAL Alarm Code
C.ALARM CODES
(ID=51)
SEAL-000 ABORT Dispensetool internal error [Cause] This error is caused when Dispensetool encounters a problem it is unable to solve internally. This fault is almost always caused by style paths which do things which were not anticipated when this software was written. The reasons for this could be: 1. The sealing path is too fast 2. The sealing instructions (SS and SE) are too close together 3. The delay and timing values specified in your sealing schedules are too large or do not make sense. 4. Your robot's CPU has failed [Remedy] Write down the exact error number and message shown. Write down exactly what your robot was doing at the time of the failure. Make sure you include: Program name, line number, robot's location in the work cell, any cell I/O or other communciation activity, and exactly what the robot was doing right before the fault occured. This fault is usually fixed by doing a COLD start. If that does not work, contact your supervisor or call the FANUC robotics Hot Line. SEAL-001 WARN %s [Cause] This error is caused when Dispensetool encounters a problem it is unable to solve internally. This fault is almost always caused by style paths which do things which were not anticipated when this software was written. The reasons for this could be: 1. The sealing path is too fast 2. The sealing instructions (SS and SE) are too close together 3. The delay and timing values specified in your sealing schedules are too large or do not make sense. 4. Your robot's CPU has failed [Remedy] Write down the exact error number and message shown. Write down exactly what your robot was doing at the time of the failure. Make sure you include: Program name, line number, robot's location in the work cell, any cell I/O or other communciation activity, and exactly what the robot was doing right before the fault occured. This fault is usually fixed by doing a COLD start. If that does not work, contact your supervisor or call the FANUC robotics Hot Line. SEAL-002 STOP Flow rate update failed [Cause] This error is caused when Dispensetool encounters a problem it is unable to solve internally. This fault is almost always caused by style paths which do things which were not anticipated when this software was written. The reasons for this could be: 1. The sealing path is too fast 2. The sealing instructions (SS and SE) are too close together 3. The delay and timing values specified in your sealing schedules are too large or do not make sense. 4. Your robot's CPU has failed [Remedy] Write down the exact error number and message shown. Write down exactly what your robot was doing at the time of the failure. Make sure you include: Program name, line number, robot's location in the work cell, any cell I/O or other communciation activity, and exactly what the robot was doing right before the fault occured. This fault is usually fixed by doing a COLD start. If that does not work, contact your supervisor or call the FANUC robotics Hot Line.
- 1207 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SEAL-003 STOP Digital I/O update failed [Cause] This error is caused when Dispensetool encounters a problem it is unable to solve internally. This fault is almost always caused by style paths which do things which were not anticipated when this software was written. The reasons for this could be: 1. The sealing path is too fast 2. The sealing instructions (SS and SE) are too close together 3. The delay and timing values specified in your sealing schedules are too large or do not make sense. 4. Your robot's CPU has failed [Remedy] Write down the exact error number and message shown. Write down exactly what your robot was doing at the time of the failure. Make sure you include: Program name, line number, robot's location in the work cell, any cell I/O or other communciation activity, and exactly what the robot was doing right before the fault occured. This fault is usually fixed by doing a COLD start. If that does not work, contact your supervisor or call the FANUC robotics Hot Line. SEAL-004 WARN Dispensetool error at %d [Cause] This error is caused when Dispensetool encounters a problem it is unable to solve internally. This fault is almost always caused by style paths which do things which were not anticipated when this software was written. The reasons for this could be: 1. The sealing path is too fast 2. The sealing instructions (SS and SE) are too close together 3. The delay and timing values specified in your sealing schedules are too large or do not make sense. 4. Your robot's CPU has failed [Remedy] Write down the exact error number and message shown. Write down exactly what your robot was doing at the time of the failure. Make sure you include: Program name, line number, robot's location in the work cell, any cell I/O or other communciation activity, and exactly what the robot was doing right before the fault occured. This fault is usually fixed by doing a COLD start. If that does not work, contact your supervisor or call the FANUC robotics Hot Line. SEAL-005 WARN Dispensetool error at %s [Cause] This error is caused when Dispensetool encounters a problem it is unable to solve internally. This fault is almost always caused by style paths which do things which were not anticipated when this software was written. The reasons for this could be: 1. The sealing path is too fast 2. The sealing instructions (SS and SE) are too close together 3. The delay and timing values specified in your sealing schedules are too large or do not make sense. 4. Your robot's CPU has failed [Remedy] Write down the exact error number and message shown. Write down exactly what your robot was doing at the time of the failure. Make sure you include: Program name, line number, robot's location in the work cell, any cell I/O or other communciation activity, and exactly what the robot was doing right before the fault occured. This fault is usually fixed by doing a COLD start. If that does not work, contact your supervisor or call the FANUC robotics Hot Line.
- 1208 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SEAL-006 STOP Memory request failed [Cause] This error is caused when Dispensetool encounters a problem it is unable to solve internally. This fault is almost always caused by style paths which do things which were not anticipated when this software was written. The reasons for this could be: 1. The sealing path is too fast 2. The sealing instructions (SS and SE) are too close together 3. The delay and timing values specified in your sealing schedules are too large or do not make sense. 4. Your robot's CPU has failed [Remedy] Write down the exact error number and message shown. Write down exactly what your robot was doing at the time of the failure. Make sure you include: Program name, line number, robot's location in the work cell, any cell I/O or other communciation activity, and exactly what the robot was doing right before the fault occured. This fault is usually fixed by doing a COLD start. If that does not work, contact your supervisor or call the FANUC robotics Hot Line. SEAL-007 STOP Condition handler failed [Cause] This error is caused when Dispensetool encounters a problem it is unable to solve internally. This fault is almost always caused by style paths which do things which were not anticipated when this software was written. The reasons for this could be: 1. The sealing path is too fast 2. The sealing instructions (SS and SE) are too close together 3. The delay and timing values specified in your sealing schedules are too large or do not make sense. 4. Your robot's CPU has failed [Remedy] Write down the exact error number and message shown. Write down exactly what your robot was doing at the time of the failure. Make sure you include: Program name, line number, robot's location in the work cell, any cell I/O or other communciation activity, and exactly what the robot was doing right before the fault occured. This fault is usually fixed by doing a COLD start. If that does not work, contact your supervisor or call the FANUC robotics Hot Line. SEAL-008 STOP System call failed [Cause] This error is caused when Dispensetool encounters a problem it is unable to solve internally. This fault is almost always caused by style paths which do things which were not anticipated when this software was written. The reasons for this could be: 1. The sealing path is too fast 2. The sealing instructions (SS and SE) are too close together 3. The delay and timing values specified in your sealing schedules are too large or do not make sense. 4. Your robot's CPU has failed [Remedy] Write down the exact error number and message shown. Write down exactly what your robot was doing at the time of the failure. Make sure you include: Program name, line number, robot's location in the work cell, any cell I/O or other communciation activity, and exactly what the robot was doing right before the fault occured. This fault is usually fixed by doing a COLD start. If that does not work, contact your supervisor or call the FANUC robotics Hot Line.
- 1209 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SEAL-009 WARN Data missing: %s [Cause] This error is caused when Dispensetool encounters a problem it is unable to solve internally. This fault is almost always caused by style paths which do things which were not anticipated when this software was written. The reasons for this could be: 1. The sealing path is too fast 2. The sealing instructions (SS and SE) are too close together 3. The delay and timing values specified in your sealing schedules are too large or do not make sense. 4. Your robot's CPU has failed [Remedy] Write down the exact error number and message shown. Write down exactly what your robot was doing at the time of the failure. Make sure you include: Program name, line number, robot's location in the work cell, any cell I/O or other communciation activity, and exactly what the robot was doing right before the fault occured. This fault is usually fixed by doing a COLD start. If that does not work, contact your supervisor or call the FANUC robotics Hot Line. SEAL-021 WARN Gun on/off too late: Sch %d [Cause] In the Schedule number listed, the Gun On signal has been set up to turn on or off too long after the node the SS[] or SE is attached to. Currently, if this signal is set up to turn on or off greater than 100ms after the node, this warning will be posted and the signal will fore 100ms after the node. These are the formulas used to determine when the gun will be turned on or off relative to the node for seal schedule 'n': For SS[n]: Time_Before = EQUIPMENT_DELAY GUNON_DELAY For SE: Time_Before = EQUIPMENT_DELAY - GUNOFF_DELAY Note that a NEGATIVE Time_Before means AFTER the node. [Remedy] There is no real danger in this condition. You should be aware that if you try to turn the gun on or off after 100ms AFTER the node, the signal will always be fired 100ms after the node and this warning will be posted. To correct this problem, make the equipment_delay more positive or the gunon/gunoff delay more negative, to move the firing of the signal up earlier. SEAL-022 WARN Meter on too late: Sch %d [Cause] In the Schedule number listed, the Start Meter signal has been set up to turn on or off too long after the node the SS[] or SE is attached to. Currently, if this signal is set up to turn on or off greater than 100ms after the node, this warning will be posted and the signal will fire 100ms after the node. These are the formulas used to determine when this signal will be turned on or off relative to the node for seal schedule 'n': For SS[n]: Time_Before = PRE_PRESSURE_DELAY + EQUIPMENT_DELAY - GUNON_DELAY For SE[n]: Time_Before = DE_PRESSURE_DELAY + EQUIPMENT_DELAY - GUNOFF_DELAY Note that a NEGATIVE Time_Before means AFTER the node. [Remedy] There is no real danger in this condition. You should be aware that if you try to turn this signal on or off after 100ms AFTER the node, the signal will always be fired 100ms after the node and this warning will be posted. To correct this problem, make the pre/de_pressure_delay or equipment_delay more positive or the gunon/gunoff delay more negative, to move the firing of the signal up earlier.
- 1210 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SEAL-023 WARN Air on/off too late: Sch %d [Cause] In the Schedule number listed, the Atomizing Air signal has been set up to turn on or off too long after the node the SS[] or SE is attached to. Currently, if this signal is set up to turn on or off greater than 100ms after the node, this warning will be posted and the signal will fire 100ms after the node. These are the formulas used to determine when this signal will be turned on or off relative to the node for seal schedule 'n': For SS[n]: Time_Before = ATOMIZING_ON_DELAY + EQUIPMENT_DELAY - GUNON_DELAY For SE[n]: Time_Before = ATOMIZING_OFF_DELAY + EQUIPMENT_DELAY GUNOFF_DELAY Note that a NEGATIVE Time_Before means AFTER the node. [Remedy] There is no real danger in this condition. You should be aware that if you try to turn this signal on or off after 100ms AFTER the node, the signal will always be fired 100ms after the node and this warning will be posted. To correct this problem, make the atomizing_on/off/_delay or equipment_delay more positive or the gunon/gunoff delay more negative, to move the firing of the signal up earlier. SEAL-024 WARN Error in motion triggering [Cause] The high performance I/O triggering system (Motion Trigger) has returned a bad status. When this occurs, the redundant triggering system will take over, but the quality of the SSs and SEs will be poor. This condition is usually caused by one or more of the following: 1. A Gun On output is assigned to a output point which is nonzero and does not exist. 2. A Start Meter output is assigned to a output point which is nonzero and does not exist. 3. A Atomizing Air output is assigned to a output point which is nonzero and does not exist. 4. There is a problem with the software setup of the I/O system. 5. There is a problem with the hardware setup of the I/O system. [Remedy] Go to the Equipment Output menu and verify that all the Gun on, Start Meter, and Atomizing Air outputs are correctly defined or their indexes are set to zero. If the VALUE of a output port is '****', then the index number must be set to zero and the robot must be cold started. You must cold start the robot after changing anything on this menu. SEAL-031 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. SEAL-032 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. SEAL-033 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. SEAL-034 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. SEAL-035 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. SEAL-036 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. - 1211 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SEAL-037 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. SEAL-038 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. SEAL-039 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. SEAL-040 WARN %s [Cause] Site-specific alarm caused by changes made for customer [Remedy] Please consult FANUC regarding specific changes made for your site. SEAL-041 STOP Seal not ready [Cause] The system ready signal(DI) turns off when the sealant is dispensed. [Remedy] Check the system ready signal of the sealing equipment or disable the system ready signal. SEAL-042 ABORT Part ID mismatch detected [Cause] Transmitted and received part IDs to dispensing equipments do not match. [Remedy] Check wiring of group I/O line for part ID and part ID acknowledge signals. Check dispensing equipment for proper operation. SEAL-043 STOP High pressure [Cause] The pressure signal is above its upper limit for set time when the sealant is dispensed. [Remedy] Check the pressure signal of the sealing equipment, disable to check the high pressure signal, or set the time high pressure timeout to a larger value. SEAL-044 STOP Low pressure (E%d) [Cause] The pressure signal is below its lower limit for set time when the sealant is dispensed. [Remedy] Check the pressure signal of the sealing equipment, disable to check the low pressure signal, or set the time low pressure timeout to a larger value. SEAL-045 STOP High pressure (E%d) [Cause] The pressure signal is above its upper limit for set time when the sealant is dispensed. [Remedy] Check the pressure signal of the sealing equipment, disable to check the high pressure signal, or set the time high pressure timeout to a larger value. SEAL-046 STOP Seal not start [Cause] The gun full open signal(DI) has been on for the set time since sealing start. [Remedy] Check the gun full open signal of the sealing equipment, disable the check for this feature, or set the timeout for a longer period. SEAL-047 STOP Seal interrupt [Cause] The gun full open signal(DI) has been on for the set time since sealing start. [Remedy] Check the gun full open signal of the sealing equipment, disable the check for this feature, or set the timeout for a longer period.
