Posts by jstavevene

    Hello,
    I recently got a call from a division I have not worked at in over a year, they have a mrc welding machine they wanted to fire up.
    Nobody took my advice about keeping power to the machine and they shut it all down and off.


    So I took a look, I am checking the deadman switch right now as we speak.


    Normally, I make sure the safety doors are closed, and that all the sensors are green and nothing to it, throw it in teach turn on servos, and master job call and they are rolling..


    I really like these old motoman machines, but when they go down, and people have no documentation at all, it sucks!



    Does anyone have any tips or advice about troubleshooting? (I at this moment can not get the stations to reset?
    no obvious errors to clear (am not sure I am looking in all the right places, I I went from NX, to XRC, to MRC ,,,(started in erc's, then went to IGM,s so).



    (I am pulling out voltmeters and looking, at switches for continuity)
    I also am thinking battery issues are gonna be part of this.
    Also I just noticed the shock sensor even when the head is jostled its lit like its in place? (wondering if someone shorted around it?),,,this worries me.



    _____________update-----
    Verified the dead man switch, appears good.


    So on the the holding circuit?



    Thanks!

    In theory, most anything with a ethernet card should be networkable in such a manner, however in practice motoman does not, much more then recomend their own SDK kits, and maybe if you know a tech or programmer they may have some advice. (I would try anything once, but would not bet the bank on it) Motoman is notoriously proprietary, but times change, and I think I would encourage everyone to try any and all alternatives, (but if a boss or customer is on my back I would say its motosim,, or moto programs,, only but,,,, in my own I want other software,, and would like open source stuff...) I wish you good luck, and yes I would try it.. (famous last words).

    I am unsure of abb, but IGM and motoman's you pull the robots parameter files and put those into the offline programs,,, that usually gets us most of the way there (did you do that?) How far off are the points and positions?
    Which programs are you using? (and version)?

    I actually have met Ed Craig, incidently,,, a scary good gut (hard to find a welder who can program, and it is that order I think he likes to be referred as) . (He worked for corvette, ford, chrysler, and I think he did pipe and nuclear water jackets,,(million dollar welds),,,

    This is a terribly old topic, has anything changed? Are there any connectivity solutions not listed here? are these still all flaky? (I just tore into 4 xrc's today, and am a plc guy but starting to think pc based might have too many advantages now, especially for (IGM we had we could direct connect on the network and push or pull files robot,,to server,,to workstation and back and forth,, kept my offline on workstation, my backups on server,, and could load them without opening doors, covers, or stopping production.. (could message operators from pc also,,,) (and we thought that was primitive,) Motoman's I have seen linked with (device net?) to small touch screen pc's in control pods which could do some things, but still very archaic,, (I do like the backing up on pcmcia cards on motomans, but I see most of our people are so scared to work with these that they may damage them that its easier to weld by hand then program, and try to run through,, (a real shame, I am trying to change). (any tips on that? how to better network the machines, and get the people more involved?)

    YAY! I found a possible backup from a controls guy (I am not sure if this man initialized these or not,, but looks like his work was butchered, (these machines do not have the parellel start option,, (this may be a orginal motoman example? or ? but I like this,, and think this might be something I can splice and call my own jobs into,,, maybe)..(if I can restore this, does this look okay?) (I would like to have part numbers as job names then just call them in ,, (maybe later set up variables to change what job is called so operators can do changeovers,,) 1992 predates the xrc's so this was erc originally coded on?)



