Posts by kwakisaki

    If you are in Teach Mode and using JOINT Interpolation and your problems are occurring, then it points to incorrect zeroing or the motion limits have been changed to below where the robot joint angles actually are (Joints are outside of their software limits).
    - Check the axis monitor screen on the Teach Pendant and see the joint angles or alternatively use KRterm and type in WHERE.
    - I suspect 2/3/4 are all outside of their motion limits - resulting in only the opposite direction of travel.
    - Using BASE or TOOL moves ALL the joints - So if they are incorrectly zero'd, then the errors you receive are inline with what I would expect.

    If the angles displayed are outside of the limits, then you will need to re-zero the joints affected using the 'scribe' lines on the robot (these are for zeroing = mechanical zero degrees).
    - Question is what has caused this...........loading data, incorrect zeroing......
    - Easiest way is reset the encoder rotation count of the specific joint, to 0 degrees at the current position = should enable you jog the joint to align the scribe lines.
    - Then re-zero at the scribe lines correctly in 2 parts in the correct order:
    a. Aux 503 - Encoder Rotation Counter Reset for the specified joint to 0 degrees.
    b. Aux 501 - Zeroing the specified joint to 0 degrees.
    - You have to do both parts, in the above order.

    Regarding the home position error - sounds like you are not typing in the correct command:

    Hope this helps...........

    - I have never used it, but according to the manual for general fieldbus it does exist for D Controller.
    - Appendix D - uses Anybus Slave Ethernet/IP Adapter Card for Modbus/TCP.
    No idea if it's actually available/works.......

    That error is usually related to 'external axis limit switches' which may have been added at some point, or do not exist at all.
    - These are usually visible on the external body of the arm.
    - Even if these switches are not fitted, these lines are still monitored and originate from the controller out to the arm via X3/X3A (see troubleshooting manual for FS30x Machine Harness List X3A LSxP and LSxN).
    - When any LS becomes OC, immediately removes motor power, and the robot can only be moved using the 1KP over travel switch or by individual brake release, until the LS is returned to correct status.
    - LS are connected using dual channel and are integrated into the main safety circuit via the Estops etc.
    - Internal to the robot arm should be X120 and X126 and these should have the limit switches wired here, or are linked out if not used.
    - With the age of the system, and if you don't have switches fitted, could point to an internal harness issue, causing a disconnect of the LS lines back from arm to controller.
    - Only way of checking this is to check continuity on the X3A Connector of the robot between LS1P and LS1N.........LS2P and LS2N (power off obviously).

    Other than that, could be:
    - External X3 Harness.
    - X3/X3A Connector pin/socket damage.
    - X222 on 1KX motherboard disconnected.
    - 1KP Board failure.
    - Possible Ext Estop/Safety Fence/E Stop/Teach/Repeat Switch (1KP X7 and X8 interfaces)......(but if you can move the move the robot using the over travel switch - I would not consider these to be the source of the issues...)

    Hope that helps..............

    Simplest way would be to assign a motor power button to the I/F Panel if you are not using the dedicated input for EXT MOTOR POWER ON function and link with the dedicated output for motor power too.
    You could go OTT and then have a specific background task to monitor and control it for certain conditions etc.......

    Aux 111 - Dedicated Input Signals
    - If you are not using EXT MOTOR POWER ON - then allocate this input to a software signal not being used eg. 2254
    Aux 112 - Dedicated Output Signals
    - MOTOR POWER ON Output - Make a note of the output no. allocated, if not, allocate an available output no/software signal eg. 2253
    Aux 131 - Interface Panel
    - Select a location, select Push Button with Lamp option.
    - Enter applicable label(s).
    - Select colors for ON/OFF states.
    - Select Signal Number (switch) same software signal as allocated in dedicated input.
    - Select Lamp same signal as allocated in dedicated output.

    - Moved to General Discussions -

    This type of information may lie within the scope of NDA (None Disclosure Agreement) of car manufacturers -
    - Please verify permission of publication before posting any diagrams of any layouts.
    - Some information on this topic -…utomotive_Framing_Systems

    For those unaware of 'BIW'


    Body in white or BIW refers to the stage in automotive design or automobile manufacturing in which a car body's sheet metal components have been welded together. BIW is termed before painting & before moving parts (doors, hoods, and deck lids as well as fenders), the motor, chassis sub-assemblies, or trim (glass, seats, upholstery, electronics, etc.) have been assembled in the frame structure.