- 1212 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SEAL-048 ABORT Dispenser mode mismatch (E%d) [Cause] Dispenser switch position does not match equipment set up [Remedy] Check key switch on the dispensing equipment and equipment setup SEAL-049 WARN Calibrations not complete (E%d) [Cause] One or more calibration procedures are not complete [Remedy] Visit equipment SETUP menu and complete all calibration procedures SEAL-050 WARN Shot meter not full (E%d) [Cause] The dispenser should be full at this point, and is not. [Remedy] Check that the dispenser is full for this operation. SEAL-051 WARN Both Drums are empty (E%d) [Cause] Both drums are empty [Remedy] Check sealant supply drums to be sure they are properly filled SEAL-052 ABORT Same fault posted repeatedly (E%d) [Cause] Same fault occurs repeatedly [Remedy] Check dispensing equipment and clear the reported fault SEAL-053 WARN Robot is in dry run mode [Cause] Dry run parameter is ON. [Remedy] Set DRY RUN parameter to OFF and run calibration again. SEAL-054 WARN Robot lock mode is ON [Cause] Robot lock parameter is ON. [Remedy] Set ROBOT LOCK parameter to OFF and run calibration again. SEAL-055 ABORT Part ID out of range [Cause] The Part ID in the JOB header is out of the allowed range for this robot. [Remedy] Make sure the Part ID in the JOB header is between 0 and the maximum Part ID allowed on this equipment. SEAL-056 WARN Dispenser not ready (E%s) [Cause] Dispenser ready input signal from dispenser is OFF. [Remedy] Check dispenser manual for further information. SEAL-057 WARN Dispenser fault (E%s) [Cause] A fault was detected at the dispensing controller. [Remedy] Perform the standard dispenser fault recovery procedure. See the dispensing controller's manual for more information. SEAL-058 WARN Flow rate fault (E%s) [Cause] The dispenser has detected a abnormally low or high material flow rate. This could be caused by a plugged gun. [Remedy] See the dispensing equipment manual for more information. You could try cleaning and purging the gun. SEAL-059 WARN Not calibrated warning (E%s) [Cause] One or more calibration procedures are not complete [Remedy] Visit equipment SETUP menu and complete all calibration procedures
- 1213 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SEAL-060 WARN High pressure (E%d) [Cause] The high pressure signal(DI) has been on for the configured time during sealing. [Remedy] Check the sealing equipment high pressure signal, disable the check for the high pressure signal, or set the timeout value for a longer period SEAL-061 WARN Seal not ready [Cause] The system ready signal(DI) turns off when sealant is being dispensed. [Remedy] Check the sealing equipment ready signal or disable the check of the equipment ready signal. SEAL-062 WARN Reload fault (E%d) [Cause] There is a reload problem with the meter [Remedy] Check the shot meter SEAL-063 WARN High pressure [Cause] The high pressure signal(DI) has been on for the configured time during sealing. [Remedy] Check the sealing equipment high pressure signal, disable the check for the high pressure signal, or set the timeout value for a longer period SEAL-064 WARN Not at purge position [Cause] Robot is not at purge position [Remedy] Make sure the robot returns to purge position at the end of each cycle SEAL-065 WARN Maximum purge count reached [Cause] The Auto Purge feature has determined that the robot should purge now, but the maximum number of purges it is allowed to perform in a row (as set in the equipment setup menu) has been reached. [Remedy] Increase the maximum number of purges allowed or remove the disposable mixing tip from the gun, to prepare it for long term inactivity. SEAL-066 WARN Seal not start [Cause] The gun full open signal(DI) has been on for the set time since sealing start. [Remedy] Check the gun full open signal of the sealing equipment, disable the check for this feature, or set the timeout for a longer period. SEAL-067 WARN Seal interrupt [Cause] Gun full open signal(DI) has been on for too long while dispensing. [Remedy] Check the gun full open signal of sealing equipment, disable the checking of this alarm, or set the timeout value to a longer time. SEAL-068 WARN Flow command excessive%s [Cause] Flow command output voltage is larger than the maximum output. [Remedy] Decrease the motion speed or increase the maximum output. SEAL-069 WARN Dispenser malfunction (E%d) [Cause] The dispensing equipment controller has detected a fault in its hardware. [Remedy] Perform maintenance and debug procedures as described in the dispensing equipment manual. SEAL-070 WARN Gun malfunction (E%d) [Cause] A dispensing gun malfunction has been detected by the dispensing controller. [Remedy] Perform dispensing gun maintenance and debug procedures.
- 1214 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SEAL-071 WARN Gun full open too long (E%d) [Cause] A low pressure condition has been detected by the dispensing controller [Remedy] Check the pressure sensors at all points in the system. Perform standard system debug and maintenance procedures. SEAL-072 WARN High nozzle pressure (E%d) [Cause] A high pressure condition has been detected in the dispensing gun nozzle. In specific, nozzle pressure signal is greater than (NOZZLE SENSOR RATING/100) * 5 volts for over one second. [Remedy] Reduce system pressure if it is permissible. Select a nozzle pressure transducer with a wider operating range. SEAL-073 WARN High dispensed volume (E%d) [Cause] The volume of material dispensed on the previous job was above the preset limit. [Remedy] Verify that the volume limits are correct for the specified job. SEAL-074 WARN Low dispensed volume (E%d) [Cause] The volume of material dispensed on the previous job was below the preset limit [Remedy] Verify that the volume limits are correct for the specified job. SEAL-075 WARN Flow meter fault (E%d) [Cause] A error was detected in the flow meter readings. [Remedy] Verify that the flowmeter is operating correctly. SEAL-076 WARN Bead defect detected (E%d) [Cause] An incorrect bead condition was detected. [Remedy] Perform dispensing gun maintenance procedures. SEAL-077 WARN Sealer equipment fault (E%d) [Cause] An unknown error code was received from the dispensing controller. [Remedy] Check the dispensing controller for an error condition. Also check the communication link between the dispensing controller and robot controller. SEAL-078 WARN Dispenser comm fault (E%d) [Cause] An error was encountered reading fault data from the dispenser [Remedy] Check the communications link between the dispenser and robot SEAL-079 WARN Dispenser E-stop (E%d) [Cause] An Emergency Stop condition was detected at the dispensing controller [Remedy] Clear the fault and perform the proper Emergency Stop recovery procedure. SEAL-080 WARN Dispenser fault (E%d) [Cause] A fault was detected at the dispensing controller. [Remedy] Perform the standard dispenser fault recovery procedure. See the dispensing controller's manual for more information. SEAL-081 WARN Volume comp at maximum (E%d) [Cause] Interim value for volume has exceeded maximum interim limit. [Remedy] Re-learn part or increase maximum limit.
- 1215 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SEAL-082 WARN Drum A empty (E%d) [Cause] The first of the two drums is empty [Remedy] This is a warning to the operator that the drum might need service SEAL-083 WARN Drum B empty (E%d) [Cause] The second of the two drums is empty. [Remedy] This is a warning to the operator that the drum might need service. SEAL-084 WARN Reload timed out (E%d) [Cause] Reload of shot meter took longer than the specified time. [Remedy] Check your dispensing equipment for faults, to make sure time out is long enough. SEAL-085 WARN Calibration aborted [Cause] Calibration aborted due to user request or possible fault. [Remedy] If unknown cause -- see next most recent alarm for help. SEAL-086 WARN Volume strobe timeout (E%d) [Cause] Volume present signal not received from Pro-Flo unit. [Remedy] Run calibration again - check Pro-Flo unit for malfunction. SEAL-087 WARN Volume above limit (E%d) [Cause] The volume of material dispensed on the previous job was above the preset limit. [Remedy] Verify that the volume limits are correct for the specified job. SEAL-088 WARN Material cal timeout (E%d) [Cause] Material cal complete signal not received from Pro-Flo unit. [Remedy] Check Pro-Flo for malfunction or increase dispense time. SEAL-089 WARN Volume below limit (E%d) [Cause] The volume of material dispensed on the previous job was below the preset limit [Remedy] Verify that the volume limits are correct for the specified job. SEAL-090 WARN Nozzle over pressure (E%d) [Cause] The problem is either the nozzle pressure is greater than setpoint for more than time limit or the upstream hose is ruptured and is leaking material. [Remedy] Use on-board diagnostics on the dispensing controller to verify that the nozzle pressure sensor is in order, replace sensor as required. Check for clog in gun or nozzle tip. If the problem is ruptured hose, replace hose SEAL-091 WARN Matl weight input = 0 (E%d) [Cause] User input was zero for material weight. [Remedy] Run calibration again - do not enter zero for material weight. SEAL-092 WARN Specific gravity = 0 (E%d) [Cause] User input was zero for specific gravity. [Remedy] Assign a nonzero value for specific gravity. Run cal again. SEAL-093 WARN Volume read is zero (E%d) [Cause] Zero volume was detected from Pro-Flo analog signals. [Remedy] Check Pro-Flo for malfunction.
- 1216 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SEAL-094 WARN Dispense time is zero (E%d) [Cause] User input was zero for dispense time. [Remedy] Assign a nonzero value for dispense time. Run cal again. SEAL-095 WARN Nozzle worn out (E%d) [Cause] Nozzle pressure has dropped below setpoint value for more than time limit. [Remedy] Use on-board diagnostics on the dispenser controller to verify that the nozzle pressure sensor is in order, replace sensor as required. SEAL-096 WARN Matl press entered=0 (E%d) [Cause] User input was zero for material pressure. [Remedy] Check why material pressure is zero during calibration. SEAL-097 WARN Pressure read is zero (E%d) [Cause] No change in analog signal from pressure transducer. [Remedy] Check pressure transducer and ensure varying pressures during calibration. SEAL-098 WARN Upstream over pressure (E%d) [Cause] Upstream pressure is greater than setpoint for more than time limit. [Remedy] Use on-board diagnostics on the dispenser controller to verify that the upstream pressure sensor is in order, replace sensor as required. Check for clog in gun or nozzle tip SEAL-099 WARN Air pressure entered=0 (E%d) [Cause] User input was zero for air pressure. [Remedy] Check why air pressure is zero during calibration. SEAL-100 WARN NO scale factor/bias (E%d) [Cause] The Scale factor or bias is zero [Remedy] Perform the calibration procedures SEAL-101 WARN Volume strobe timeout (E%d) [Cause] The volume timer expired [Remedy] Check dispensing equipment for faults, or give the time out variable more time SEAL-102 WARN Press calib incomplete (E%d) [Cause] Pressure calibration has not been completed. [Remedy] Perform pressure calibration before running this calibration. SEAL-103 WARN Dispenser not in AUTO (E%d) [Cause] Dispenser Auto Mode signal to the robot has dropped. [Remedy] Make sure dispenser mode selection is set to AUTO or MANUAL as needed SEAL-104 WARN Analog cal incomplete (E%d) [Cause] Analog voltage calibration has not been completed. [Remedy] Perform analog calibration before running this calibration. SEAL-105 STOP Dispenser not ON (E%d) [Cause] The Dispenser On signal (from the dispenser to the robot) has dropped. [Remedy] Turn on the dispenser.
- 1217 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SEAL-106 WARN Upstream under press (E%d) [Cause] Upstream pressure has dropped below setpoint value for more than time limit. [Remedy] Use on-board diagnostics on the dispenser controller to verify that the upstream pressure sensor is in order, replace sensor as required. SEAL-107 WARN Matl calib incomplete (E%d) [Cause] Material learn calibration has not been completed. [Remedy] Perform material calibration before running this calibration. SEAL-108 WARN Material timeout = 0 (E%d) [Cause] Material learn timeout value is zero [Remedy] Set timeout to nonzero value before running this calibration. SEAL-109 WARN Low press>=high press (E%d) [Cause] Low pressure atomizing air input was greater or equal to high pressure [Remedy] Check atomizing air equipment SEAL-110 STOP System/drive not ready (E%d) [Cause] System and Drive Ready signal (from the dispenser to the robot) has dropped. [Remedy] Perform standard dispenser maintenance procedures. SEAL-111 WARN Negative volume read (E%d) [Cause] Volume read was negative. [Remedy] Check dispensing equipment and run calibration again. SEAL-112 WARN Vol sig cal incomplete (E%d) [Cause] Volume signal calibration has not been completed. [Remedy] Perform volume signal calibration. SEAL-113 WARN I/O config incomplete (E%d) [Cause] At least one I/O signal assignment is zero. [Remedy] Set proper I/O ports for all necessary dispenser I/O. SEAL-114 WARN Dispenser not ready (E%d) [Cause] Dispenser ready input signal from dispenser is OFF. [Remedy] Check dispenser manual for further information. SEAL-115 WARN Too low material flow (E%d) [Cause] The dispenser has detected a abnormally low or high material flow rate. This could be caused by a plugged gun. [Remedy] See the dispensing equipment manual for more information. You could try cleaning and purging the gun. SEAL-116 WARN Flow command too low [Cause] Flow command output voltage is lower than the minimum output. [Remedy] Increase the motion speed or decrease the minimum output. SEAL-117 WARN System/drive not ready (E%d) [Cause] System and Drive Ready signal (from the dispenser to the robot) has dropped. [Remedy] Perform standard dispenser maintenance procedures.
- 1218 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SEAL-118 WARN Dispenser not in AUTO (E%d) [Cause] Dispenser Auto Mode signal to the robot has dropped. [Remedy] Make sure dispenser mode selection is set to AUTO or MANUAL as needed SEAL-119 WARN Low pressure (E%d) [Cause] A low pressure warning has been detected by the dispensing controller [Remedy] Check system pressure. Check the pressure sensors in the system. Perform standard system debug and maintenance procedures. SEAL-120 WARN Dispenser not ON (E%d) [Cause] The Dispenser On signal (from the dispenser to the robot) has dropped. [Remedy] Turn on the dispenser. SEAL-121 STOP Dispense signal fault (E%d) [Cause] The Dispensing signal (from the dispenser to the robot) should be high during dispensing, but it is not. [Remedy] Perform dispenser maintenance procedures to determine why dispensing is not occurring as it should. Also verify that the dispensing schedule data is correct, and that the dispenser I/O to/from the robot has been mapped correctly. SEAL-122 ABORT Sealing task already active [Cause] You tried to run a JOB or PROC TPP while another JOB or PROC TPP is already running in another task. [Remedy] Only one sealing task may be running at any time. This means that only one JOB or PROC may be running at any time. You must abort the JOB or PROC which is already running before starting a new one. SEAL-123 ABORT Job aborted [Cause] The current Job has been aborted due to a fatal error. [Remedy] Correct the cause of this error, which is usually posted immediately after this one. SEAL-124 ABORT Critical IO is invalid [Cause] This error is usually caused by an IO point which is required by Dispensetool being set to an invalid index number or type. [Remedy] Make sure that all inputs and outputs on the Dispenser IO screen are set to valid IO points (the VALUE is not shown as *****) or the index number has been is set to 0. Cold start the robot controller after making any changes to this screen. SEAL-129 ABORT Index incorrect [Cause] The index value of seal start instruction is invalid. [Remedy] Check the index value of this SS instruction.