    here is some of the jobs,,


    main job below,,
    /JOB
    //NAME MAIN
    //POS
    ///NPOS 1,0,0,0,0,0
    ///TOOL 0
    ///POSTYPE PULSE
    ///PULSE
    C00000=-33,-58257,-130774,-164,38734,829
    //INST
    ///DATE 1992/01/22 23:44
    ///ATTR SC,RW
    ///GROUP1 RB1
    NOP
    MOVJ C00000 VJ=20.00
    DOUT OT#(25) OFF
    DOUT OT#(26) OFF
    DOUT OT#(29) OFF
    DOUT OT#(33) ON
    *LOOP
    CALL JOB:A_SIDE IF IN#(25)=ON
    CALL JOB:B_SIDE IF IN#(26)=ON
    TIMER T=0.10
    JUMP *LOOP
    END


    side a
    /JOB
    //NAME A_SIDE
    //POS
    ///NPOS 14,0,0,0,0,0
    ///TOOL 0
    ///POSTYPE PULSE
    ///PULSE
    C00000=-35,-58270,-130798,-165,38729,829
    C00001=-23223,-58270,-90935,-165,38728,829
    C00002=-53290,-54561,-96191,-23577,46584,19658
    C00003=-53351,-48598,-108700,-36702,55891,27214
    C00004=-56216,-44380,-105048,-39222,55297,29341
    C00005=-51728,-53239,-105376,-25977,51401,21119
    C00006=-8715,-63179,-91238,6638,35489,-6105
    C00007=-53290,-54561,-96191,-23577,46584,19658
    C00008=-52084,-46336,-105501,-29733,54688,23662
    C00009=-55526,-41622,-101564,-32710,54253,26212
    C00010=-52370,-54711,-106795,-26223,51048,21381
    C00011=-33496,-75784,-121763,-10088,50299,8025
    C00012=-9068,-84404,-102584,260,21981,2018
    C00013=-35,-58270,-130798,-165,38729,829
    //INST
    ///DATE 1992/01/24 16:23
    ///ATTR SC,RW
    ///GROUP1 RB1
    NOP
    MOVJ C00000 VJ=20.00
    '********************************
    '********************************
    '********************************
    'START ROBOT 2 A SIDE WELD 1
    DOUT OT#(25) ON
    WAIT IN#(27)=ON
    WAIT IN#(29)=OFF
    WAIT IN#(32)=OFF
    DOUT OT#(25) OFF
    '********************************
    '********************************
    '********************************
    'START WELD 1
    MOVJ C00001 VJ=20.00
    CALL JOB:ENTER_ZN
    MOVL C00002 V=250.0
    MOVL C00003 V=250.0
    ARCON AC=290 AV=20.0 V=5.5
    MOVL C00004 V=8.5
    ARCOF
    MOVL C00005 V=84.7
    MOVL C00006 V=250.0
    CALL JOB:EXIT_ZN
    'WELD 1 FINISHED
    '********************************
    '********************************
    '********************************
    'WAIT ROBOT 2 A SIDE WELD 1 DONE
    WAIT IN#(25)=ON
    'START ROBOT 2 A SIDE WELD 2
    DOUT OT#(29) ON
    WAIT IN#(29)=ON
    DOUT OT#(29) OFF
    '********************************
    '********************************
    '********************************
    'WELD 2
    CALL JOB:ENTER_ZN
    MOVL C00007 V=250.0
    MOVL C00008 V=250.0
    ARCON AC=290 AV=20.0 V=5.5
    MOVL C00009 V=8.5
    ARCOF
    MOVL C00010 V=84.7
    MOVL C00011 V=84.7
    CALL JOB:EXIT_ZN
    'WELD 2 FINISHED
    '********************************
    '********************************
    '********************************
    'WAIT ROBOT 2 A SIDE WELD 2 DONE
    WAIT IN#(32)=ON
    MOVL C00012 V=84.7
    CALL JOB:CLEAN
    MOVL C00013 V=211.7
    END


