Posts by greenman

Thanks for the feedback.

Perhaps this should be the start of a new thread, but the context of this query is that I am hoping I can use touch sensing to overcome a small challenge. The robot zero plates seem to have been tampered with in the past, and the TCP doesn't stay fixed when rotated about tool TCP. The implication is that I cannot change the tool angle without changing the TCP position.

The BA series robots don't have an available zero kit like the RS series.

This is a video of the TCP shift during angular change

The paint lines on the bolts don't match up anymore, I suspect they were removed and replaced when the robot was painted. Kawasaki told me that some of the blue robots were painted on the production line and others were done after the fact. I think this is an after-the-fact one.

I got the factory zero settings for the encoders, but that doesn't improve the situation. It actually makes the TCP stability worse. I have double-checked the Tool definition, and I tried the automatic tool definition process (repeatedly), but it gave many errors and didn't result in a satisfactory result.

I am going to add a smaller tool to the robot flange (calibration spike) with measurable offsets and then double-check the TCP stability again. The welding tool offsets are very difficult to measure accurately.

As plan B, if I am unable to re-zero the robot, is to try and get around the x,y,z position error by adding an offset to each weld position, into free space, then using SSENS or XAC to detect the exact position of each weld start and end before it is executed. I big cycle time hit for the process.

Reporting back on successful resolution - instead of removing the split, I added in jumpers to X204 cable to pass through the signals.

Temporary fix for the time being. and easier to reinstate cubic-s in the future should I get to that point. But i do need to buy a connector rather than this temporary wire-only solution...

Thanks for all the assistance in this thread.

Thank you for sharing the code. This is very interesting implementation to find the start point for a weld kwakisaki. Considering that the SSENSING option exists and is intended to achieve the same thing. However, as I understand things (so far), SSENSING doesn't shift the weld end-point (to preserve the weld trajectory), and SSENSE also doesn't have the ability to record the amount that the target point differs from the new detected start point.

Therefore, I deduce that without TRPM, SSENSE is not as powerful as the example that you provided above. Have I missed anything in the logic?

I don't have the RTPM board, but would like to shift the entire weld seam by the shift in the start point. I suppose the safest option would be to shift the start point using an adaptation of your example (XAC rather then SSENSE) , and then measure and shift the end-point of the weld seam (with XAC as well). Based on how much difference there is between the start-point shift and the end-point shift, I can decide if using the start-point shift alone is sufficient to shift the end-point and have a successful weld.

It was as you deduced, however, with Fronius job mode there are different ways to specify the welding parameters.

SET_ARC_W1JOBNO 1=1 ;corrolate job number and weld condition number
SET_ARC_W2JOBNO 1=1 ;corrolate job number and weld condition number for crater en end
Set_ARC_WELDMODE 3 ;3 = job mode
SET_ARC_W1JOBCOND 1=38,1 ;weld speed cm/min ,job number
SET_ARC_W2JOBCOND 1=1,1 ;TIME, job number

And it welded away.

thanks for your help...

Now onto start point sensing that doesn't seem to be working... but that is another thread if I cannot get to the bottom of it myself.

Thank you kwakisaki - I will try that.

I was advised by Kawasaki to use the SETCONDW1 and SETCONDW2. previously, I was just using the settings in AUX1401 and AUX1402 to set the weld parameters for the different conditions. But based on your explanation, I suspect I have implemented the parameters incorrectly.

I am using a Fronius welding system in job mode. it is one of 4 possible operational modes. I know that much of this data in the SETCONDW1 and SETCONDW2 (Aux 1401 and 1402) is not used or communicated to the Fronius welding system when using job mode. The Fronius power supply controls it in its job definitions. I may therefore be inadvertently causing the clash by trying to specify data that is not used. I duplicated the job data in both the Kawasaki weldconditions and in the Fronius Power supply, assuming that if it were not needed or used that it would be ignored.

I spent some more time in the manuals and I found an example of job mode, where the unused/unnecessary parameters are all 0. hopefully making the superfluous data 0 will fix my problem.