    Quote taken from Wikipedia

    Just for future reference to anyone coming across this thread who may not be aware of Extended IO:

    R(except RS3)/Z/M/B/CP/BA Series manipulators (usually supplied) use additional Arm ID board and extended IO(NPN or PNP versions available): (refer to Arm ID Instruction Manual)
    (Older Z/M Series manipulators may have Arm Id Board/Extended IO fitted as option not standard supplied).

    - Extended IO ability for local connection to EOAT - no external harness required back to controller.
    - Z/M/B Series have additional 24 Inputs and 8 Outputs available.
    - R/CP/BA Series (Not RS3) have additional 12 Inputs and 8 Outputs available.
    - When this is fitted, if you allocate signal numbers in Aux 0607, these signals are subtracted from Total IO (Aux 0611).
    - Standard setting for single 1TW board is Total IO 32.
    - Results in specific IO not be available on fitted 1TW.

    Therefore, to retain full 32 IO on 1TW and have all additional IO on Arm ID Extended IO:
    - Increase Total IO (Aux 0611) - Inputs to 56 and Outputs to 40 for Z/M/B Series or Inputs to 44 and Outputs to 40 for R/CP/BA Series
    - Allocate additional IO to Arm ID in Aux 0607

    Output Top Signal (starting signal no.) - 33 and Signal Number (No.of Signals) - 8
    Input Top Signal - 1033 and Signal Number - either 24 for Z/M/B Series or 12 for R/CP/BA Series
    - This will enable you to use extended IO without losing 1TW IO.
    - If you do not want to use extended IO or is not fitted, then just make sure signal number field(s) in Aux 0607 are set to 0 to disable
    - Also Aux 0610 both sensor and valve options should be disabled if NOT using RS3.

    If you fail to see correct output/input on 1TW.....check signal are not allocated to Arm ID Aux 0607 or Aux 0610 is incorrectly set.

    Hope this helps...............

    - Yes this confusion I have seen several times (edited)
    - COM means common rail and could be 0V or 24V depending on NPN/PNP (sourcing/sinking) version 1TW Board, which means VIN(1/2) would be opposite.
    - Must be correct for functions to operate correctly so NPN or PNP important.
    - If not, damage may occur.

    Ok, I understand what you wrote clearer now:
    - You were wiring input configuration for inputs, but connected to outputs by accident.
    - VIN(1/2) were connected to 0V and COM(1/2) were connected to 24V.
    - This would be common for both 16 outputs, therefore if damage occur, I would expect damage on 17-32 outputs also.......
    - Either unlucky 8 outputs damaged.... ??? or signal allocation is preventing outputs 9-16 working.

    Standard for electrical connections:
    Pins (male) = Inputs
    Socket (female) = Outputs

    BUT with Kawasaki Controllers (C/D/E) IO Boards (1GW/1HW/1TW) opposite is correct:
    Pins (male) = Outputs (CN2)
    Socket (female) = Inputs (CN4)

    Without having access to 1TW board circuit diagram, difficult to say if control circuits damaged but I do know:

    VIN-1 (Pin 18 CN2 = 24V+ External Supply) and COM-1 (Pin 36 CN2 = 0V External Supply)
    - These 2 rails supply 1st 16 Outputs (1-16)

    VIN-2 (Pin 19 CN2 = 24V+ External Supply) and COM-2 (Pin 37 CN2 = 0V External Supply)
    - These 2 rails supply 2nd 16 Outputs (17-32)

    All Outputs from my knowledge have individual opto isolator per output, so in theory, only opto isolator(s) will be damaged if incorrect polarity connected.
    - Possible damaged opto(s) maybe short circuited, causing permanent output on.......or Opto open circuit, result in no output.........
    - What is strange is that you have only lost 8 outputs on 1st 16 outputs and no damage to 2nd 16 maybe not damaged, just allocated differently will need to check.