- 1219 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SEAL-131 ABORT SS/SE timing invalid [Cause] This error is caused by timing problems with Sealing commands (SS or SE). Timing problems could occur if the robot does not have enough time to plan for a sealing instruction before the robot passes that point in the path. For example: If the user is using a sealing schedule with a gunon delay of 1000ms and a gunoff delay of -1000ms and the robot executes the seam in 1500ms, the Dispensetool will detect the logic problem and post this fault. A path which has many sealing instructions very close to each other (closer than 30mm at 500mm/sec) is likely to have this problem. [Remedy] Make sure there is adequate time for each SS and SE to execute. You may do this by making sure you have only the minimum number of points in your path that you require. Dispensetool works best with as few points as possible. Also, make sure none of your schedules have gunon, gunoff, or equipment delays beyond that which is needed (usually between -100ms and +100ms is adequate). NOTE: Whenever a SEAL-131 occurs, the robot MUST be cold started to recover. SEAL-132 WARN Seam segment too short [Cause] There was not enough time between a SS and the next SS or SE for the flow rate computations to be done. [Remedy] Step through your sealing PROCess program, making sure there is at least a centimeter between the points attached to each sealing instruction. Increase the distance between sealing instructions, delete one of the sealing instructions, or slow the robot down. SEAL-144 WARN Joint motion [Cause] Robot moved with joint motion during sealing. [Remedy] Change motion type from joint to linear or circular. SEAL-147 ABORT Equipment does not exist [Cause] This equipment is not exist. [Remedy] Check the equipment number in the program detail display. SEAL-148 ABORT No SE Instruction [Cause] SE instruction is not exist. [Remedy] Add an SE instruction. SEAL-149 ABORT No equipment number set [Cause] Equipment is not set on this program. [Remedy] Set the equipment number in the program detail display. SEAL-150 ABORT Equipment is already busy [Cause] Other program is using this equipment now. [Remedy] Change the equipment number or check interlock of each program. SEAL-151 ABORT TPP not created correctly [Cause] The teach pendant program is not created properly [Remedy] Check program header if the teach pendant program is either a JOB or a PROCESS type to ensure application data header is created correctly SEAL-152 WARN I/O not correctly assigned [Cause] The index value or type of this I/O port is incorrectly assigned. [Remedy] If you wish to use this I/O port, set the port index and I/O type to the correct values. Verify that a valid value is shown on the I/O menu for this I/O port instead of If you do not wish to use this I/O point, set the index number to zero. - 1220 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SEAL-153 WARN Program is running [Cause] You can not set volume set point while a program is running [Remedy] Volume set points must be established after program execution SEAL-155 WARN No SS Instruction before SE [Cause] There is no SS instruction before SE. [Remedy] Check SS instruction on this program. SEAL-156 WARN MOV_ TPP execution failure [Cause] Unsuccessful execution of a MOV_ type program. [Remedy] Ensure MOV_ program is executable. Reset holds and emergency stops. SEAL-157 WARN Seal schedule data is zero [Cause] Desired volume or bead width for first sealing schedule was zero. [Remedy] Enter a valid setting for desired volume or bead width. SEAL-159 WARN UTOOL #1 is not taught [Cause] Current utool is zero - has not been taught. [Remedy] Teach utool before running this calibration. SEAL-160 WARN REFPOS is not taught [Cause] Current REFPOS has not been taught - is zero. [Remedy] Teach REFPOS before running OFFSET calibration. SEAL-161 WARN OFFSET out of range [Cause] Difference between REFPOS and OFFSET positions was too large. [Remedy] Check for damaged tool, change tip and run calibration again. SEAL-162 WARN OFFSET config mismatch [Cause] Difference exists between REFPOS and OFFSET position configurations. [Remedy] Run calibration again while maintaining REFPOS configuration SEAL-163 WARN File is not closed [Cause] File to be executed is not closed. [Remedy] Perform cold start or temporarily SELECT a different file. SEAL-164 WARN File does not exist [Cause] File to be executed does not exist. [Remedy] Create and teach the file. SEAL-170 WARN Invalid tool position [Cause] Commanded tool position is not valid [Remedy] Check supply air to the tool Check proximity sensors on the tool SEAL-171 WARN Gripper not opened (GP%s) [Cause] All grippers are not opened [Remedy] Check to see if release mechanism is working SEAL-172 WARN Gripper not closed (GP%s) [Cause] All grippers on this valve are not closed [Remedy] Check to see if clamping mechanism is working - 1221 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SEAL-173 WARN Part not present (GP%s) [Cause] Sensors not reporting part present [Remedy] Check sensor correct operation SEAL-174 WARN Part Present (GP%s) [Cause] Sensors reporting part present [Remedy] Check sensor correct operation SEAL-175 WARN Un-assigned Bit mask [Cause] Variable $sltlstup[1].valve is not assigned [Remedy] Go to Tool Setup and setup gripper configuration SEAL-177 WARN EOAT timed out: Flip [Cause] The Four Position End of Arm tool was moved, but the FLIP sensor reports that the tool is not in the correct FLIP/UNFLIP position (could be ON or OFF) after the timeout period set on the tool setup menu expired. [Remedy] Check air supply to the four position tool. Check proximity sensors on the four position tool. If the tool is slow, increase the timeout delay on the tool setup screen to allow enough time for the tool to complete motion. SEAL-178 WARN EOAT timed out: Unflip [Cause] The Four Position End of Arm tool was moved, but the UNFLIP sensor reports that the tool is not in the correct UNFLIP/FLIP position (could be ON or OFF) after the timeout period set on the tool setup menu expired. [Remedy] Check air supply to the four position tool. Check proximity sensors on the four position tool. If the tool is slow, increase the timeout delay on the tool setup screen to allow enough time for the tool to complete motion. SEAL-179 WARN EOAT timed out: Extend [Cause] The Four Position End of Arm tool was moved, but the EXTEND sensor reports that the tool is not in the correct EXTEND/RETRACT position (could be ON or OFF) after the timeout period set on the tool setup menu expired. [Remedy] Check air supply to the four position tool. Check proximity sensors on the four position tool. If the tool is slow, increase the timeout delay on the tool setup screen to allow enough time for the tool to complete motion. SEAL-180 WARN EOAT timed out: Retract [Cause] The Four Position End of Arm tool was moved, but the RETRACT sensor reports that the tool is not in the correct RETRACT/EXTEND position (could be ON or OFF) after the timeout period set on the tool setup menu expired. [Remedy] Check air supply to the four position tool. Check proximity sensors on the four position tool. If the tool is slow, increase the timeout delay on the tool setup screen to allow enough time for the tool to complete motion. SEAL-182 WARN Invalid kinimatic solution [Cause] Current robot position invalid. [Remedy] Run calibration again. SEAL-183 WARN Tool offset internal error [Cause] Internal tool offset calibration error. [Remedy] Contact FANUC Robotics Hotline. - 1222 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SEAL-200 WARN Dispenser malfunction (E%s) [Cause] The dispensing equipment controller has detected a fault in its hardware. [Remedy] Perform maintenance and debug procedures as described in the dispensing equipment manual. SEAL-201 WARN Gun malfunction (E%s) [Cause] A dispensing gun malfunction has been detected by the dispensing controller. [Remedy] Perform dispensing gun maintenance and debug procedures. SEAL-202 WARN Gun full open too long (E%s) [Cause] A low pressure condition has been detected by the dispensing controller [Remedy] Check the pressure sensors at all points in the system. Perform standard system debug and maintenance procedures. SEAL-203 WARN High nozzle pressure (E%s) [Cause] A high pressure condition has been detected in the dispensing gun nozzle. In specific, nozzle pressure signal is greater than (NOZZLE SENSOR RATING/100) * 5 volts for over one second. [Remedy] Reduce system pressure if it is permissible. Select a nozzle pressure transducer with a wider operating range. SEAL-204 WARN High dispensed volume (E%s) [Cause] The volume of material dispensed on the previous job was above the preset limit. [Remedy] Verify that the volume limits are correct for the specified job. SEAL-205 WARN Low dispensed volume (E%s) [Cause] The volume of material dispensed on the previous job was below the preset limit [Remedy] Verify that the volume limits are correct for the specified job. SEAL-206 WARN Flow meter fault (E%s) [Cause] A error was detected in the flow meter readings. [Remedy] Verify that the flowmeter is operating correctly. SEAL-207 WARN Bead defect detected (E%s) [Cause] An incorrect bead condition was detected. [Remedy] Perform dispensing gun maintenance procedures. SEAL-208 WARN Volume comp at max (E%s) [Cause] Interim value for volume has exceeded maximum interim limit. [Remedy] Re-learn part or increase maximum limit. SEAL-209 WARN Nozzle over pressure (E%s) [Cause] The problem is either the nozzle pressure is greater than setpoint for more than time limit or the upstream hose is ruptured and is leaking material. [Remedy] Use on-board diagnostics on the dispensing controller to verify that the nozzle pressure sensor is in order, replace sensor as required. Check for clog in gun or nozzle tip. If the problem is ruptured hose, replace hose
- 1223 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SEAL-210 WARN Nozzle under press (E%s) [Cause] Nozzle pressure has dropped below setpoint value for more than time limit. [Remedy] Use on-board diagnostics on the dispenser controller to verify that the nozzle pressure sensor is in order, replace sensor as required. SEAL-211 WARN Upstream over press (E%s) [Cause] Upstream pressure is greater than setpoint for more than time limit. [Remedy] Use on-board diagnostics on the dispenser controller to verify that the upstream pressure sensor is in order, replace sensor as required. Check for clog in gun or nozzle tip SEAL-212 WARN Upstream under press (E%s) [Cause] Upstream pressure has dropped below setpoint value for more than time limit. [Remedy] Use on-board diagnostics on the dispenser controller to verify that the upstream pressure sensor is in order, replace sensor as required. SEAL-213 WARN Sealer equipment fault (E%s) [Cause] An unknown error code was received from the dispensing controller. [Remedy] Check the dispensing controller for an error condition. Also check the communication link between the dispensing controller and robot controller. SEAL-214 WARN No material flow (E%s) [Cause] The dispenser has detected a abnormally low or high material flow rate. This could be caused by a plugged gun. [Remedy] See the dispensing equipment manual for more information. You could try cleaning and purging the gun. SEAL-215 WARN Reload timed out (E%s) [Cause] Reload of shot meter took longer than the specified time. [Remedy] Check your dispensing equipment for faults, to make sure time out is long enough. SEAL-216 WARN Reload fault occured (E%s) [Cause] There is a reload problem with the meter [Remedy] Check the shot meter SEAL-217 WARN NO scale factor/bias (E%s) [Cause] The Scale factor or bias is zero [Remedy] Perform the calibration procedures SEAL-218 ABORT Same fault posted (E%s) [Cause] Same fault occurs repeatedly [Remedy] Check dispensing equipment and clear the reported fault SEAL-219 WARN Volume strobe timeout (E%s) [Cause] The volume timer expired [Remedy] Check dispensing equipment for faults, or give the time out variable more time
- 1224 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SEAL-220 WARN Volume out of range (E%s) [Cause] The volume dispensed in the last job was out of the normal volumetric range of material dispensed for this job. This could be caused by terminating the job early, causing much less material to be dispensed. This could also be caused by problems with the material, such as using material which has exceeded its shelf life. [Remedy] This warning is normal if it was caused by terminating a job early. If this error happens during normal production, examine the quality of the dispensed job and verify that the dispenser and material are in good condition. SEAL-221 WARN Bubble detected (E%d) [Cause] A significant bubble was dispensed with the material during the job. This is usually caused by improper loading of new material. NOTE: This will often cause poor quality sealing. Examine the finished part for any gaps in the sealant bead. [Remedy] Make sure any new material is loaded properly into the supply pump. Make sure all excess air has been drained off before using any new material. SEAL-222 WARN Dispenser not ON (E%s) [Cause] The Dispenser On signal (from the dispenser to the robot) has dropped. [Remedy] Turn on the dispenser. SEAL-223 WARN Dispenser not in AUTO (E%s) [Cause] Dispenser Auto Mode signal to the robot has dropped. [Remedy] Make sure dispenser mode selection is set to AUTO or MANUAL as needed SEAL-224 WARN System/drive not ready (E%s) [Cause] System and Drive Ready signal (from the dispenser to the robot) has dropped. [Remedy] Perform standard dispenser maintenance procedures. SEAL-225 WARN Low pressure warning (E%s) [Cause] A low pressure warning has been detected by the dispensing controller [Remedy] Check system pressure. Check the pressure sensors in the system. Perform standard system debug and maintenance procedures. SEAL-226 WARN High pressure warning (E%s) [Cause] The pressure signal is above its upper limit for set time when the sealant is dispensed. [Remedy] Check the pressure signal of the sealing equipment, disable to check the high pressure signal, or set the time high pressure timeout to a larger value. SEAL-227 WARN Low pressure fault (E%s) [Cause] A low pressure warning has been detected by the dispensing controller [Remedy] Check system pressure. Check the pressure sensors in the system. Perform standard system debug and maintenance procedures. SEAL-228 WARN High pressure fault (E%s) [Cause] The pressure signal is above its upper limit for set time when the sealant is dispensed. [Remedy] Check the pressure signal of the sealing equipment, disable to check the high pressure signal, or set the time high pressure timeout to a larger value. SEAL-229 WARN Calibration incomplete (E%s) [Cause] One or more calibration procedures are not complete [Remedy] Visit equipment SETUP menu and complete all calibration procedures
- 1225 -
C.ALARM CODES
APPENDIX
SEAL-230 WARN High Dispensed Volume (E%d) [Cause] High Dispensed Volume. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-231 WARN Low Dispensed Volume (E%d) [Cause] Low Dispensed Volume. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-232 WARN High Material Supply Pressure (E%d) [Cause] High Material Supply Pressure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-233 WARN Low Material Supply Pressure (E%d) [Cause] Low Material Supply Pressure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-234 WARN No Material Supply Pressure (E%d) [Cause] No Material Supply Pressure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-235 WARN Nozzle Clog or Down Stream Blockage (E%d) [Cause] Nozzle Clog or Down Stream Blockage. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-236 WARN Gun Cable Failure (E%d) [Cause] Gun Cable Failure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-237 WARN Flowmeter/Booster Pump Failure (E%d) [Cause] Flowmeter/Booster Pump Failure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-238 WARN Nozzle Pressure Transducer Failure (E%d) [Cause] Nozzle Pressure Transducer Failure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-239 WARN Flowmeter cable Failure (E%d) [Cause] Flowmeter cable Failure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-240 WARN Upstream Pressure Transducer Failed (E%d) [Cause] Upstream Pressure Transducer Failed. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-241 WARN Upstream Pressure Transducer Cable Failed (E%d) [Cause] Upstream Pressure Transducer Cable Failed. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-242 WARN Robot Signal Out of Sequence (E%d) [Cause] Robot Signal Out of Sequence. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document.
- 1226 -
B-82594EN-4/01
B-82594EN-4/01
APPENDIX
SEAL-243 WARN Gun Failure (E%d) [Cause] Gun Failure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-244 WARN Bead Defect Detected (E%d) [Cause] Bead Defect Detected. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-245 WARN Joint Motion While Dispensing [Cause] Joint motion is used between SS and SE instructions [Remedy] Use Linear or Circular motion between SS and SE instructions SEAL-250 WARN High Dispensed Volume (E%s) [Cause] High Dispensed Volume. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-251 WARN Low Dispensed Volume (E%s) [Cause] Low Dispensed Volume. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-252 WARN High Material Supply Pressure (E%s) [Cause] High Material Supply Pressure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-253 WARN Low Material Supply Pressure (E%s) [Cause] Low Material Supply Pressure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-254 WARN No Material Supply Pressure (E%s) [Cause] No Material Supply Pressure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-255 WARN Nozzle Clog or Down Stream Blockage (E%s) [Cause] Nozzle Clog or Down Stream Blockage. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-256 WARN Gun Cable Failure (E%s) [Cause] Gun Cable Failure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-257 WARN Flowmeter/Booster Pump Failure (E%s) [Cause] Flowmeter/Booster Pump Failure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-258 WARN Nozzle Pressure Transducer Failure (E%s) [Cause] Nozzle Pressure Transducer Failure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-259 WARN Flowmeter cable Failure (E%s) [Cause] Flowmeter cable Failure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document.