I will let you know tomorrow if that solves my challenges. Thanks again for taking the time to assist.

I have a welding robot and I have been welding in block step without problem. Robot motion instructions are specified with AC (air cut). WS (weld start), WC, (weld continue) and WE (weld end).

I now want to move to implement the code that I have been testing in K-Roset, which uses the AS language. But I get Error E1102 -

This Code creates the error:

Jappro testpoint1,200

setcondw1 1= 31,500,1,1,0,0,1
setcondw2 1= 1.5,1,550,0,1
LWS testpoint1
LWE testpoint2 ,1,1
Ldepart 200

This code in block step works fine:

AC JOINT SPEED4 ACCU4 TIMER0 OX= WX= #[93.479,39.738,-124.75,101.16,-62.735,-127.57,0] ;
WS LINEAR SPEED4 TIMER0 OX= WX= #[88.229,47.754,-122.92,109.47,-63.288,-134.58,0] ;
WE LINEAR WELD_COND1 OX= WX= #[88.319,46.178,-127.01,110.53,-64.153,-137.21,0] ;
AC JOINT SPEED9 ACCU4 TIMER0 OX= WX= #[92.957,39.02,-128.77,103.3,-63.305,-131.21,0] ;

I feel like the error indicates that there is an option that Kawasaki needs to assist me to turn on? I cannot find anything more than the Error text int he manuals, and my internet searching hasn't helped, yet.

Does anybody here have any ideas?

Thanks

Quote from ArcadeMachinist

Here is the pic before I removed it.

I have no idea how you reached down there to disconnect it. I tried unsuccessfully to remove the Power unit to get underneath it. I dropped a screw that took me ages to recover. Eventually, I resorted to the wiring diagrams and added jumpers to the plug on the branch - not a long-term solution as the jumpers are not held in place by anything more than friction. but it will do until I can source a plug and crimp the connections - but it worked and the robot is functioning. Thank you for the assistance.

Quote from ArcadeMachinist

The weird thing is I get "Torch interference" error on every power on.
It can come immediately on boot or 2 minutes later, robot is not even moving.
After resetting, it does not pop up again.

Sorry, I am a bit late to this thread. As you discovered, all Fronius communication is over ethernet. and Fronius has a torch collision detection mechanism with a magnetic connection between robot and the torch. If the torch collides it breaks the magnet pair, and the "torch interference" signal is given. Without a torch, or more specifically, without the torch side of the magnet pair, the system will always detect the "torch collision", as the circuit is always broken.

Without any ethernet comms, and therefore nothing to tell you that the magnet circuit is good or bad, I assume that the "torch interference" is by default 'high'.

Nice to read about "setting to 1000" being an override option - I didn't know about that.

Quote from ArcadeMachinist

X204 is branched, you need either remove the branch or figure out Cubic XIN_1 and a loopback for "SAF1", which might be a challenge. I did remove that extra cable.

I tried hard to find this in my controller. But I guess we have the same thing, but different. I traced all wires from XIN1 and SAF1 and didn’t find a 204 spliced cable as per your post. Either it’s just late in the day (possible) or the harness is different in my controller.
Might be the case, as my SAF2 as connected to cubic-s. And you mentioned yours was just an empty harness inside?
I made a video trying to explain the harness as I understand it.
Thx

Quote from kwakisaki

Of course, that is not checking the umbilical to the arm if it was jumpered controller side.

I did the responsible thing and replaced the faulty wire so it still does the check on power up to confirm that the cables are all connected correctly. Thanks for the explanation.

I feel a little bad that I didn’t actually find the cause of the fault. That wire shouldn’t just fail. I just fixed it without actually diagnosing the fault.

Quote from ArcadeMachinist

X204 is spliced.

Half going to external SAF1 XRTGC_n pins, half to Cubic-S XIN_1

What did you replace the 204 splice with?

