Posts by tomcat955

    Hello, I have a couple kawasaki zx200s on d controllers that do not have the arc welding firmware and kawasaki says the firmware was never made for this series of robot... I would like to convert this robot to arc weld particularly mig weld. Has anybody done similar, used robots without arc welding firmware to arc weld? How did it work out for you?

    Its actually a d series control but i think im still stuck in the same boat of no firmware, well i have 2 c controllers aswell but those robots need to be messed with to get running. I reached out to Kawasaki waiting to here back im going to assume I will be out of luck there. Really the issue im having here is I dont know how to control the machine fluidly, I can pick a set of points for the robot to drive along and set the speed with my 1-10 option, but it stops and takes a pause in-between each step. how do I control the movement speed more accurately and keep it from stopping at each point. , is there a way to define a pattern? I was hoping that the arc welding firmware would be better set up for it and solve these issues. Im really not to worried about changing voltage and wire speed... I think worst comes to worst if I was welding different thicknesses of metal together I could set the program to stop before the next weld so I could change the wire speed and voltage manually. Id really like to continue with this project, it would be amazing to have robots in my shop and the coolest thing ever just feel kind of frustrated, but maybe the robot can do these things and I'm just ignorant. Would learning AS programming solve this or is there a way to easily do it on the teach pendant.

    Hey so after doing a lot of research and some planning I have a couple questions. Do you think it’s viable to convert a robot to a arc welding robot? Would I be able to update the firmware/buy a weld controller board if I don’t have one. Seems there’s a lot to be desired in the arc welding firmware. I’m not sure how I would program it to make it weave otherwise. I really like these robots because of the size, but if this is just a big waste of time and in the end I’m left with a robot that can’t weld id be disappointed. I had a good month so I’m able to raise the budget a little for the project and was looking at buying a purpose built used robot welding power supply vs converting a old Miller cp-200 to be mounted to the end and using the io signal to basically replace the trigger of the mig gun. My concern here is that I’m going to do all this work and it will be extremely difficult to program. What variables does the robot work with when arc welding? How smart are the robots? Can they increase wire speed voltage and distance from part automatically to optimize the weld?

    I’m a little bit of a newbie here so pardon my French, but I have a couple of old Kawasaki zx200s I play with mainly for pleasure. I started to use chat gpt4 last night and had the brilliant idea of uploading the Kawasaki programming manual to it and it was able to write me lines of code for whatever simple task I asked it to do. I also noticed that chat gpt is efficient at recognizing what is in a photograph. I have not messed around to much with it been super busy keeping the lights on at my shop but this really sparked my curiosity. I don’t think chat gpt could control the robot directly live time but it could tell it where to go in essence and maybe write the code. For example a welding robot could be set up to take photos of the part and chat gpt could identify welded joints and where would be smart to weld them. What are your 2 cents on this topic? How are ai and vision systems currently integrated for industrial robots? Maybe at some point it will get so advanced you could plop a part into a jig say “hey Siri can you weld my part up”, it will ask you in a ai voice “I have came up with these potential tool paths to weld do you approve” and it would shine lasers to represent welded joints or show on a pc screen then go ahead and weld it all up. :thinking_face: :face_with_tongue:

    Thanks kwakasaki I’m sure I will have a lot more questions as the project progresses and for that I am extremely grateful you are a member of this community. For now I will leave you with a little film I created, it’s a little unprofessional and does not quite meet the etiquette of the forum little dangerous and abusive on my 50k hour robot but you may enjoy it. Enjoy…

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    I was not planning to do any of that, If there's a error in the source the robot can just keep running. I understand this is not the best way to do it, the best way to do it would be to buy a new robot set up to do this.... My robot has the io boards to weld I dont know to much about it maybe i can plug in a robot welding supply maybe I am wrong.... I have some old regular welding power supplys around my shop with separate wire feeders I could mount on the back of the arm and machine a tool holder to hold the gun. I will pre set the wire feed speed and amperage to what i am welding, really I never mess with it to much when im welding by hand aslong as the material is similar thickness. I just need to figure out how to program the robot to drive to the position where it will start welding, give a output signal to a relay to turn on the welding gun. follow along a predetermined weld path at a predetermined speed. then turn off the welder gun and move to the next spot. I am not concerned to much about detecting errors, or changing wire speed and amperage thats all a luxury and if im making the same part over and over Im sure I could work out the bugs. If you have a better idea to remain in a reasonable budget please let me know, maybe I am better off fixing painting and selling my army of kawasakis and trade in for a already set up welding cell. The reach of the zx200s is pretty sweet though.

    Okay so my robot has been running good, ive done alot of messing around with it teaching it basic programs and smashing beer cans after hours, appreciate the help getting it going... Id like to set it up to mig weld, My idea is to just hook the switch on the welding gun to a output signal and fabricate my own mounts to hold the gun. not the best way to do it but I think would work. What do you recommend is the best way to program it? basically so it stays slow and consistent when welding the bead. seems like block teaching is more for picking and placing.

    I think I figured out how to bypass the safety fence. Maybe someone will read this and it will help them not much comes up searching the forum. Jump terminals 1-2 and 3-4 on the terminal block connector x8 on the 1kp board. I found a copy of the I/o manual as well.

    Okay so I solved all of the servo gun issues did a initialize again selected 999 this time to bring it back to factory zrobot to select factory setting, was able to write steps. Once I set the robot to repeat I have a mismatch of safety circuit fence condition failure I checked the manual it lead me to 1kp board and stated I need to check the io manual for further circuit. Do you have the io manual or know what circuit I should be looking for to bypass? I’m also starting to think too that my other failure could be caused by 1kp board slowly failing maybe why it has problems when it’s first turned on. But I will just leave it running for now overnight. :smiling_face:

    Other then the not starting issue, I also have a issue with recording steps when ever I try it states Gun of CC is not servo weld gun. Can’t find much in the manual about this, I tried setting all the setting in the aux to 0. I think it’s keeping it from creating a step because it still thinks it has the servo gun. Any way to bypass or disable it? Thanks

    I got it powered up and got it to jog around zeroed it out etc your right I need to do more reading. Been studying it. Just is a lot to take on Ive been living in a 3axis world and we all gotta start somewhere. I am having a odd issue I have been having from the start. Sometimes the robot when powered up especially after sitting it will get stuck at the Kawasaki boot screen. I fixed it previously by turning it on and off a bunch of times, now that seemed to stop working and I am stuck at the Kawasaki boot screen. It’s not a issue once it’s been on and running seems like only when the machine is cold? Maybe a relay? Normally when it starts good I here some fans power on sounds like it’s a jet engine taking off not when it get stuck.

    Turns out the Ethernet cable going from the inside of the cabinet to the outside was not allowing it to work, I bypassed the cable plugged directly into the board and now it can connect, any advice on taking backups I’m connected to krterm messing with it right now with my friend.

    Okay so I have been trying to connect the past few days. The IP adress on my controller is and subnet mask is

    I changed my lan settings to those numbers and when I try to connect I get a error. Any advice here? I tried to change the ip adress on the controller to the default ip listed in the guide still did not work.

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