- 1227 -
C.ALARM CODES
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SEAL-260 WARN Upstream Pressure Transducer Failed (E%s) [Cause] Upstream Pressure Transducer Failed. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-261 WARN Upstream Pressure Transducer Cable Failed (E%s) [Cause] Upstream Pressure Transducer Cable Failed. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-262 WARN Dispense IO Sequence error (E%s) [Cause] Robot Signal Out of Sequence. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-263 WARN Gun Failure (E%s) [Cause] Gun Failure. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-264 WARN Bead Defect Detected (E%s) [Cause] Bead Defect Detected. [Remedy] Refer to Nordson Pro-Flo II dispenser equipment user document. SEAL-265 STOP Major Dispenser Fault on (E%s) [Cause] A Major Fault was detected on the dispensing equipment. [Remedy] Refer to dispensing equipment for fault details. SEAL-266 WARN Minor Dispenser Fault on (E%s) [Cause] A Minor Fault was detected on the dispensing equipment. [Remedy] Refer to dispensing equipment for fault details. SEAL-267 STOP Volume dispensed out of range (E%s) [Cause] Volume OK signal NOT received from dispensing equipment. [Remedy] Refer to dispensing equipment for fault details. SEAL-268 WARN Flow rate is zero (E%d) [Cause] This error is reported when the process mode is wet and the computed flow rate is equal to zero. [Remedy] Refer to dispensing equipment for fault details. SEAL-269 WARN Flow command below minimum (E%d) [Cause] This error is reported when the computed flow rate command is less than the minimum flow rate specified by the user during the equipment setup. [Remedy] Refer to dispensing equipment for fault details. SEAL-270 WARN Flow command above maximum (E%d) [Cause] This error is reported when the computed flow rate command is great than the user specified (or calibrated) maximum flow rate, which is specified specified under the equipment setup. [Remedy] Refer to dispensing equipment for fault details. SEAL-271 WARN Channel 2 analog is zero (E%d) [Cause] This error is reported when the process mode is wet and the computed Channel 2 analog command is equal to zero. [Remedy] Refer to dispensing equipment for fault details.
- 1228 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SEAL-272 WARN Channel 2 analog is below set point (E%d) [Cause] This error is reported when the computed Channel 2 analog command is less than the minimum Channel 2 analog output specified by the user during the equipment setup. [Remedy] Refer to dispensing equipment for fault details. SEAL-273 WARN Channel 2 analog is above set point (E%d) [Cause] This error is reported when the computed Channel 2 analog is great than the user specified (or calibrated) maximum Channel 2 analog output, which is specified under the equipment setup. [Remedy] Refer to dispensing equipment for fault details. SEAL-274 WARN Dispenser not pressurized (E%s) [Cause] Dispenser is not pressurized [Remedy] Refer to dispensing equipment for fault details. SEAL-275 WARN Dispenser meter not full (E%s) [Cause] Dispenser meter is not full [Remedy] Refer to dispensing equipment for fault details. SEAL-276 WARN Dispense meter not pressurized (E%s) [Cause] Dispense meter is not pressurized [Remedy] Refer to dispensing equipment for fault details. SEAL-277 WARN Drum empty (E%s) [Cause] Drum is empty [Remedy] Refer to dispensing equipment for fault details. SEAL-278 WARN Auto purge requested (E%s) [Cause] Auto purge is requested [Remedy] Refer to dispensing equipment for fault details. SEAL-279 WARN primer check passed (E%s) [Cause] Primer check passed (E%s) [Remedy] Refer to dispensing equipment for fault details. SEAL-280 WARN Primer check failed (E%s) [Cause] Primer check failed [Remedy] Refer to dispensing equipment for fault details. SEAL-281 WARN Felt not advanced (E%s) [Cause] Felt not advanced [Remedy] Refer to dispensing equipment for fault details. SEAL-282 WARN Meter Empty (E%d, Mtr %s) [Cause] This warning is posted when the system detects that the meter has reached to its stroke limit during dispensing. After this condition, the system automatically switches to the other meter, and continue dispensing. [Remedy] 1. Reposition the meter prior to start dispensing for the seam. 2. Lower the flow rate so that it can cover the entire seam
- 1229 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SEAL-283 WARN Both Meters Empty [Cause] This warning is posted when the system detects that both meters have reached to their stroke limit during dispensing. This situation occurs if the material supply pressure is too low. After this condition, the system automatically stops dispensing, but the robot keeps moving. Use Error table to change the severity to PAUSE if you want to pause the program with this warning. [Remedy] 1. Increase the material supply pressure. 2. Lower the flow rate. SEAL-284 WARN Plugged Tip Detected (E%d) [Cause] The system has detected that the material flow has been blocked. [Remedy] 1. Check and clean the gun tip. SEAL-285 WARN Premature Reload Term (E%d) [Cause] One meter could not complete reloading before the other meter has come to near-empty zone. [Remedy] 1. Increase the material supply pressure 2. Lower the flow rate SEAL-286 WARN Low Air Pressure (E%d) [Cause] This error message is not currently not implemented [Remedy] N/A SEAL-287 WARN Cmd prs NOT achieved (E%d) [Cause] The material pressure did not reach the specified pressure within the specified time. [Remedy] 1. Check the IPD air supply pressure 2. Increase the pressure tolerance ($ipd_config[].press_tol) SEAL-288 WARN Application setup not done [Cause] The application specific TPPs and macros have not been loaded. [Remedy] Perform a controlled start, then select SETUP APPLICATION under the FCTN menu while the application disk is in the drive. SEAL-289 STOP Macro table already full [Cause] Dispenstool has attempted to install additional macros, but the macro table (under menu SETUP:Macros) was already full. [Remedy] Reduce number of macros needed and remove them from the macro table or contact FANUC and request a update to expand macro table size. SEAL-290 STOP Invalid call to SL__INST [Cause] SL__INST has been called, but there was no valid macro index number in register 32. [Remedy] Do not run SL__INST as a program, only call SL__INST from a macro after setting a valid macro index number up in register 32. SEAL-291 WARN No start sealing input defined [Cause] The PNS Ack Verified input, which is needed with the current communication configuration, has not been defined. [Remedy] Set up a PNS Ack Verified in the Cell Input I/O menu and restart the robot.
- 1230 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SEAL-292 STOP Max Error table entry exceeded [Cause] In setting up the Default error table the maximum number of error table entries ($ERRSEV_NUM) was exceeded. [Remedy] Go into controlled start, Press MENU-0, then choose PROGRAM SETUP. Change the Error Severity Table entry to be a larger number in order to contain all default errors, and press FCTN-START (COLD). After Cold Start, go back into the Error Table setup screen and manually enter in those error that were not setup correctly. SEAL-294 WARN Style bit is out of range (E%s) [Cause] The style bit in your JOB program is either less than 0 or great than the maximum style bit value. [Remedy] Set up a bigger maximum style bit or change the style bit in your JOB header SEAL-295 WARN I/O not assigned Eq%s [Cause] The key dispenser input such as dispenser ready is not assigned. [Remedy] You must set the port index and the type of the dispener input to the correct values. Verify that a valid value is shown on the I/O menu for the I/O port instead of SEAL-296 STOP Configurable error table empty [Cause] The Dispenstool configurable error table is empty. [Remedy] No action is required, but user should be aware that configurable fault reporting will not function at full capacity. SEAL-297 WARN Dispenser meter near empty (E%s) [Cause] This warning is posted when the system detects that the meter near empty signal is asserted during dispensing. [Remedy] 1. Reload the meter prior to start dispensing for the seam. 2. Lower the flow rate so that it can cover the entire seam SEAL-298 WARN %s option has not been loaded [Cause] The option required to setup this equip- ment has not been loaded. [Remedy] Please load the required option, and then try to set this equipment type. SEAL-299 WARN Enc Belt slip (E%d, Mtr %s) [Cause] System has detected that the encoder to meter belt linkage is slipping. [Remedy] Tighten the belt tension. SEAL-300 WARN %s I/O not mapped correctly [Cause] Specified I/O point has not been assigned. [Remedy] Assign specified I/O point before attempting calibration. SEAL-301 WARN OK to reload timeout (E%d) [Cause] Timed out waiting for the OK to reload signal from the Cell controller. [Remedy] Make sure that the Input signal for OK to Reload is mapped and is coming on in response to the Reload Request signal. SEAL-302 WARN ISD not configured (ISD%d) [Cause] IPD mastering and/or calibrations have not been completed. IPD cannot leave SHUTOFF mode unless they are completed. [Remedy] Complete IPD mastering and calibrations.
- 1231 -
C.ALARM CODES
APPENDIX
B-82594EN-4/01
SEAL-303 WARN Unable to go FULL resume dist [Cause] Robot was unable to go back the full resume distance because the last taught point was reached before full distance was traversed. Gap may result. [Remedy] 1. Shorten the resume distance. 2. Re-teach points so that there is more distance between points. SEAL-304 WARN Force FFR Process Recov items [Cause] Fast Fault Recovery has ended and process specific recovery options must be displayed. [Remedy] Choose a process specific recovery option SEAL-305 WARN Dispense complete timeout (E%s) [Cause] Fast Fault Recovery has ended and process specific recovery options must be displayed. [Remedy] Choose a process specific recovery option SEAL-308 WARN Fault Reset Timeout (E%s) [Cause] The dispenser was unable to clear the fault. [Remedy] Check the dispenser controller, and clear the cause of the dispenser fault. SEAL-309 WARN IN_PROCESS ON before Job [Cause] The IN_PROCESS dispenser signal is ON before the styleID communication starts. [Remedy] Check the dispenser controller, and make sure that the dispenser is performing the I/O handshaking correctly. SEAL-310 STOP IN_PROCESS OFF before DispComp [Cause] The IN_PROCESS dispenser signal is OFF before the DispenseComplete communication starts. [Remedy] Check the dispenser controller, and make sure that the dispenser is performing the I/O handshaking correctly. SEAL-311 STOP VOL_OK ON before DispComp [Cause] The VolumeOK dispenser signal is ON before the DispenseComplete communication starts. [Remedy] Check the dispenser controller, and make sure that the dispenser is performing the I/O handshaking correctly. SEAL-313 WARN VOL_OK ON before sending style ID [Cause] VolumeOK dispenser signal is ON before sending the style ID to the dispense controller. [Remedy] Consult the dispenser controller, and make sure that the dispenser does the I/O handshaking correctly. SEAL-314 WARN Rmt Strt/Purge req. timeout (E%s) [Cause] The dispense ready signal was not received within the Remote Start/Purge request time. [Remedy] Consult the dispenser controller, and clear the cause of the dispenser fault. SEAL-315 WARN Flow meter disabled (E%s) [Cause] Flow meter has been disabled via setup menu item. [Remedy] Enable setup menu item. SEAL-316 WARN Adaption disabled (E%s) [Cause] Real-time adaption has been disabled via setup menu item. [Remedy] Enable setup menu item.
- 1232 -
B-82594EN-4/01
APPENDIX
C.ALARM CODES
SEAL-317 WARN %s [Cause] Parameter checking has determined that the value is too high or low. [Remedy] Check variable indicated for source of the problem. SEAL-318 WARN Bubble detected (E%s) [Cause] A significant bubble was dispensed with the material during the job. This is usually caused by improper loading of new material.
NOTE This will often cause poor quality sealing. Examine the finished part for any gaps in the sealant bead. [Remedy] Make sure any new material is loaded properly into the supply pump. Make sure all excess air has been drained off before using any new material.
- 1233 -
D.SYSTEM VARIABLES
D
APPENDIX
B-82594EN-4/01
SYSTEM VARIABLES This part of this manual describes the names, functions, standard settings, and valid ranges of system variables. Contents of this appendix D.1 FORMAT OF A SYSTEM VARIABLE TABLE ..................1235 D.2 SYSTEM VARIABLES .........................................................1237
- 1234 -
APPENDIX
B-82594EN-4/01
D.1
D.SYSTEM VARIABLES
FORMAT OF A SYSTEM VARIABLE TABLE Whether the power must be turned off then on again
System variable name
$PARAM_GROUP [ group ] . $PPABN_ENBL BOOLEAN Variable type
RW
PU
Changeable/unchangeable
Standard value
TRUE UE / FALSE Valid range
Table D.1 Format of a system variable table System variable name Standard value Variable type
Changeable/unchangeable Whether the power must be turned off then on again Valid range (unit)
* Intrinsic value for each model BOOLEAN True/false type (TRUE/FALSE) BYTE Integer (0 to 255) SHORT Integer (-32768 to 32767) INTEGER Integer (-1000000 to 1000000) REAL Real number (-10000000000 to 1000000000) CHAR Character string (“abcdefg”) XYZWPR Cartesian coordinates RW Changeable RO Unchangeable PU Indicates that the power must be turned on again.
Procedure D-1 Setting a system variable
Step 1 2 3
Press the MENUS key. Select 0 (NEXT), then select 6 (SYSTEM). Press the F1 (TYPE) key.
- 1235 -
D.SYSTEM VARIABLES
APPENDIX
B-82594EN-4/01
4
Select Variables. Then, the system variable screen is displayed.
5
To change the value of a system variable, move the cursor to a desired item, enter a new value, then press the ENTER key or select a desired item by pressing the corresponding function key. When a system variable contains multiple system variables, move the cursor to a desired item and press the ENTER key. Then, the low-order system variables are displayed.
6
7
After changing the setting of the system variable for which PU is specified, turn off the power, then turn it on again. (PU is specified for all $PARAM_GROUP system variables.)
NOTE The setting of a system variable for which RO (unchangeable) is specified cannot be changed.
- 1236 -
APPENDIX
B-82594EN-4/01
D.2
D.SYSTEM VARIABLES
SYSTEM VARIABLES
Hot start $SEMIPOWERFL FALSE BOOLEAN RW TRUE/FALSE [Description] Specifies whether to perform a hot start when power is recovered. After a hot start, the robot is restored near the status immediately before a power failure. TRUE: Performs a hot start after power recovery. FALSE: Does not perform a hot start. Instead, performs a cold start.
Power failure recovery $PARAM_GROUP[ group ] . $SV_OFF_ALL TRUE BOOLEAN RW PU TRUE / FALSE [Function] Enables or disables the break control function [Description] Specifies how the brakes are applied. TRUE: It puts on/off breaks for all axes at same time, i.e. it does not put on all breaks till all axes finish to move and it puts off all breaks when one axis start to move. FALSE: It puts on/off breaks independently, i.e. it puts on each break which axis finish to move and it never put off each break which axis starts to move.
Mastering $MASTER_ENB 0 ULONG RW 1/0 [Function] Displays positioning screen [Description] When this variable is enabled, the positioning screen [6 (SYSTEM).Master/Cal] is displayed on the teach pendant. 0: Positioning screen not displayed. 1: Positioning screen displayed. $DMR_GRP[ group ]. $MASTER_DONE TRUE BOOLEAN RW TRUE / FALSE [Function] Indicates if mastering is completed. [Description] Indicates if mastering has been completed. [Setting] On the positioning screen [6 (SYSTEM).Master/Cal] $DMR_GRP[ group ]. $MASTER_COUN[ 1 ] * $DMR_GRP[ group ]. $MASTER_COUN[ 2 ] * $DMR_GRP[ group ]. $MASTER_COUN[ 3 ] * $DMR_GRP[ group ]. $MASTER_COUN[ 4 ] * $DMR_GRP[ group ]. $MASTER_COUN[ 5 ] * $DMR_GRP[ group ]. $MASTER_COUN[ 6 ] * $DMR_GRP[ group ]. $MASTER_COUN[ 7 ] * $DMR_GRP[ group ]. $MASTER_COUN[ 8 ] * $DMR_GRP[ group ]. $MASTER_COUN[ 9 ] * INTEGER RW 0 to 100000000 ( pulse ) [Function] Store mastering pulse counts [Description] Pulse coder count at zero degree position is stored. This value is calculated from current count at mastering and current position.