Replaced the offending wire and no more errors.
Yay…

But, something I have never seen before… when I try move the robot with the TP I get

“Turn on trigger”

All I can find in the manuals is P1046 : turn on trigger switch.
If anybody has some hints for me? Ta

Found this thread. But it’s on a different robot and controller. Although the symptoms sound similar. And I have cubic s in the mix as well, although I thought I had disabled it.

Thank you kwakisaki located all the pin outs and wiring diagrams. Checked all connectivity at all steps and …

between pin1 of X314 and pin 69 of X4 there is no connection.
Pins 69 and 70 are jumpered in the robot base. So it seems they are simply to check the cable isn’t sheared. There is no temperature check in this system.
Is there a good reason not to jumper it directly at x314?

An afternoon of trial and error circles - I still have one error.

after disconnecting the 7th axis in AUX2002 and loading the new MOD file for the 8th axis which is configured for the 5kW motor - I still have the error that I started with.

E1342 – motor harness disconnected or robot temperature exceeded the limit. (MC1)

MC1 I thought referred to the external motor - and there is no thermal line to the RTU.

I guess I need to look for a thermal line in the arm. So I need to search for a Pin layout for plugs X3 and X4 to see which is the thermal line.

X314 disappears into the depths of the controller - so I don't know where it goes...

I couldn't attach a save/full of the current status.

Any assistance is appreciated.

Loaded up with aux function - it asked what axis - I said 8 and got an error... There isn't an 8th axis.

Used the maintenance code to change the configuration to 8 axis, power cycle, now it can load to axis 8, but axis 7 gives me the usual set of errors.

E1496 – JT7 axis servo parameters data does not support connected power block

E1501 – JT7 code set in software do not support power block or servo software

D1500 – Encoder misread error JT7

E1035 – encoder response error (JT7)

With an additional E0903 check sum error of system data that will not reset with AUX 0803 - [cannot clear check sum error, check the following command or auxiliary data, ZZERO (no zero for the new axis 8 perhaps?

Indeed - zero'd the 7th (non existent) and new 8th axis and was able to reset the checksum error.

Now to figure out how to remove the ghost 7th axis...

Anybody got suggestions?

Breaking news - Kawasaki have sent me a new file for the configuration.

5.0kW MOD File for RTU EUR502ENT.

They confirmed it would be for Channel 8 (as axis to use with the external 100A KHI amplifier (internal axis 7 is only 30A, so the 5kw motor is too large)

They didn't tell me if it needed to go anywhere special, or if anything other than KRterm is needed to load it... fingers crossed...

seems I can only insert two images per post.axis parameter page

7th axis on the main board and 8th axis as a separate KHI amplifier that goes to the RTU.

Update time...

recap:

• I have disabled and bypassed cubic S,
• as well as initialized the system (Controller off – dip_switch 8 to ON on the comms board, power on, initialize to 1 (system initialize), power off, Dip switch 8 back to OFF, power on)
• to remove the previous owners code without deleting the robot setup.
• i jumpered x313 A1-B1 to remove the need for motor on feedback from the RTU same as ArcadeMachinist ) (I did it on the 26 pin SAF1 plug that I have fly lead for)

I am struggling and now need to reach out for assistance again.

I thought my issue was due to the external axis not being connected. But I got the necessary harting plugs (its own saga) and it is now connected up but still the error persists.

I can get it to two different error sets depending on the channel that I assign to the external axis on this page–

For channel 7 – I get 4 errors encoder and software/configuration

E1496 – JT7 axis servo parameters data does not support connected power block

E1501 – JT7 code set in software do not support power block or servo software

D1500 – Encoder misread error JT7

E1035 – encoder response error (JT7)

For channel 8 (the one I think it should be) I get 1 error –

E1342 – motor harness disconnected or robot temperature exceeded limit.

The troubleshooting manual pg 3-152 - 90206-1045DEN implies that it is in the robot arm - so i might be looking in completely the wrong place. And also not sure where to begin looking for a thermal line in the robot motor harness. But the fact that changing the external axis channel makes it go away makes me think I am looking in the right place. but there is no thermal line in the RTU motor harness, only 3 power phases and 2 brake wires. The encoder has 6 wires that plug into the board, I just maintained the 1..6 labels.