    Have a look in AUX 06 (Inputs/Outputs) - Specifically:
    AUX 0611 for Total No. of IO signals being 32 each for Outs/Ins.
    AUX 0610 (if your robot arm is NOT RS03) - Both Sensor/Valve setting is set to disabled.
    AUX 0607 for Arm ID IO if allocation for outputs being set as 9 for top signal and no. of signals being 8.
    AUX 0608 (if using fieldbus, check signals have not been allocated for fieldbus use - If fieldbus not enabled, then this AUX function will not be available).

    Other than that, it maybe that 1TW board requires replacing......but I find strange only 8 outputs effected...... ???

    Hope this helps.........


    - Is it possible to cast from real to integer and vice versa ?

    - Not sure what you mean, could you clarify this?


    - How can I allocate a variable name to a signal so I can use e.g. IF SIG(buffer.full) ?

    - If buffer.full is to be mapped to a specific output, ie output number 20 - would be written as:
    buffer.full = 20
    SIG buffer.full; Turns on Output 20
    - Outputs/Inputs are not mapped specifically to a signal, they are just mapped to real values.
    - The command used, will then execute the real value in conjunction with the command.


    - Is it possible to use something like IFNOT ?

    - Yes.
    IF NOT SIG(buffer.full) THEN

    I don't quite understand what you are trying to from your example, as it's written.

    I'm assuming you wish to read 'words' (16 bits) based on signals coming into the Controller (inputs) and define local variables with the integer value - probably via a fieldbus protocol.
    Then CALL a subroutine and parse in the received variables (BCD integer values from the incoming signals).
    - defining is done from right side of '=' to the left.
    - Also your BITS are referring to output signals not input signals and are overlapping too.

    For example:
    BITS 289,16 = .height
    - Means, set Outputs (289 - 304) with the (BCD) integer value of .height
    - .height needs to be defined with an integer value first.
    - in its current condition, would produce an 'undefined variable' error.
    BITS 290,16 = .width
    - Means, set Outputs (290 - 305) with the (BCD) integer value of .width
    - .width needs to be defined with an integer value first.
    - in its current condition, would produce an 'undefined variable' error.

    In this arrangement, your outputs (BITS) are overlapping also..........

    So your program re-written to read incoming signals would be:

    - If using fieldbus protocol, obviously your signals need to mapped in the signal allocation aux function also.......

    Hope this helps........................


    The cubic-S module is installed inside the controller casing - I can see it. The CPU-A,B settings I cannot determine remotely and I do not remember them.

    - That's a new one on me then........there's no dedicated mounting location inside the E7x Series.....or even space from memory/available harnesses.....but if you can see it in there.
    - Where is the Yellow Override button mounted?

    - The CPU A and B settings, you need to find out (Aux 0804), this will tell you if the option is enabled or not.
    - If you are not receiving any Cubic-S related error on the Teach Pendant, then the option is not enabled.
    - If CPU A and CPU B are not there at all, then the option needs enabling.
    - If CPU A and CPU B fields are there, but are empty, (the option is enabled) then the module has failed to start up (C0 displayed on Cubic-S Module) - and is defective or wired incorrectly (you will also receive a Cubic-S related error on the Teach Pendant).

    I suspect the option is not enabled and also still question whether Cubic-S can be used on the E7x Series and on an arm lower than the RS006L and also if the harness is also suitable/connected correctly.
    - You need to contact your distributor to clarify whether this is an allowable configuration....and also how to enable the option (could be chargeable).

    Hope this helps................

    Controller Workspaces are not safety zones
    - Workspaces DO NOT prevent/prohibit/restrict robot motion unless specifically programmed in.
    - Workspace(s) outputs are triggered purely on TCP location in reference to the workspace(s) cube configuration - If your TCP values are incorrectly set, then workspace outputs will be triggered incorrectly.
    - Workspaces are relative to the current BASE Co-ordinate, if you adjust the BASE, the workspace(s) values will not change, but as it is relative to the BASE, the workspace(s) will move also.