- 1237 -
D.SYSTEM VARIABLES
APPENDIX
B-82594EN-4/01
$PARAM_GROUP[ group ]. $MASTER_POS[ 1 ] * $PARAM_GROUP[ group ]. $MASTER_POS[ 2 ] * $PARAM_GROUP[ group ]. $MASTER_POS[ 3 ] * $PARAM_GROUP[ group ]. $MASTER_POS[ 4 ] * $PARAM_GROUP[ group ]. $MASTER_POS[ 5 ] * $PARAM_GROUP[ group ]. $MASTER_POS[ 6 ] * $PARAM_GROUP[ group ]. $MASTER_POS[ 7 ] * $PARAM_GROUP[ group ]. $MASTER_POS[ 8 ] * $PARAM_GROUP[ group ]. $MASTER_POS[ 9 ] * REAL RW PU -100000 to 100000 ( deg ) [Function] Store jig position for jig mastering [Description] Jig position for jig mastering is stored. Mastering pulse count is calculated from this data.
Quick mastering $DMR_GRP[ group ]. $REF_DONE FALSE BOOLEAN RW TRUE / FALSE [Function] Indicates if setting of the reference point for quick mastering is completed. [Description] When the reference point of simple mastering is set, the pulse coder count and coordinate values of the reference position are stored. [Setting] On the positioning screen [6 (SYSTEM).Master/Cal] $DMR_GRP[ group ]. $REF_COUNT[ 1 ] 0 $DMR_GRP[ group ]. $REF_COUNT[ 2 ] 0 $DMR_GRP[ group ]. $REF_COUNT[ 3 ] 0 $DMR_GRP[ group ]. $REF_COUNT[ 4 ] 0 $DMR_GRP[ group ]. $REF_COUNT[ 5 ] 0 $DMR_GRP[ group ]. $REF_COUNT[ 6 ] 0 $DMR_GRP[ group ]. $REF_COUNT[ 7 ] 0 $DMR_GRP[ group ]. $REF_COUNT[ 8 ] 0 $DMR_GRP[ group ]. $REF_COUNT[ 9 ] 0 INTEGER RW 0 to 100000000 ( pulse ) [Function] Store reference point mastering count [Description] Store the count of the pulse coder when the robot is positioned at the reference point. $DMR_GRP[ group ]. $REF_POS[ 1 ] 0 $DMR_GRP[ group ]. $REF_POS[ 2 ] 0 $DMR_GRP[ group ]. $REF_POS[ 3 ] 0 $DMR_GRP[ group ]. $REF_POS[ 4 ] 0 $DMR_GRP[ group ]. $REF_POS[ 5 ] 0 $DMR_GRP[ group ]. $REF_POS[ 6 ] 0 $DMR_GRP[ group ]. $REF_POS[ 7 ] 0 $DMR_GRP[ group ]. $REF_POS[ 8 ] 0 $DMR_GRP[ group ]. $REF_POS[ 9 ] 0 REAL RW -100000 to 100000 ( deg ) [Function] Store reference point to be set during quick mastering [Description] Store the reference point to be set during quick mastering.
- 1238 -
B-82594EN-4/01
APPENDIX
D.SYSTEM VARIABLES
Positioning $MOR_GRP[ group ]. $CAL_DONE TRUE BOOLEAN RW TRUE / FALSE [Function] Indicates if calibration is completed. [Description] To check the current position of the robot, the count of the pulse coder issued and the current position is calculated using mastering count. This check is usually performed when the power is turned on. [Setting] On the positioning screen [6 (SYSTEM).Master/Cal]
Specifying coordinate systems $MNUFRAMENUM[ group ] 0 BYTE RW 0 to 9 [Function] Specifies user coordinate system number [Description] Specifies the number of the user coordinate system currently used. 0: World coordinate system 1 to 9: User coordinate system [Setting] On the tool coordinate system setting & screen [6 SYSTEM, Coordinate, User] $MNUFRAME[ group, 1 ] XYZWPR $MNUFRAME[ group, 2 ] XYZWPR $MNUFRAME[ group, 3 ] XYZWPR $MNUFRAME[ group, 4 ] XYZWPR $MNUFRAME[ gropu, 5 ] XYZWPR $MNUFRAME[ group, 6 ] XYZWPR $MNUFRAME[ group, 7 ] XYZWPR $MNUFRAME[ group, 8 ] XYZWPR $MNUFRAME[ group, 9 ] XYZWPR POSITION RW XYZWPR [Function] Specifies user coordinates system number [Description] Specifies the Cartesian coordinates in the user coordinate system. Up to nine user coordinate systems can be registered. $MNUTOOLNUM[ group ] 0 BYTE RW 0 to 9 [Function] Specifies tool coordinate system number [Description] Specifies the number of the tool coordinate system currently used. 0: Mechanical interface coordinate system 1 to 9: Tool coordinate system [Setting] On the tool coordinate system setting screen [6 SYSTEM.Coordinate.Tool]
- 1239 -
D.SYSTEM VARIABLES
APPENDIX
B-82594EN-4/01
$MNUTOOL[ group, 1 ] XYZWPR $MNUTOOL[ group, 2 ] XYZWPR $MNUTOOL[ group, 3 ] XYZWPR $MNUTOOL[ group, 4 ] XYZWPR $MNUTOOL[ group, 5 ] XYZWPR $MNUTOOL[ group, 6 ] XYZWPR $MNUTOOL[ group, 7 ] XYZWPR $MNUTOOL[ group, 8 ] XYZWPR $MNUTOOL[ group, 9 ] XYZWPR POSITION RW XYZWPR [Function] Specifies the tool coordinate system [Description] Specify the Cartesian coordinates in the tool coordinate system. Nine tool coordinate systems can be registered. $JOG_GROUP[ group ]. $JOG_FRAME XYZWPR POSITION RW XYZWPR [Function] Specifies the jog coordinate system [Description] Specifies the Cartesian coordinates in the jog coordinate system. [Setting] On the jog coordinate system setting screen [6 SYSTEM, Coordinate, jog]
Setting motors $SCR_GRP[ group ]. $AXISORDER[ 1 ] 1 $SCR_GRP[ group ]. $AXISORDER[ 2 ] 2 $SCR_GRP[ group ]. $AXISORDER[ 3 ] 3 $SCR_GRP[ group ]. $AXISORDER[ 4 ] 4 $SCR_GRP[ group ]. $AXISORDER[ 5 ] 5 $SCR_GRP[ group ]. $AXISORDER[ 6 ] 6 $SCR_GRP[ group ]. $AXISORDER[ 7 ] 0 $SCR_GRP[ group ]. $AXISORDER[ 8 ] 0 $SCR_GRP[ group ]. $AXISORDER[ 9 ] 0 BYTE RW 0 to 16 [Function] Specify axis order [Description] Specifies the order of axes by assigning the physical number of a servo motor controlled by the servo amplifier (servo register) to the logical number of a robot joint axis specified in software (Jx-axis). For instance, when $AXISORDER[1] = 2, servo motor 2 is assigned to the J1-axis. When $AXISORDER[1] = 0, no servo motor is assigned as the J1-axis. $SCR_GRP[ group ]. $ROTARY_AXS[ 1 ] * $SCR_GRP[ group ]. $ROTARY_AXS[ 2 ] * $SCR_GRP[ group ]. $ROTARY_AXS[ 3 ] * $SCR_GRP[ group ]. $ROTARY_AXS[ 4 ] * $SCR_GRP[ group ]. $ROTARY_AXS[ 5 ] * $SCR_GRP[ group ]. $ROTARY_AXS[ 6 ] * $SCR_GRP[ group ]. $ROTARY_AXS[ 7 ] * $SCR_GRP[ group ]. $ROTARY_AXS[ 8 ] * $SCR_GRP[ group ]. $ROTARY_AXS[ 9 ] * BOOLEAN RO TRUE / FALSE [Function] Specify axis type [Description] Specifies whether joint axes of the robot are rotational or linear. TRUE: Rotational FALSE: Linear - 1240 -
B-82594EN-4/01
APPENDIX
D.SYSTEM VARIABLES
$PARAM_GROUP[ group ]. $MOSIGN[ 1 ] * $PARAM_GROUP[ group ]. $MOSIGN[ 2 ] * $PARAM_GROUP[ group ]. $MOSIGN[ 3 ] * $PARAM_GROUP[ group ]. $MOSIGN[ 4 ] * $PARAM_GROUP[ group ]. $MOSIGN[ 5 ] * $PARAM_GROUP[ group ]. $MOSIGN[ 6 ] * $PARAM_GROUP[ group ]. $MOSIGN[ 7 ] * $PARAM_GROUP[ group ]. $MOSIGN[ 8 ] * $PARAM_GROUP[ group ]. $MOSIGN[ 9 ] * BOOLEAN RW PU TRUE / FALSE [Function] Specify direction of rotation around axes [Description] Specify whether the robot moves in the positive or negative direction when the motor rotates positively for each axis. TRUE: The robot moves in a positive direction when the motor rotates positively. FALSE: The robot moves in a negative direction when the motor rotates positively. $PARAM_GROUP[ group ]. $ENCSCALES[ 1 ] * $PARAM_GROUP[ group ]. $ENCSCALES[ 2 ] * $PARAM_GROUP[ group ]. $ENCSCALES[ 3 ] * $PARAM_GROUP[ group ]. $ENCSCALES[ 4 ] * $PARAM_GROUP[ group ]. $ENCSCALES[ 5 ] * $PARAM_GROUP[ group ]. $ENCSCALES[ 6 ] * $PARAM_GROUP[ group ]. $ENCSCALES[ 7 ] * $PARAM_GROUP[ group ]. $ENCSCALES[ 8 ] * $PARAM_GROUP[ group ]. $ENCSCALES[ 9 ] * REAL RW PU -10000000000 to 10000000000 ( pulse/deg, pulse/mm ) [Function] Specify unit of pulse coder count [Description] Specify how many pulses are required for the pulse coder when the robot moves around a joint axis one degree or the robot moves along a joint axis 1 mm. Rotation axis: $ENCSCALES = 2E19 x deceleration ratio/360 $PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 1 ] * $PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 2 ] * $PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 3 ] * $PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 4 ] * $PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 5 ] * $PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 6 ] * $PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 7 ] * $PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 8 ] * $PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 9 ] * INTEGER RW PU 0 to 100000 ( rpm ) [Function] Specify maximum motor speed [Description] Specifies the maximum speed of each servo motor for the robot for each axis. When the robot moves around or along a certain axis at a speed exceeding the maximum speed, a warning is issued. Then, the robot decelerates and moves at a speed not exceeding the maximum speed. In this case, the robot may not trace the specified path.
- 1241 -
D.SYSTEM VARIABLES
APPENDIX
B-82594EN-4/01
Override $SHIFTOV_ENB 0 ULONG RW 0/1 [Function] Enables or disables shift override [Description] The shift override function changes the feedrate override in five steps. To change the feedrate override, press and hold down the SHIFT key, then press the override key as many times as necessary to select the desired override. 1: Enables shift override. 0: Disables shift override. Press and hold down the SHIFT key, then press the override key: The feedrate override changes in the order: VFINE " FINE → 5% → 50% → 100%. $MCR. $GENOVERRIDE 10 INTEGER RW 0 to 100 ( % ) [Function] Specifies the rate of change in feedrate override [Description] Specifies the rate of changes in the robot feedrate in percentage. The feedrate changes in this order: FINE " VFINE → 0% → 50% → 100%. From 0% to 100% it changes in 5% increments. [Setting] Use the override keys on the teach pendant. $MCR. $PROGOVERRIDE 100 INTEGER RW 0 to 100 ( % ) [Function] Specifies program override [Description] Specifies the percentage of the robot feedrate while the program is being played back. $SCR_GRP . $JOGLIM 12 INTEGER RO 0 to 100% [Function] Maximum speed scale for coordinate jogging [Description] Percentage of the maximum speed when jogging the robot in the x, y, or z directions using XYZ or TOOL frame. The maximum speed at linear motion is specified in $PARAM_GROUP[group].$SPEEDLIM. $SCR . $JOGLIMROT 12 INTEGER RO 0 to 100% [Function] Maximum speed scale for orientation jogging [Description] Percentage of the maximum speed when jogging the robot about the x, y, or z axes using XYZ or TOOL frame. The maximum speed at orientation motion is specified in $PARAM_GROUP[group].$ROTSPEEDLIM.