    side b
    /JOB
    //NAME B_SIDE
    //POS
    ///NPOS 4,0,0,0,0,0
    ///TOOL 0
    ///POSTYPE PULSE
    ///PULSE
    C00000=-35,-58270,-130798,-165,38729,829
    C00001=49436,-63180,-91241,6638,35489,-6104
    C00002=49436,-60301,-107133,7900,44286,-7122
    C00003=-35,-58271,-130801,-164,38729,828
    //INST
    ///DATE 1992/01/23 21:30
    ///ATTR SC,RW
    ///GROUP1 RB1
    NOP
    MOVJ C00000 VJ=20.00
    '********************************
    '********************************
    '********************************
    'START ROBOT 2 B SIDE WELD 1
    DOUT OT#(26) ON
    WAIT IN#(28)=ON
    WAIT IN#(29)=OFF
    WAIT IN#(32)=OFF
    DOUT OT#(26) OFF
    '********************************
    '********************************
    '********************************
    'START WELD 1
    MOVJ C00001 VJ=20.00
    TIMER T=5.00
    'WELD 1 FINISHED
    '********************************
    '********************************
    '********************************
    'WAIT ROBOT 2 B SIDE WELD 1 DONE
    WAIT IN#(26)=ON
    'START ROBOT 2 B SIDE WELD 2
    DOUT OT#(29) ON
    WAIT IN#(29)=ON
    DOUT OT#(29) OFF
    '********************************
    '********************************
    '********************************
    'WELD 2
    MOVJ C00002 VJ=20.00
    TIMER T=5.00
    'WELD 2 FINISHED
    '********************************
    '********************************
    '********************************
    'WAIT ROBOT 2 B SIDE WELD 2 DONE
    MOVJ C00003 VJ=20.00
    WAIT IN#(32)=ON
    END



    zn
    /JOB
    //NAME ENTER_ZN
    //POS
    ///NPOS 0,0,0,0,0,0
    //INST
    ///DATE 1992/01/23 14:59
    ///ATTR SC,RW
    ///GROUP1 RB1
    NOP
    '********************************
    '********************************
    '********************************
    'WAIT ROBOT 2 CLR OF ZONE
    WAIT IN#(33)=ON
    DOUT OT#(33) OFF
    TIMER T=0.30
    WAIT IN#(33)=ON
    END



    zn out
    /JOB
    //NAME EXIT_ZN
    //POS
    ///NPOS 0,0,0,0,0,0
    //INST
    ///DATE 1992/01/23 14:59
    ///ATTR SC,RW
    ///GROUP1 RB1
    NOP
    DOUT OT#(33) ON
    END


    cleaner
    /JOB
    //NAME CLEAN
    //POS
    ///NPOS 13,0,0,0,0,0
    ///TOOL 0
    ///POSTYPE PULSE
    ///PULSE
    C00000=-47530,-63002,-85032,-22633,30749,22399
    C00001=-96789,-38830,-82271,-42179,22767,45221
    C00002=-96789,-34370,-89693,-44527,26671,48096
    C00003=-96789,-38830,-82271,-42179,22767,45221
    C00004=-92415,-48225,-91700,-41717,24042,43576
    C00005=-92633,-43164,-100436,-44637,28487,47010
    C00006=-92397,-42781,-100495,-44762,28747,47077
    C00007=-92660,-43319,-100311,-44567,28382,46941
    C00008=-92441,-48205,-91830,-41743,24077,43615
    C00009=-97997,-29019,-70594,-42266,22379,45648
    C00010=-97997,-25430,-77150,-44195,25704,48069
    C00011=-97997,-29019,-70594,-42266,22379,45648
    C00012=-32072,-54021,-76020,-19205,27698,14297
    //INST
    ///DATE 1992/01/24 15:10
    ///ATTR SC,RW
    ///GROUP1 RB1
    NOP
    MOVJ C00000 VJ=20.00
    CALL JOB:ENTER_ZN
    MOVL C00001 V=250.0
    WAIT IN#(8)=ON
    MOVL C00002 V=100.0 PL=0
    DOUT OT#(6) ON
    TIMER T=0.50
    DOUT OT#(5) ON
    TIMER T=2.00
    WAIT IN#(8)=OFF
    DOUT OT#(5) OFF
    TIMER T=2.00
    WAIT IN#(8)=ON
    DOUT OT#(6) OFF
    TIMER T=1.00
    MOVL C00003 V=250.0
    MOVL C00004 V=250.0
    MOVL C00005 V=250.0
    MOVL C00006 V=50.0 PL=0
    PULSE OT#(191) T=0.50
    TIMER T=1.00
    DOUT OT#(7) ON
    TIMER T=0.50
    DOUT OT#(7) OFF
    TIMER T=0.50
    MOVL C00007 V=16.7
    MOVL C00008 V=83.3
    MOVL C00009 V=83.3
    MOVL C00010 V=83.3 PL=0
    DOUT OT#(8) ON
    TIMER T=0.50
    DOUT OT#(8) OFF
    MOVL C00011 V=83.3
    MOVL C00012 V=250.0
    CALL JOB:EXIT_ZN
    END