The X314 pair of wires disappear down into the depths of the controller and I cannot follow them. so I don't know where they go...

Something that will no doubt be my next challenge... I am a little perplexed by the axis/joint labels/numbering.

The servo amplifier has 7 axis that go into the robot power plug x4 (x551-7) but I don’t know what the 7^th axis might control on the robot, its only got 6 axis.

Then I also have P/N 50607-0128 R02, external axis KHI amplifier for Kawasaki that goes to the external axis. I believe this is designated JT8? (pg 6 of the external axis addition manual 90210-1292DEC)

The robot had this axis on a rotary axis initially (pic below)– and I need to re-configure it for the linear axis of the RTU. Which I started to do - I am not yet sure how to get the mm/bit as I have no info on the encoder (yet).

robot-forum.com/attachment/40705/

The external axis addition manual (90210-1292DEC) indicates that I should contact KHI for the correct settings, Which I have done.

robot-forum.com/attachment/40704/

The RTU has

Motor 28 (50601-0128) R2AA2250ALCPKL5 kw

I was unable to find any information about the encoder – but it has a separate box that looks like a battery backup. I have not checked the battery status yet… 6 wires in and only 4 onwards to the encoder. I just maintained the 1..6 lables when connecting to the E01 controller. Tracing the wires in the controller they appear to go into the Jt7? encoder plug

As a last resort – should I consider removing the 7^th axis completely from the system to be able to get the welding system commissioned and working in pararobot-forum.com/attachment/40704/robot-forum.com/attachment/40705/llel with getting the RTU functional? I haven't dug into how I would achieve that, as I would just have to undo it all afterwards.

kwakisaki I restored the original configuration as you suggested I try, but there were 28847 errors in it.

, and at least 4 pages of system errors on the TP .. so I immediately initialized the controller again and went back to my two options of 1 error for channel 8, and 4 errors for channel 7.

Thanks - J

Well done ArcadeMachinist .

I have some wiring diagrams you might be interested in... one is attached - if you are going to use a Fronius welding system I have two more docs you might be interested in.

I am still struggling with the RTU 7th axis that might actually be designated an 8th axis. I am about to post an update to my thread.

Project update just as a FYI -

The plan is to connect up the 7th axis to remove the MC1 error before restoring the backup and tackling the remainder or the errors - I will also connect up the external systems as per the traced wires for the external plug, and wiring diagram that I was able to source for the original project (lots of time on the phone). And order and install the missing welding equipment for the system.

Plan A (and plan F) - I identified the part numbers for the motor and encoder cables for the RTU and have a quote in hand from Kawasaki - 120 day lead time for the cable set.

Plan B - I approached Harting for just the connectors to replace the incompatible plugs on the RTU cables and wire in correct plug pair. - 16 weeks lead time from Europe.

Plan C is to go back to Kawasaki for just the connectors - they are used elsewhere on my robot, so I am hoping they have them as singles, not as a cable sets (long shot).

Plan D is to replace the controller connector as well as the wire hood with a pair for each connection from Harting. (not ideal with unnecessary work)

Plan E (in parallel with plan D) - scour the internet for compatible plugs (if anybody reading this in North America knows of sources with large stock please ping me - Digikey is my first stop this morning.

Plan F - execute plan A and wait 120 days for cables from Japan.

Here is some info on the connectors for those interested:

Han 3A-gg-M25 | HARTING Technology Group

And the insert as well.

Han Q 7/0-M | HARTING Technology Group

similar issues with the motor power plug

Han CD module, crimp male | HARTING Technology Group

Han 10A Halterahmen für 1 Modul | HARTING Technology Group

Han A Hood Side Entry HC 2 Pegs M25 | HARTING Technology Group

It’s the partners that plug into these on the rear of the E01 controller -