- 1242 -
B-82594EN-4/01
APPENDIX
D.SYSTEM VARIABLES
$SCR_GRP[ group ]. $JOGLIM_JNT[ 1 ] * $SCR_GRP[ group ]. $JOGLIM_JNT[ 2 ] * $SCR_GRP[ group ]. $JOGLIM_JNT[ 3 ] * $SCR_GRP[ group ]. $JOGLIM_JNT[ 4 ] * $SCR_GRP[ group ]. $JOGLIM_JNT[ 5 ] * $SCR_GRP[ group ]. $JOGLIM_JNT[ 6 ] * $SCR_GRP[ group ]. $JOGLIM_JNT[ 7 ] * $SCR_GRP[ group ]. $JOGLIM_JNT[ 8 ] * $SCR_GRP[ group ]. $JOGLIM_JNT[ 9 ] * INTEGER RO 0 to 100 ( % ) [Function] Specify joint jog override [Description] The joint jog override function specifies the percentage of the robot feedrate for each axis during jog feed. Specify a low jog override because it is generally unnecessary to move the robot at high speed, and because it is always prudent to avoid danger. $SCR. $COLDOVRD 10 INTEGER RO 0 to 100 ( % ) [Function] Specifies maximum feedrate override after a cold start [Description] The feedrate override is set to this value after a cold start. $SCR. $COORDOVRD 10 INTEGER RO 0 to 100 ( % ) [Function] Specifies maximum feedrate override when the manual-feed coordinate system is changed [Description] The feedrate override is set to this value or less when the manual-feed coordinate system is changed. $SCR. $TPENBLEOVRD 10 INTEGER RO 0 to 100 ( % ) [Function] Specifies the maximum feedrate override when the teach pendant is enabled [Description] The feedrate override is set to this value when the teach pendant is enabled. $SCR. $JOGOVLIM 100 INTEGER RO 0 to 100 ( % ) [Function] Specifies the maximum feedrate override during jog feed [Description] The feedrate override is set to this value or less during jog feed. $SCR. $RUNOVLIM 50 INTEGER RO 0 to 100 ( % ) [Function] Specifies the maximum feedrate override when the program is executed [Description] The feedrate override is set to this value or less when the program is executed. $SCR. $FENCEOVRD INTEGER RO 0 to 100 ( % ) [Function] Maximum feedrate override when the safety fence is open [Description] When the safety fence is opened (*SFSPD input is turned off), the feedrate override is set to this value or below. $SCR. $SFJOGOVLIM 50 INTEGER RO 0 to 100 ( % ) [Function] Maximum feedrate override of jog feed when the safety fence is open [Description] If jog feed is performed while the safety fence is open, the feedrate override is set to this value or below. - 1243 -
D.SYSTEM VARIABLES
APPENDIX
B-82594EN-4/01
$SCR. $SFRUNOVLIM 30 INTEGER RO 0 to 100 ( % ) [Function] Maximum feedrate override of program execution while the safety fence is open [Description] When a program is executed with the safety fence open (*SFSPD input set off), the feedrate override is set to this value or below. $SCR. $RECOV_OVRD FALSE BOOLEAN RW TRUE/FALSE [Function] Function to restore feedrate override when the safety fence is closed [Description] When the safety fence is closed (*SFSPD input set on), the previous feedrate override is restored. Then, automatic operation can be started immediately. This function is enabled when the following conditions are satisfied: 1 $SCR.$RECOV_OVRD is set to TRUE. 2 The system is in the remote state. 3 The feedrate override is not changed while the safety fence is open. If the safety fence is closed while the above conditions are not satisfied, the previous override cannot be restored. [Setting] General item setting screen [6 SETTING, GENERAL]
Feedrate $PARAM_GROUP[ group ]. $JNTVELLIM[ 1 ] * $PARAM_GROUP[ group ]. $JNTVELLIM[ 2 ] * $PARAM_GROUP[ group ]. $JNTVELLIM[ 3 ] * $PARAM_GROUP[ group ]. $JNTVELLIM[ 4 ] * $PARAM_GROUP[ group ]. $JNTVELLIM[ 5 ] * $PARAM_GROUP[ group ]. $JNTVELLIM[ 6 ] * $PARAM_GROUP[ group ]. $JNTVELLIM[ 7 ] * $PARAM_GROUP[ group ]. $JNTVELLIM[ 8 ] * $PARAM_GROUP[ group ]. $JNTVELLIM[ 9 ] * REAL RW PU 0 to 100000 ( deg/sec, mm/sec ) [Function] Specify the maximum joint speed [Description] Specify the maximum joint speed for each axis. When the robot moves around or along a certain axis at a speed exceeding the maximum joint speed, a warning is issued. Then, the robot decelerates and moves at a speed not exceeding the maximum joint speed. $PARAM_GROUP[ group ]. $SPEEDLIM 2000 REAL RW PU 0 to 3000 ( mm/sec ) [Function] Specifies the maximum linear feedrate [Description] Specifies the maximum feedrate during linear or circular motion under path control. $PARAM_GROUP[ group ]. $ROTSPEEDLIM 90 REAL RW PU 0 to 1440 ( deg/sec ) [Function] Specifies the maximum circular feedrate [Description] Specifies the maximum feedrate during circular motion under attitude control.
- 1244 -
D.SYSTEM VARIABLES
APPENDIX
B-82594EN-4/01
Jog feedrate (joint feed) = Maximum joint speed ×
Joint jog override
Jog feedrate (linear feed) (mm/sec) = Jog override Maximum linear feedrate × 100
×
Jog feedrate (circular feed) (mm/sec) = Jog override Maximum circular feedrate× 100 Joint jog override Jog override Maximum joint speed Maximum linear feedrate Maximum circular feedrate
Feedrate override
×
100
×
100
Feedrate override 100 Feedrate override 100
$SCR_GRP. $JOGLIM_JNT [ i ] (%) $SCR. $JOGLIM (%) $PARAM_GROUP. $JNTVELLIM $PARAM_GROUP. $SPEEDLIM (mm/sec) $PARAM_GROUP. $ROTSPEEDLIM (deg/sec)
Operation speed (joint motion) = Maximum joint speed×
Coefficient of joint speed
2000 ×~
Programmed
×
Programmed speed 100
override
100
×
Feedrate override 100
Operation speed (linear motion) (mm/sec) = Programmed speed ×
Programmed override 100
×
Feedrate override 100
Operation speed (circular motion) (deg/sec) = Programmed speed × Programmed override Coefficient of joint speed
Programmed override 100
×
Feedrate override 100
$MCR_GRP. $PROGOVERRIDE (%) $PARAM_GROUP. $SPEEDLIMJNT
$PARAM_GROUP[ group ]. $LOWERLIMS[ 1 ] * $PARAM_GROUP[ group ]. $LOWERLIMS[ 2 ] * $PARAM_GROUP[ group ]. $LOWERLIMS[ 3 ] * $PARAM_GROUP[ group ]. $LOWERLIMS[ 4 ] * $PARAM_GROUP[ group ]. $LOWERLIMS[ 5 ] * $PARAM_GROUP[ group ]. $LOWERLIMS[ 6 ] * $PARAM_GROUP[ group ]. $LOWERLIMS[ 7 ] * $PARAM_GROUP[ group ]. $LOWERLIMS[ 8 ] * $PARAM_GROUP[ group ]. $LOWERLIMS[ 9 ] * REAL RW PU -100000 to 100000 ( deg, mm ) [Function] Specify the lower limit of the joint operating area [Description] Specify the lower limit of the joint operating area which is the limit of the motion in the negative direction. [Setting] Joint operating area screen [6 (SETTING).Joint Area]
- 1245 -
D.SYSTEM VARIABLES
APPENDIX
B-82594EN-4/01
$PARAM_GROUP[ group ]. $UPPERLIMS[ 1 ] * $PARAM_GROUP[ group ]. $UPPERLIMS[ 2 ] * $PARAM_GROUP[ group ]. $UPPERLIMS[ 3 ] * $PARAM_GROUP[ group ]. $UPPERLIMS[ 4 ] * $PARAM_GROUP[ group ]. $UPPERLIMS[ 5 ] * $PARAM_GROUP[ group ]. $UPPERLIMS[ 6 ] * $PARAM_GROUP[ group ]. $UPPERLIMS[ 7 ] * $PARAM_GROUP[ group ]. $UPPERLIMS[ 8 ] * $PARAM_GROUP[ group ]. $UPPERLIMS[ 9 ] * REAL RW PU -100000 to 100000 ( deg, mm ) [Function] Specify the upper limit of the joint operating area [Description] Specify the upper limit of the joint operating area, which is the limit of the motion in the positive direction. [Setting] Joint operating area screen [6 (SETTING).Joint Area]
Payload specification If load information has not been set up on the load setting screen, it is necessary to enter the following information. If no load setting condition number has been selected, be sure to enter the information correctly, since the robot uses it when it runs. Therefore, be particularly careful when setting these values. • $GROUP[group].$PAYLOAD • $PARAM_GROUP[group].$PAYLOAD • $PARAM_GROUP[group].$PAYLOAD_X • $PARAM_GROUP[group].$PAYLOAD_Y • $PARAM_GROUP[group].$PAYLOAD_Z • $PARAM_GROUP[group].$PAYLOAD_IX • $PARAM_GROUP[group].$PAYLOAD_IY • $PARAM_GROUP[group].$PAYLOAD_IZ • $PARAM_GROUP[group].$AXISINTERTIA[1 to 9] • $PARAM_GROUP[group].$AXISMOMENT[1 to 9] • $PARAM_GROUP[group].$AXIS_IM_SCL • $PARAM_GROUP[group].$ARMLOAD[1 to 3] $GROUP [ group ] . $PAYLOAD * REAL RW 0 to 10000(kgf) [Function] Payload [Description] Specify a payload. If the load varies during an operation, specify the maximum value. $PARAM_GROUP [ group ] . $PAYLOAD * REAL RW PU 0 to 10000(kgf) [Function] Payload [Description] Specify a payload. If the load varies during an operation, specify the maximum value.
- 1246 -
D.SYSTEM VARIABLES
APPENDIX
B-82594EN-4/01
$PARAM_GROUP[ group ]. $PAYLOAD_X * $PARAM_GROUP[ group ]. $PAYLOAD_Y * $PARAM_GROUP[ group ]. $PAYLOAD_Z * REAL RW PU -100000 to 10000(cm) [Function] Load gravity center distance [Description] Center of gravity of load viewed on the mechanical interface coordinate system (default tool coordinate system). The center of gravity of a load is measured along the X-axis, Y-axis, and Z-axis of the mechanical interface coordinate system. $PARAM_GROUP[ group ]. $PAYLOAD_IX * $PARAM_GROUP[ group ]. $PAYLOAD_IY * $PARAM_GROUP[ group ]. $PAYLOAD_IZ * REAL RW PU 0 to 10000(kg ⋅ cm2) [Function] Load gravity center inertia [Description] Inertia around the center of gravity of load. The inertia of a heavy load is calculated around the X-axis, Y-axis, and Z-axis of the mechanical interface coordinate system. The meaning of $PARAM_GROUP[group].$PAYLOAD_* is as illustrated below: Center of robot flange
x
x
y
z Mass m (kg) xg (cm)
Iy (kg⋅cm2)
Center of gravity
Center of gra it
Iz
yg (cm)
Ix (kg⋅cm2)
zg (cm) xg (cm) yg (cm) zg (cm) 2 Ix (kg⋅cm ) 2 Iy (kg⋅cm ) Iz (kg⋅cm2)
2
: : : : : :
PARAM_GROUP[group].$PAYLOAD_X PARAM_GROUP[group].$PAYLOAD_Y PARAM_GROUP[group].$PAYLOAD_Z PARAM_GROUP[group].$PAYLOAD_IX PARAM_GROUP[group].$PAYLOAD_IY PARAM_GROUP[group].$PAYLOAD_IZ
$PARAM_GROUP [ group ]. $AXISINERTIA[ 1 ] * $PARAM_GROUP [ group ]. $AXISINERTIA[ 2 ] * $PARAM_GROUP [ group ]. $AXISINERTIA[ 3 ] * $PARAM_GROUP [ group ]. $AXISINERTIA[ 4 ] * $PARAM_GROUP [ group ]. $AXISINERTIA[ 5 ] * $PARAM_GROUP [ group ]. $AXISINERTIA[ 6 ] * $PARAM_GROUP [ group ]. $AXISINERTIA[ 7 ] * $PARAM_GROUP [ group ]. $AXISINERTIA[ 8 ] * $PARAM_GROUP [ group ]. $AXISINERTIA[ 9 ] * SHORT RW PU 0 to 32767 ( kgf ⋅ cm ⋅ sec2 ) [Function] Payload inertia [Description] For each axis, specify an integer as the value of the inertia resulting from the applied payload. The values for the 1st to 3rd axes are calculated automatically; therefore, they need not be specified. (Set a value for each of the 4th, 5th, and 6th axes.) The inertia for each axis is calculated using the following expression: - 1247 -
D.SYSTEM VARIABLES
APPENDIX
$AXISINERTIA[i] =
payload ×( l_max [i] )2 g
B-82594EN-4/01
2 (kgf⋅cm⋅sec )
Payload : Payload [kgf] l_max[i] : Maximum distance from the rotation center of the axis (axis i) to the mass center of the load on the robot [cm] For the 4th and 5th axes, the distance may vary depending on the angle of the other axes. In such a case, set the maximum distance than can be achieved. G : Gravity acceleration (= 980 [cm/sec2]) [NOTE] When specifying or changing this variable, refer to the explanation of $PARAM_GROUP[].$AXIS_IM_SCL, below. $PARAM_GROUP [ group ]. $AXISMOMENT[ 1 ] * $PARAM_GROUP [ group ]. $AXISMOMENT[ 2 ] * $PARAM_GROUP [ group ]. $AXISMOMENT[ 3 ] * $PARAM_GROUP [ group ]. $AXISMOMENT[ 4 ] * $PARAM_GROUP [ group ]. $AXISMOMENT[ 5 ] * $PARAM_GROUP [ group ]. $AXISMOMENT[ 6 ] * $PARAM_GROUP [ group ]. $AXISMOMENT[ 7 ] * $PARAM_GROUP [ group ]. $AXISMOMENT[ 8 ] * $PARAM_GROUP [ group ]. $AXISMOMENT[ 9 ] * SHORT RW PU 0 to 32767 ( kgf ⋅ m ) [Function] Axis moment [Description] For each axis, specify an integer as the moment value resulting from the applied payload. The values for the 1st to 3rd axes are calculated automatically; therefore, they need not be specified. (Set a value for each of the each of 4th, 5th, and 6th axes.) The moment value for each axis is calculated using the following expression: $AXISMOMENT[i] = payload ×l_max[i] (kgf⋅m)
Payload : Payload [kgf] l_max[i] : Maximum distance from the rotation center of the axis (axis i) to the mass center of the load on the robot [m] For the 4th and 5th axes, the distance may vary depending on the angle of the other axes. In such a case, set the maximum distance than can be achieved. [NOTE] When specifying or changing this variable, refer to the explanation of $PARAM_GROUP[].$AXIS_IM_SCL, below. $PARAM_GROUP [ group ] . $AXIS_IM_SCL 1 SHORT RW PU 0 to 32767 [Function] Inertia and moment value adjustment scale [Description] This scale is used to set up a number in decimal places for the inertia and moment values of each axis stated above. [NOTE] It is usually unnecessary to re-set this variable. Actually, the following inertia and moment values are used. (Inertia value) =
$PARAM_GROUP[group].$AXISINERTIA[i] $PARAM_GROUP[group].$AXIS_IM_SCL
(Moment value) =
$PARAM_GROUP[group].$AXISMOMETN[i] $PARAM_GROUP[group].$AXIS_IM_SCL
It is therefore necessary to assign $AXISINERTIA[i] and $AXISMOMENT[i] with values that match the setting of this variable. To enter the value "1.23," for example, as the inertia value for the fourth axis of the robot: - 1248 -
APPENDIX
B-82594EN-4/01
• • •
D.SYSTEM VARIABLES
Set up $PARAM_GROUP[group].$AXIS_IM_SCL = 100 Set up $PARAM_GROUP[group].$AXISINERTIA[4] = 123 Change these inertia and moment values for other axes according to the value of $AXIS_IM_SCL. $PARAM_GROUP [ group ]. $ARMLOAD[ 1 ] $PARAM_GROUP [ group ]. $ARMLOAD[ 2 ] $PARAM_GROUP [ group ]. $ARMLOAD[ 3 ] REAL RW PU 0 to 10000 ( kgf )
* * *
[Function] Equipment weight [Description] When equipment such as welding equipment is installed on a robot axis, specify the payload incurred by that equipment. $ARMLOAD[1]: Specify the weight of the equipment installed on the 3rd-axis arm. $ARMLOAD[2]: Specify the weight of the equipment installed on the 2nd-axis base. $ARMLOAD[3]: Not used.
Executing a program $DEFPULSE 4 SHORT RW 0 to 255 ( 100 msec ) [Function] Specifies the standard DO output pulse width [Description] This value is used when the pulse width is not specified for the output of a DO signal pulse.