    Remote mode is more primitive than that even. (I think you can only control some very simple and basic commands, like start, stop and maybe on newer ones forward, and backward and servo on,, (I do not think much control can be done in remote, maybe a elaborate setup possibly but I have never seen one)..

    Uhm has anyone here used offline programming from IGM for IGM robots?
    They used a hybrid of 3ds max, and dll's you could take a solidworks fixture, clamps, and parts, then load them into a virtual cell, then step through welds,, and play back in a simulated or sped up time, (we used them to help determine bids for contracts),, I suspect there is more then one way to skin this cat, motoman, I like,, I use,, I am still learning,, but they do not share manuals,,or passwords or anything ,,they gouge customers ,,(yet they keep selling so they must be value),, uhm I like the idea that open source is free, and tailored as needed,, I like the idea a educated customer will be better for the robot,,, and the companies who use them,,, I have experienced a competitor walking into our company,, then copying our work,, so I know this,,personally,,, If,,a customer can make a working open source 3d graphic program which can translate ,,that into inform language,,,or whatnot,, and then they can write a transfer software to communicate with robot,,, I say COOL!! Motoman has neutered techs,,and small companies,, (they are getting a little better with sharing some manuals,, but I work for a nonprofit right now,, and paying more then 12k for basic programming classes for a couple people is ,,painful! and Motoman,, could make tutorials free,, software,,free,, manuals free,,, then when people play with the offline programming and see how easy it is or well it works,,, this would make them a much bigger power! (where I am tween 3 companies we have 32, and 39, and 7 more systems,, ) we like the motoman machines,, this,,, would make them more attractive,,, (handicapped people loading and unloading welding robots, for 7) the 32 and 39 are local atv for profit manufacturers,, but we all like them,, but I think we need to support some linux and or open source solutions on these,,,, sometimes I feel like corporate types are trolling this forum so I do not post at all,,,well

    Nope, there is supposed to be a laptop, (older with pcmcia slots,,) but has possibly disapeared.
    I will need to key it all in on the machine, ( I will start shopping for a usb adapter to pcmcia)


    but the gist is similar to:


    Dout 26 OFF
    Dout 27 OFF
    Dout 30 ON
    *Loop
    IF I 26 Call 084 sub
    IF I 27 Call 085 sub
    Jump Loop


    I will copy down what they currently have (which is not working) then read some more and look for some examples, (we at another shop would use index switches for our variables,, operator would dial in job based on what the switch was,,later we added small allen bradley pc's running wince which would send variables to set jobs,, so we had a vary generic main job and spent our time on the called jobs,,,
    I have not mucked about with this in a long time..

    Hello, I recently rejoined a former employer who bought 7 or so motoman xrc's and a mrc.
    I am having a devil of a time, I got into them, and was able to write subjobs just fine (welding) but the Main jobs are very bad, and cycle wrong, (the worst is actually acting like the switch (25 and 26) are shorted,, the machine will run perfect stepping through, or if I play with the cycle but the momen its in auto it just wants to do the called job continually! (I think the previous programmer had some variables in strange places and am not sure what he was thinking) Maybe I can write a new Main Job?


    XRC 2 arm machines mostly, arm type is YR UP20M with a UP20m Controller.