    Cubic-S Zones
    - These are monitored areas.
    - They can be configured for constant prohibited, or selectively allowed/prohibited.
    - You can use dedicated dual channel inputs/outputs to activate allowed/prohibited functions and can directly control safety devices (light curtains etc).
    - The Flange centre (is always monitored) enter/exit these areas without permission or the areas are constantly monitored/prohibited, then the robot WILL immediately stop based on the selected Stop Category.
    - TCP/Tool shape points can be optionally setup in addition to the flange centre.......These have to be configured if you require to the monitor them.
    - Arm Lines/Segment points can either be enabled/disabled to be monitored also.

    No idea really, I'd be surprised if Obara (I've never dealt with them) get that involved with the robots as they are just a supplier of the Servo Gun - worth asking if you can contact a rep for data sheets........... :justice:

    - I think they can provide the initial setup data for max electrode force, stroke distances, speeds, deflection distance/force applied etc.
    - But I think from a calibration perspective, this would have to be on the robot itself because the forces will be different depending on the posture of the servo gun, speed/direction of the moving tip during the weld.
    - No harm in throwing some values in there as long as you don't exceed the max current of the servo gun motor I suppose...... ???

    You need to use an electrode force meter, with load cell to obtain force readings.
    (Obara had one but I cannot find any further information on it.......Model was IFM-10)

    Attach load cell electrode to fixed tip of servo weld gun.
    - Aux 1023 is Force Calibration.
    - You then operate Gun, measure force and do current calculation.
    - This allows robot to set current to servo motor for correct force requirement for weld.

    I think force calibration etc is detailed in Servo Gun Instruction Manual

    I have not had much experience with setup as it is a mine field........ but I have located some information (see attached).

    The common areas for setup include references from the gun data sheets (speed/pressure/distance) are:
    - Setting the Mechanical Parameters (Motion limits, Direction, Speed, Encoder Resolution)
    - Setting the Servo Gun Data (Clearance distances for fixed/moving tip, clamp forces - max/min, Tool Z direction).
    - Force Calibration
    - Force Compensation
    - Deflection Measurement
    - Tip Wear Measurement

    Most setup data, can usually be found in the gun data sheets, but you will have to look for them/calculate them.........

    The main area is correct setting of the Mechanical Parameters.
    The other areas are more of a 'fine tuning' in my opinion to make sure the correct forces/clearances are applied (force meter required).

    Mechanical Parameters are in Aux 1011
    - Set the max/min motion limits
    - Travel direction
    - Speed of gun
    - Encoder resolution, you have to calculate the correct resolution for the encoder, to ensure stroke distance is actual distance.
    - This will then allow correct pressures to be set more accurately etc.....

    The formula used is:
    Resolution=Distance of tip travel for one rotation of motor/8192

    So lets say the manufacturer data sheet says distance of tip travel = 11.53mm, the resolution would be:
    - 11.53/8192 = 0.001407470703125
    - Apply the resolution exponent 3................
    - Resolution = 1.407470

    Once the mechanical parameters are set, you can then set forces and servo gun data for usage.

    Not much to go on, but that's the limit of what I have.......Hope it helps.

    Hmmm.....Interesting, I see the Teach Pendant (from block diagrams) has a connection to the NIF01 - which may well be linked with the 1218 error (especially as the alarm no's are very close to each other).
    - I certainly think an alternative Teach Pendant (if that can easily be done) is worthwhile swapping over which would rule in/out the Teach Pendant and connecting harness.

    Again, I hope I'm not leading you down an incorrect path here with my lack of product experience, but certainly seems like a logical troubleshooting area considering the Teach Pendant fault you mentioned.

    No worries......
    - I wish I could assist further but have no experience with these systems.
    - What I can ascertain from a brief look at the NIF01 board, it appears this is the main interface for the complete system including dual channel safety circuits - PLD 1 and PLD 2 may relate to the safety circuits.
    - Therefore I can only hazard a guess that one of these channels could be short circuited (ie a mismatch in dual channel status - one of the channels may have failed)....
    - I would definitely check the integrity of external safety devices (e/stops, cabling and connections etc - with the power off obviously)

    As I mentioned, I have no experience and maybe completely wrong.........there are plenty of experienced Yaskawa/Motoman users here who will undoubtedly be able to assist you further.