Manual for welding for Kawasaki robot C40F-A021

This are those manuals I have never been able to track down, so if you do have any luck in obtaining one, please share them.

There will likely to be 3 main documents that will be of help using C Controller Arc Weld:

- C Controller Arc weld installation and connection manual - Contains 1GN and 1HW information.

- C Controller Arc Weld Operations Manual.

- C Controller Arc Weld AS Language Manual.

Kawasaki structure used in D Controller is very similar and can be used as a reference/assistance.

I have attached the 3 equivalent manuals.

Regarding weld parameters, this purely depends on the kind of setup you have.

If you have a conventional setup, which uses the 1GN board and 1GW/1HW Analog outputs to and IO connections to the weld power source.

Assuming your setup is wired correctly for the IO control and the current/voltage has been mapped correctly to provide either 0-15VDC or 0-10VDC for the correct values to the weld power source.

However some fundamental understanding of the Kawasaki process and also a weld process is required.

Fundamentally and conventionally, Kawasaki and weld power source exchange IO for control and weld power source receives voltage/current analog values to control voltage/current/wire feed speed.

- Robot sends 'start weld' output.

- Waits for 'current flowing', resends (no retries), if no signal received, error out with arc failure.

- If current flow is received, start moving to WC/WE positions and output signal to weld power source.

- During move, if current flow signal lost, robot will stop, error received, weld power source stops.

- If current flow maintained, WC/WE commands executed using weld condition applied.

- These weld conditions send voltage/current to weld power source.

- WE command also invokes crater settings to send to weld power source to stop welding.

In your backup, you can see the above in the BLOCK programming you have.

AS commands include ARC_SPOTxx No.

WC and WS commands include WELD_CONDxx No.

Weld Condition xx are set in Aux Func 28 for C controller.

So I would try and create a simple straight line program of 5 steps to weld 70cm line.

Assuming the conventional setup has been followed then:

- AC move above the weld start.

- WS move for the weld start position.

- WC move approx 35cm from weld start position - set a weld condition no. ie no.1

- WE move approx 70cm from weld start position - set a weld condition no. ie no.1

- AC move above the weld end position.

Locate Aux Func 28, set weld condition no.1 parameters for weld and crater settings.

Make sure Weld ON/OFF button on teach pendant is set to ON and execute it and see the results.

If using BLOCK, just set Aux 28 Weld Conditions and then allocate which weld condition to use when programming the WC and WE steps.

Alternatively, if you are using AS check out the following commands in the Arc Weld AS Language Manual for correct format and syntax:

LWS, LWC, LWE, W1SET, W2SET