Automatic operation $RMT_MASTER 0 INTEGER RW 0 to 3 [Function] Specifies which remote unit is used [Description] Specifies which remote unit is used. The specified remote unit has the right to start the robot. 0: Peripheral unit (remote controller) 1: CRT/keyboard 2: Host computer 3: No remote unit
Deleting the warning history $ER_NOHIS 0 BYTE RW 0/3 [Function] Warning history delete function [Description] WARN alarms, NONE alarms and resets can be deleted from the alarm history. 0: Disables the function. (All alarms and resets are recorded in the history.) 1: Does not record WARN and NONE alarms in the history. 2: Does not record resets. 3: Does not record resets, WARN alarms, and NONE alarms.
Disabling alarm output $ER_NO_ALM. $NOALMENBL 0 BYTE RW 0/1 [Function] Enables the no-alarm output function [Description] When this function is enabled, the LEDs on the teach pendant and the machine operator's panel corresponding to the alarms specified with system variable $NOALM_NUM do not light. In addition, the peripheral I/ O alarm signal (FAULT) is not output. - 1249 -
D.SYSTEM VARIABLES
APPENDIX
B-82594EN-4/01
$ER_NO_ALM. $NOALM_NUM 5 BYTE RW 0 to 10 [Function] Specifies the number of alarms not output [Description] Specifies the number of alarms that are not output. $ER_NO_ALM. $ER_CODE1 11001 $ER_NO_ALM. $ER_CODE2 11002 $ER_NO_ALM. $ER_CODE3 11003 $ER_NO_ALM. $ER_CODE4 11007 $ER_NO_ALM. $ER_CODE5 11037 $ER_NO_ALM. $ER_CODE6 0 $ER_NO_ALM. $ER_CODE7 0 $ER_NO_ALM. $ER_CODE8 0 $ER_NO_ALM. $ER_CODE9 0 $ER_NO_ALM. $ER_CODE10 0 INTEGER RW 0 to 100000 [Function] Specify the alarms not output [Description] Specify the alarms that are not output. Setting : 11 002 ( Meaning: SERVO-002 alarm ) Alarm ID Alarm number
Error code output $ER_OUT_PUT. $OUT_NUM 0 LONG RW 0 to 512 [Function] DO start number for error code output [Description] Specify the start number for the DOs used for error code output. An error code is output, in binary format, using 33 DOs starting from that having the specified number. If 0 is specified, no error code is output. $ER_OUT_PUT. $IN_NUM 0 LONG RW 0 to 512 [Function] DO number for error code output request [Description] Every time the DO specified in this variable is set to ON, an error code is output to the DOs specified in $ER_OUTPUT.$OUT_NUM, explained above.
User alarm $UALRM_SEV[ ] 6 BYTE RW 0 to 255 [Function] User alarm severity [Description] Sets the user alarm severity. $UALRM_SEV[i] corresponds to the severity of user alarm [i]. 0 WARN 6 STOP.L 38 STOP.G 11 ABORT.L 43 ABORT.G The initial severity for each user alarm is 6 (STOP.L).
- 1250 -
B-82594EN-4/01
APPENDIX
D.SYSTEM VARIABLES
Jogging $JOG_GROUP . $FINE_DIST 0.5 REAL RW 0.0 to 1.0 ( mm ) [Function] Move distance for linear step jogging [Description] Specify an amount of travel in low-speed linear step feed by Cartesian/tool manual feed. The amount of travel in very low speed step feed is one tenth of the value specified here. $SCR . $FINE_PCNT 10 INTEGER RO 1 to 100 % [Function] Move distance for joint or orientation step jogging [Description] Specify an amount of travel for step feed in attitude rotation by axial manual feed or Cartesian/tool manual feed. Specify manual feed with a precentage and an override of 1%.
I/O setting $OPWORK . $UOP_DISABLE * BYTE RW 0/1 [Function] Enable/disable UOP I/O [Description] Specify whether the peripheral equipment input signal is enabled or disabled. If the peripheral equipment input signal is enabled when the robot is operated without any peripheral equipment connected, an alarm cannot be cleared. By disabling the signal with this setting, the alarm can be cleared. When any peripheral equipment is connected, set this variable to 0 before using that equipment. $SCR . $RESETINVERT FALSE BOOLEAN RW TRUE / FALSE [Function] FAULT_RESET input signal detection. [Description] When you set this value to "TRUE", an error is reset by rising edge of FAULT_RESET input signal. If "FALSE" is set, an error is reset by falling edge is detected. TRUE: Check rising edge of reset input signal. FALSE: Check falling edge of reset input signal. $PARAM_GROUP . $PPABN_ENBL FALSE BOOLEAN RW TRUE / FALSE [Function] Enable/disable pressure abnormal *PPABN input [Description] Specifies if pressure abnormal signal is detected or not. If you want to use *PPABN input, you should set this variable to TRUE. TRUE: Enable FALSE: Disable $PARAM_GROUP. $BELT_ENBLE FALSE BOOLEAN RW TRUE / FALSE [Function] Belt rupture signal enabled/disabled [Description] Specify whether the belt rupture signal (RI[7]) is detected. For a robot utilizing the belt rupture signal (A-510, L-1000), this value is automatically set to TRUE. TRUE: Belt rupture signal enabled FALSE: Belt rupture signal disabled
- 1251 -
D.SYSTEM VARIABLES
APPENDIX
B-82594EN-4/01
Software version $ODRDSP_ENB 0 ULONG RW 1/0 [Function] Display of an order file [Description] An order listing, showing the configuration of the software components installed in the controller can be displayed on the display (order file screen) of the teach pendant.
Soft float function $SFLT_ERRTYP 0 INTEGER RW 1 to 10 [Function] Flag for specifying the alarm to be generated when time-out occurs during follow-up processing of the soft float function [Description] This variable specifies the alarm (a servo alarm or program pause alarm) to be generated if a time-out occurs during follow-up processing of the soft float function. 0: Generates servo alarm "SRVO-111 Softfloat time out." 1: Generates program pause alarm "SRVO-112 Softfloat time out." $SFLT_DISFUP FALSE BOOLEAN RW TRUE / FALSE [Function] Specifies whether to perform follow-up processing at the start of each motion instruction. [Description] Specify whether to perform follow-up processing of the soft float function at the start of each program motion instruction. TRUE: Does not perform follow-up processing at the start of each program motion instruction. FALSE: Performs follow-up processing at the start of each program motion instruction.
Saving files $FILE_APPBCK [Function] On the file screen, displays the name of a file to be saved as Application. $FILE_SYSBCK [Description] On the file screen, displays the name of a file to be saved as System file.
Register speed specification function
- 1252 -
B-82594EN-4/01
APPENDIX
D.SYSTEM VARIABLES
$RGSPD_PREXE FALSE BOOLEAN RO TRUE/FALSE [Function] Advanced register speed read enabled or disabled [Description] Specify whether an advanced read of operation statement is performed (enabled) or not (disabled) when the movement speed specified by an operation statement is held in a register. TRUE: Advanced read enabled FALSE: Advanced read disabled
CAUTION When an advanced register speed read is enabled with the setting indicated above, the timing at which the register value is changed is important. With some timings, a change in the register value may not be reflected in the operation speed, and the register value existing before the change may be applied to the movement. To enable advanced register speed read, some consideration is needed: The value of a register used for the movement speed during program execution should not be changed; An interlock should be provided.
Specifying an output signal of the BLAL/BZAL alarm $BLAL_OUT.$DO_INDEX 0 INTEGER RW 0 to 256 [Description] When a non-zero number is specified, DO corresponding to that number is turned on at the occurrence of BLAL/BAZL. DO stays on until the voltage is restored by the replacement backup battery or some other means. (If a program or the I/O screen is used to turn off DO forcibly, DO is turned back on immediately.) $BLAL_OUT.$BATALM_OR FALSE INTEGER RW TRUE/FALSE [Description] Specifies whether to set BATALM, a dedicated output signal, so that it has also the BZAL/BLAL function.
- 1253 -
INDEX
B-82594EN-4/01
NOTE Volume 1 : Page 1 to 943 / Volume 2 : P. 947 to 1253
INDEX
Abort Instruction ........................................................... 244
Calibration Procedure (for 6-Axis Robots) ...................597 Caution ..........................................................................602
Caution and Limitations ................................................546
Abort Instruction ........................................................... 244
Cautions ........................................................................587
About Reducer Diagnosis.............................................. 998
Cell controller setup ......................................................851
Additional Motion Instructions ..................................... 188
Cell Interface I/O...........................................................102
ADVANCED FUNCTIONS ......................................... 905
Changing a Control Instruction .....................................312
ALARM CODES ............................................... 1033,1045
Changing a Motion Instruction......................................300
ALARM RECOVERY.................................................. 959
CHANGING A PROGRAM .........................................299
Analog I/O....................................................................... 54
Changing a Standard Motion Instruction.......................283
Analog I/O Instructions................................................. 215
Changing Conditions for Executing the Resume Program577
Angle-input Shift Function............................................ 495
Changing Program Information.....................................332
APPEARANCE AND OPERATIONS.......................... 732
Changing the Operation Target Screen .........................738
Appearance and Switches.............................................. 732
Channel 2 Analog Control Setup...................................822
APPENDIX ................................................................... 967
Cold Start ......................................................................972
Application program guidelines for DispenseTool........ 858
COLLISION DETECTION for AUXILIARY AXIS....602
Application status.......................................................... 901
Color Display According to the Alarm Severity ...........745
APPLICATION STATUS............................................. 958
Comment Instruction.....................................................247
APPLICATION TOOL SOFTWARE............................. 19
Communication ...............................................................33
Application-Specific Soft Panel Function ..................... 630
Concepts........................................................................823
Arguments..................................................................... 223
Conditional Branch Instructions....................................219
Arithmetic Palletizing Register Instructions ................. 210
Conditional Wait Instructions .......................................233
ASCII File ..................................................................... 437
Configuration ................................................................532
Asynchronous Operation Group Instruction.................. 253
CONTINUOUS ROTATION FUNCTION...................515
AUTOMATIC BACKUP.............................................. 461
Continuous Test ............................................................373
AUTOMATIC ERROR RECOVERY FUNCTION ..... 558
Controlled Start .............................................................970
AUTOMATIC OPERATION ....................................... 384
CONTROLLER ..............................................................22
Automatic Operation (Operation Execution) .................. 20
Controller ......................................................................763
Automatic Operation by Robot Start Request (RSR) .... 385
Controlling the Palletizing Function by a Palletizing
Automatic Operation with Program Number Selection
Register .........................................................................724
(PNS)............................................................................. 387
Controlling WET/DRY mode manually........................893
COORDINATE SYSTEM CHANGE SHIFT
BACKGROUND EDITING.......................................... 337
FUNCTIONS ................................................................502
Backing up files ............................................................ 904
Corner adjustment .........................................................784
Bead shaping air (atomizing air) calibration ................. 795
CREATING A PROGRAM ..........................................277
BRANCH INSTRUCTIONS......................................... 217
Creating and writing a new DispenseTool program ......859 Cross Car Mirror Shift...................................................680
i-1
INDEX
B-82594EN-4/01
NOTE Volume 1 : Page 1 to 943 / Volume 2 : P. 947 to 1253 CRT/KB .......................................................................... 33
Effects of seal start offset ..............................................784
CURRENT POSITION ................................................. 408
Effects of using negative gun on ant-time .....................782
Current position display ................................................ 744
Effects of using positive gun on ant-time......................781
Custom I/O.................................................................... 631
Emergency Stop Devices ................................................35
Cycle Time.................................................................... 877
Enabling or Disabling Joint Motion Warning ...............897 Entering Distance before ...............................................542
Equipment ant-time and additional ant-time .................781
Data File........................................................................ 436
Equipment Calibration ..................................................789
Default Logic File ......................................................... 436
Equipment number ........................................................879
Default tool frame ......................................................... 879
Error Codes ...................................................................548
Default user frame......................................................... 878
Error program instruction for DispenseTool .................880
Defining a Resume Program ......................................... 562
Error Recovery (Option) ...............................................905
Defining predefined positions in DispenseTool programs867
Error Status Summary ............................................ 834,919
Definition of FSSB line............................................... 1011
ERROR STATUS SUMMARY ....................................939
DESCRIPTION OF AN ALARM CODE TABLE ..... 1034
ERROR_PROG and RESUME_PROG.........................883
DIAGNOSIS SCREEN ................................................. 998
Example 1 ...................................................................1013
Digital I/O ....................................................................... 43
Example 2 ...................................................................1014
Digital I/O Instructions ................................................. 212
Example 3 ...................................................................1015
DISABLE FAULT CHECKING................................... 963
EXECUTING A PROGRAM................................. 349,357
Disabling the Password Function .................................. 613
Executing Macro Instructions .......................................478
Dispense (seal) end instructions .................................... 880
EXECUTING THE PALLETIZING FUNCTION........721
Dispense (seal) start instructions................................... 880
EXECUTION HISTORY..............................................416
DISPENSE TOOL ........................................................ 762
Execution of the Resume Program from The Teach Pendant
DispenseTool Cell Communication Setup .................... 838
and Test Mode...............................................................577
DispenseTool Cell Controller Error Recovery .............. 854
Extended Alarm Log .....................................................671
DispenseTool Cell Interface I/O Signals....................... 840
Extended Axis .................................................................35
DispenseTool cell interface input signals...................... 842
EXTENDED AXIS SETUP ........................................1022
DispenseTool cell interface output signals.................... 845
External Override Selection Function ...........................390
DISPENSETOOL COMMON SETUP ......................... 764
DispenseTool fault recovery procedures ....................... 886 DispenseTool status ...................................................... 899
FANUC iPendant ..........................................................730
DispenseTool-specific information ............................... 905
Feedrate.........................................................................184
Dispensing Instructions ................................................. 879
FILE INPUT/OUTPUT.................................................420
Display Screen of the Teach Pendant.............................. 28
FILE INPUT/OUTPUT UNITS ....................................421
DISTANCE BEFORE FUNCTION.............................. 532
File Manipulation ..........................................................446 FILES ............................................................................435
Flip Knuckle..................................................................684
Each Item .................................................................... 1000
Flow rate calculation (traditional method) ....................772
Effects of negative bead shaping ant-time..................... 783
Flow rate calculation: 2PNT (two point calibrated
Effects of positive bead shaping ant-time ..................... 782
calculation method) .......................................................774
Effects of pre-pressure time .......................................... 783
Flow Rate Control .........................................................767
Effects of seal end offset ............................................... 784
i-2
INDEX
B-82594EN-4/01
NOTE Volume 1 : Page 1 to 943 / Volume 2 : P. 947 to 1253 Flow rate control calibration ......................................... 790
Initial Setting.................................................................602
Flow type ...................................................................... 772
Initial Start.....................................................................969
Flowchart for Resuming a Suspended Program ............ 573
Input/Output ....................................................................34
Forced Output ............................................................... 377
Inputting Initial Data .....................................................698
FORMAT OF A SYSTEM VARIABLE TABLE....... 1235
Instruction .....................................................................533
FRAME INSTRUCTIONS ........................................... 242
Interference Zone Setup ................................................850 Interference zone setup overview..................................850
Internet Browser Screen ................................................739
General.......................................................................... 602
Interruption Disable.......................................................168
General and application-specific soft panel functions... 894
INTRODUCTION.............................................................1
GENERAL SAFETY PRECAUTIONS ............................6
ISD GEAR METER ......................................................921
Generic dispense process signal timing protocols ......... 785
ISD TRANSDUCER FINE TUNING ...........................934
Generic Dispense system response time at a corner...... 780
GRAVITY COMPENSATION..................................... 605 Group 1 ......................................................................... 835
Jig Mastering.................................................................977
Group I/O ........................................................................ 50
Jog Feed of the Robot......................................................19
Group I/O Instruction .................................................... 216
JOINT OPERATING AREA ........................................142
Group Mask................................................................... 167
Guidelines for using sub type program ......................... 858
Key Switches.................................................................733
Gun on time................................................................... 878
Gun Purge ..................................................................... 821
Label Instruction ...........................................................217
Last cycle time ..............................................................878
Halt by a Hold and Recovery ........................................ 352
Last gun on time............................................................878
Halt by an Emergency Stop and Recovery.................... 351
Last material volume.....................................................878
Halt Caused by an Alarm .............................................. 353
LEDS ON THE TEACH PENDANT............................399
Halt Instruction ............................................................. 244
Limitations ....................................................................908
HIGH-SENSITIVITY COLLISION DETECTION ...... 586
"LINE NUMBER, PROGRAM END SYMBOL, AND
High-Sensitivity Collision Detection ............................ 586
ARGUMENT"...............................................................171
Hot Start ........................................................................ 974
LOAD ESTIMATION ..................................................592
How to display alarm log .............................................. 672
Load Estimation Procedure (for 6-Axis Robots) ...........592
LOAD SETTING ..........................................................588
I/O ................................................................................... 37
Loading a Specified Program File Using the File Screen451
I/O CONNECTION FUNCTION.................................... 82
LOADING FILES .........................................................449
I/O INSTRUCTIONS.................................................... 212
Loading Using the Program Selection Screen ...............449
I/O Link List Screen........................................................ 77
I/O Link SCREEN........................................................... 77
Macro commands ..........................................................853
I/O MODULE SETTING............................................ 1005
MACRO INSTRUCTION.............................................471
IMAGE BACKUP FUNCTION.................................... 467
Maintenance and Repair................................................896
INDEPENDENT ADDITIONAL AXIS BOARD
Manipulating Files ........................................................904
(NOBOT) STARTUP PROCEDURE ......................... 1028
MANUAL I/O CONTROL ...........................................377
i-3
INDEX
B-82594EN-4/01
NOTE Volume 1 : Page 1 to 943 / Volume 2 : P. 947 to 1253 Manual Operation Screen of the Automatic Error Recovery
Operations .....................................................................666
Function ........................................................................ 574
Operator Panel.................................................................32
MANUAL PLAN..............................................................2
Operator panel status display ........................................744
MASTERING ............................................................... 975
OPERATOR’S PANEL I/O ............................................74
Mastering at the Zero-degree Positions......................... 979
ORIGINAL PATH RESUME .......................................674
Material pressure calibration......................................... 804
OTHER INSTRUCTIONS............................................245
Material volume ............................................................ 878
Other Related Matters ...................................................601
Maximum analog out (meter)/maximum meter speed
OTHER SETTINGS......................................................161
calibration ..................................................................... 799
Other Specifications and Restrictions ...........................577
Maximum Speed Instructions........................................ 251
Outline...........................................................................998
Memory Card ................................................................ 424
Outline of the Automatic Error Recovery Function ......558
MEMORY USE STATUS DISPLAY........................... 418
Override Instruction ......................................................247
Message Instruction ...................................................... 247
OVERVIEW .......................................................................
Mirror Shift Function .................................................... 491
17,532,558,586,588,592,618,659,731,763,767,780,789,
MIXED LOGIC INSTRUCTION ................................. 633
840,871,872,879,882,908,921
Model B Unit List Screen................................................ 78
Overview of Automatic Backup....................................461
MODIFYING THE PALLETIZING FUNCTION........ 725
Overview of the Password Function..............................607
Motion........................................................................... 763
Motion Format .............................................................. 175
PALLETIZING ALL-POINT TEACHING ..................728
MOTION INSTRUCTIONS ......................................... 174
Palletizing End Instruction ............................................203
Motion Instructions ....................................................... 257
PALLETIZING FUNCTION ................................. 690,691
Motion of the Robot ........................................................ 35
PALLETIZING FUNCTION WITH EXTENDED AXES727
Motion Performance Screens ........................................ 588
Palletizing Instruction ...................................................202
MOTION Screen........................................................... 605
PALLETIZING INSTRUCTIONS......................... 202,694
Moving the Robot by Jog Feed ..................................... 269
Palletizing Motion Instruction.......................................203
MULTI APPLICATION ............................................... 956
Palletizing Register .......................................................722
MULTIAXIS CONTROL INSTRUCTIONS................ 252
PALLETIZING REGISTERS .......................................407
Parameter Instruction ....................................................248
NEMO PUMP ............................................................... 908
Password Auto Login Function .....................................629
NEMO Pump Status ...................................................... 917
Password Configuration File .........................................618
Nonlinear Flow Model .................................................. 833
PASSWORD FUNCTION ............................................607
Notes on Teaching the Palletizing Function.................. 720
Password Log ................................................................624
Password Operations by Program Users and Setup Users614
OFFSET CONDITION INSTRUCTION ...................... 240
Password Operations by the Install User.......................609
ONLINE POSITION MODIFICATION....................... 392
Perform Automatic Backup...........................................464
Operating Procedure...................................................... 592
Peripheral I/O ..................................................................34
OPERATING THE HAND MANUALLY ................... 382
PERIPHERAL I/O ..........................................................63
OPERATION GROUP DO OUTPUT FUNCTION...... 524
Planning a Program .......................................................858
OPERATION GROUP INSTRUCTIONS .................... 253
PLANNING AND CREATING A PROGRAM............858
OPERATION LOG BOOK (OPTION)......................... 659
PMC EDIT FUNCTION ...............................................656
i-4
INDEX
B-82594EN-4/01
NOTE Volume 1 : Page 1 to 943 / Volume 2 : P. 947 to 1253
PMC MONITOR FUNCTION...................................... 653
Quick Mastering............................................................981
Position Data ................................................................. 177 Position Register Axis Instructions ............................... 208
Position Register Instructions........................................ 207
Recorded Events............................................................662
POSITION REGISTER LOOK-AHEAD EXECUTION
REGISTER INSTRUCTIONS ......................................204
FUNCTION .................................................................. 521
Register Instructions......................................................205
POSITION REGISTERS .............................................. 403
Registering a Program...................................................278
POSITIONER SETUP ................................................ 1016
REGISTERS .................................................................401
Positioning Path ............................................................ 187
Remote Controller ...........................................................33
Predefined Position ....................................................... 259
REMOTE TCP FUNCTION .........................................580
PRINTING FILES ........................................................ 457
Resetting Pulse Coder Alarms.......................................918
Procedure ...................................................................... 999
Restore the Backup .......................................................466
Process Timing Protocols.............................................. 780
RESTRICTIONS...........................................................761
Prog Select Screen........................................................... 94
Resume program instruction for DispenseTool .............881
Program........................................................................... 19
Resuming a Program .....................................................361
PROGRAM AND FILE MANIPULATION................. 904
ROBOT ...........................................................................21
Program Comment ........................................................ 166
ROBOT AXIS STATUS ...............................................992
PROGRAM CONTROL INSTRUCTIONS.................. 244
ROBOT I/O.....................................................................59
Program Control Instructions ........................................ 880
Robot I/O Instructions...................................................213
PROGRAM DETAIL INFORMATION ....................... 165
Robot Motion ................................................................358
Program Edit Instructions.............................................. 314
Robot Service Request (RSR) .........................................87
PROGRAM ELEMENTS ............................................. 871
RSR Instruction.............................................................245
Program End Instruction ............................................... 218
Program Execution Instruction...................................... 252 Program File.................................................................. 435
SAFETY PRECAUTIONS .............................................11
PROGRAM HALT AND RECOVERY........................ 350
Safety signal status display ...........................................745
Program Header Information......................................... 872
Saving all the Program Files Using the File Screen ......440
Program Instructions ..................................................... 590
SAVING FILES ............................................................438
Program Look/Monitor ................................................. 375
Saving with a Function Menu .......................................444
Program Name .............................................................. 165
Saving with Program Selection Screen .........................438
Program Number Selection (PNS) .................................. 90
Screen Restrictions According to Password Level ........626
PROGRAM OPERATION............................................ 332
Screen Selection Menu and Screen Menus on the Edit
Program Pause and Recovery........................................ 883
Screen............................................................................742
Program Shift Function ................................................. 485
Selecting a Palletizing Instruction.................................697
Program status for DispenseTool .................................. 902
Selecting a Program ......................................................299
PROGRAM STRUCTURE ........................................... 162
Setting 1 (FSSB line)...................................................1012
PROGRAM TIMER...................................................... 413
Setting 2 (Number of total axes on FSSB line 1) ........1012
PROGRAM TOOLBOX ............................................... 680
Setting 3 (Hardware start axis) ....................................1012
PROGRAMMING ........................................................ 255
SETTING A COMMUNICATION PORT....................430 Setting a Jog Coordinate System...................................132 SETTING A REFERENCE POSITION........................138
i-5
INDEX
B-82594EN-4/01
NOTE Volume 1 : Page 1 to 943 / Volume 2 : P. 947 to 1253 Setting a Tool Coordinate System................................. 110
Soft Panel ......................................................................894
Setting a User Coordinate System................................. 121
Soft panel overview.......................................................894
SETTING AUTOMATIC OPERATION ........................ 86
SOFTWARE VERSION ...............................................989
SETTING COORDINATE SYSTEMS......................... 108
SPECIAL AREA FUNCTION......................................148
Setting Macro Instructions ............................................ 472
Specification..................................................................532
Setting Mastering Data.................................................. 987
Specification..................................................................586
Setting of Automatic Backup ........................................ 462
Specifying Test Execution ............................................367
Setting Path Pattern Conditions..................................... 712
Speed compensation......................................................767
Setting the Automatic Error Recovery Function ........... 564
Splitting the Screen .......................................................735
SETTING THE GENERAL ITEMS ............................. 159
SPOT I/O SEQUENCE .......................................... 947,948
Setting Up Book............................................................ 665
SPOT MACRO .............................................................952
Setting up Dispense Configuration................................ 926
Standby Release ............................................................380
Setting up DispenseTool cell interface I/O signals ....... 849
START MODE .............................................................968
Setting Up DispenseTool Configuration ................ 764,911
Start Up Methods ..........................................................968
Setting Up Equipment I/O............................................. 815
Starting a Program.........................................................357
Setting Up Equipment Information ............................... 786
STATE MONITORING FUNCTION...........................549
SETTING UP EQUIPMENT INFORMATION............ 930
STATUS DISPLAY ......................................................398
SETTING UP iPendant ................................................. 748
STATUS DISPLAYS AND INDICATORS .................898
SETTING UP ISD I/O .................................................. 927
Status Indicators ............................................................898
SETTING UP ISD INFORMATION ............................ 933
Status Subwindow .........................................................743
Setting Up NEMO Pump Information........................... 913
Status Window ..............................................................734
Setting Up Process Axes ............................................... 909
Step Test........................................................................ 368
SETTING UP PROCESS AXES................................... 921
Sub type ........................................................................875
Setting Up Schedules .................................................... 775
Subtype .........................................................................166
Setting Up Schedules .................................................... 915
Summary .......................................................................580
SETTING UP THE CELL ............................................ 838
Synchronous Operation Group Instruction....................254
SETTING UP THE HANDLING SYSTEM................... 36
SYSTEM CONFIG MENU...........................................152
SETTINGTHE FSSB LINE ........................................ 1011
System File/Application File.........................................436
Setup ...................................................................... 582,671
System Setting.................................................................19
Setup and calibration..................................................... 828
SYSTEM TIMER..........................................................415
Setup Examples........................................................... 1013
SYSTEM VARIABLES................................................411
SHIFT FUNCTIONS .................................................... 484
System Variables...........................................................547
Signal Count Setting Screen............................................ 80
System Variables...........................................................605
Simulated I/O ................................................................ 379
SYSTEM VARIABLES..............................................1234
SIMULATED INPUT SKIP FUNCTION....................... 84
SYSTEM VARIABLES..............................................1237
Single Axis Mastering................................................... 984
SINGULAR POINT CHECK FUNCTION................... 348
Teach Pendant .................................................................23
SKIP CONDITION INSTRUCTION............................ 237
Teach pendant program example...................................852
SOFT FLOAT FUNCTION .......................................... 508
Teach pendant status indicators.....................................898
Soft Limit Setting.......................................................... 687
Teaching a Control Instruction......................................290
SOFT PANEL ............................................................... 630
i-6
INDEX
B-82594EN-4/01
NOTE Volume 1 : Page 1 to 943 / Volume 2 : P. 947 to 1253 Teaching a Motion Instruction ...................................... 285
Warnings .......................................................................579
Teaching a Path Pattern................................................. 716
WELD MODE .............................................................. 954
Teaching a Stacking Pattern.......................................... 705
WORKERS .......................................................................5
Teaching an Supplementary Motion Instruction ........... 287
WORLD FRAME ORIGIN.........................................1004
TEACHING THE PALLETIZING FUNCTION .......... 696
Write Protection ............................................................167
Teaching the RETURN_PATH_DSBL Instruction....... 563
Writing and Modifying a Program ................................859
Test Cycle ..................................................................... 891
Test cycle setup............................................................. 891
XML Syntax for Password Configuration Files ............620
Test Operation (Test Execution) ..................................... 20 TESTING ...................................................................... 366 TESTING A PROGRAM AND RUNNING PRODUCTION ............................................................. 882 Three-Mode Switch....................................................... 263 TIME BEFORE FUNCTION........................................ 526 Timer instruction........................................................... 246 Time-specified Wait Instruction.................................... 233 Timing diagram............................................................. 833 TIPS ON EFFECTIVE PROGRAMMING................... 257 TOOL OFFSET CONDITION INSTRUCTIONS ........ 241 TOUCH PANEL ........................................................... 747 TP Start Prohibition....................................................... 296 Tuning Procedure .......................................................... 603 TURNING ON THE POWER AND JOG FEED.......... 261 Turning On the Power and Turning Off the Power ....... 261 Two point (2PNT) flow rate calibration........................ 809 Type III analog output................................................... 763
Unconditional Branch Instructions................................ 218 Usable Memory Cards................................................... 461 USB Memory ................................................................ 425 USER ALARM ............................................................. 144 User Alarm Instruction.................................................. 246 USER SCREEN ............................................................ 400 UTILITY....................................................................... 470
VARIABLE AXIS AREAS .......................................... 146 Version Management .................................................... 465
WAIT INSTRUCTIONS............................................... 233
i-7
Edition
01
Date
Apr., 2007 Contents
Edition
Date
Contents
FANUC Robot series R-30iA CONTROLLER DISPENSE TOOL OPERATOR’S MANUAL (B-82594EN-4)
Revision Record
