Posts by kwakisaki

Not good......Looks like 1RA board is broken.
Can you connect RS232 lead to connection where PCMCIA is, and open KCWin32.
Set correct com port on PC for connection.
During bootup, is any information displayed?

On 1RA board, set dipswitches:

1 and 8 to ON and the rest OFF and reboot Controller.
What does the teach pendant display?
Can you read the filesave on the PC - and attach here or attach the header of the filesave?

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The robot has not worked for 2-3 years.

It is possible data has been lost/corrupted and also disconnection of devices, boards, harnesses.

Compact flash does not exist on D/D+ Controller, only SRAM upto 4Mb and Flash memory board (1QJ - between 16Mb and 32Mb) board.
1QJ stores AS and SV firmware and SRAM is for user/system data.
Without battery for years, usually lose user/system data.
With no user/system data, Controller should boot up to teach pendant screen, but you say only backlight.

If not been used for 2-3 years, can you guarantee all boards and harnesses are connected inside cabinet?
- Can you post image of inside controller.
- Can you post image of dipswitches on 1RA board

Welcome to the forum........

Please provide more detail:
- What was status before problem occurred.
- What is displayed on teach pendant during bootup.
- What have you tried to fix the problem.
- Have you a recent file save (full controller filesave).

The teach pendant is a terminal device only.
Whether it is connected or not, there is no error related to a disconnected TP.
It is connected directly to the CPU board (1KA/1RA) via the card rack backplane (1KX) using connections X204 and X205.

Assuming that the main TP harness is ok, then have a look inside the Controller at the backplane and check/verify X204 and X205, by removing them (have a look for bent pins etc) and reseating them.

Failing that, it is possible you may have a conductor issue within the TP harness, or an issue within the TP itself.
- If you have access to an alternate TP (even an E Controller TP), you can connect this up and see if the fault repeats/vanishes.
- You could also swap the TP harness between them.....same electrical connections as an E Controller).

Sorry, I totally misread your initial post...............
Yes, I think you can only have upto 8 toolshape points as a maximum (this is what I read in the manual).
Toolshape points can only be set in the Controller, then read into CS Configurator and written to Cubic S

I am not sure, but I think the 'additional' fields in Cubic S relate to a different version of Cubic S perhaps.
- Toyota Controllers use a different version of Cubic S compared to generic Cubic S....it maybe related to those types.

Check with your local distributor regarding this, as I may be incorrect......

It sounds like you are mixing up Kawasaki Tool register reference.......Block and AS.

You need to differentiate Tool reference register you are using in the Controller as Cubic S can only READ TOOL DATA from Controller.
Tool Data can be viewed in Cubic S only.....you cannot set data in Cubic S and send to Controller....only READ from Controller:
Check out Cubic S Manual and look for System Switch references (Aux 0502).

Using Tool Aux 0304 in Pendant (Block Programming Tool or Quick Tool).
1. System Switch QTOOL ON = Aux 0304 for Tool Centre Points (T1 - T9) and Tool Shape Points (1-8) Enabling.
2. If you wish Cubic S to monitor QTOOL as Tool 1 - 9 Set System Switch CBS_AUXTOOL1 ON.
3. If you wish Cubic S to monitor QTOOL as Tool 10 - 18 Set System Switch CBS_AUXTOOL1 OFF.

Using AS Commanded Tool (Not Block Programming or Quick Tool).
1. System Switch QTOOL OFF = AS Commands for Tool Centre Point and Tool Shape Points (1-20) Enabling.
2. If you wish Cubic S to monitor AS Command Tool 1 - 9 Set System Switch CBS_AUXTOOL1 OFF.

If System Switch QTOOL is ON then:
- Cubic S will read tool data from Aux 0304
- Cubic S will read toolshape points 1-8 for the tool no. in aux 0304 (if enabled)

If QTOOL is OFF then:
- Cubic S will read tool data from AS Commanded Tool.
- Cubic S will read toolshape points 1-20 from SET_TOOLSHAPE AS Command.

According to Cubic S Manual you can enable more toolshape points for either QTOOL ON or QTOOL OFF by using command:
SET_MAXTOOLSHAPENUM Command.

IPG and Trumpf

Welcome to the forum.......

You may want to consider using position/location arrays as a naming convention for your drop locations based from a known location (centre of the pallet) which contain variable co-ordinate elements that you can modify to suit.
- This will assist with 'removing' your HERE requirements, but when you are starting out, may appear complex.....however it has it's distinct advantages to consider using something like below.....(this is not necessarily a solution to copy and paste though).

POINT drp[pall.no,lay.no,pos.no] = (SHIFT(pallet1_centre BY xshift,yshift,(lay.no+1 MOD 2)*zshift)+RZ(lay.rotate))+TRANS(app_x,app_y,app_z,0,0,rotate)

What are your pallet dimensions and each pack height?

The Encoder battery assembly is attached to the 1HG Board located behind the rear plate of the FS30.
- Where the umbilical harnesses are connected, removal of this plate reveals the 1HG Board and Encoder battery assembly.
- Disconnection and reconnection should be done with the power removed.
- Encoders remain powered by a large capacitor internally, which should allow you 30mins to replace the battery without loss of zeroing.
- The Encoder battery assembly is a common part from any Kawasaki Distributor

Could be the motor for sure, but the current feedback is from the CT's inside the Power Block.
- Usually it is these that fail, or issues with the supply electronics within the Power Block.

If you have the same Controller for the Arm knocking around, swap the Power Block over and see if the error clears.......

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If the network cable is unplugged and then connected, how does the robot recognize the disconnection and start reconnecting

As far as I know, if the cable is removed 'after' you have successfully opened a socket and bound it to a port and IP Address, the port remains open, unless your code is written to close it.
- See/Use TCP_STATUS Command to see the status of sockets.

I think there is a particular AS Version onwards, that includes an additional communication option relative to TCP/IP Connection reset, but I am not sure if this auto-reconnects, or just closes the socket.....may be worth looking in to this option with you Kawasaki Distributor.

As far as error codes are concerned, I think that during any send/receive, then if it times out, then this is the only checking that's done.
- However, if data is being transmitted at the time of the cable break during any send/receive period, then a different error is produced.
- Again, though, the socket will remain open in any circumstance I think................

I am not sure if you could make just standard 6 axis, because of 1GM board......but is worth a try I think.
Attached is maintenance manual and yes, the dipswitch you refer to is part of multi-axis configuration.
- In manual, check/change/confirm jumpers and switches on 9ZA and 1GE board for 6 axis only and disable JT7 references.
- Make note of old positions before you change.

Welcome to the forum...........

Very nice work, and also appreciation for the work/time you have allocated to create the thread and choosing Robot Forum to post it on.

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The task I have to accomplish is similar to the provided sample project RS010N_Floor_Handling

- This project, should be included in the documents folder of your installation as The Handling project manual.
- Additional to that manual are other manuals to assist in other applications.
- I found working through these to be sufficient enough without any video training requirement.

However, yes I do agree, video tutorials seem to be very few in offering directly from Kawasaki and could be seen as potential secrets......But were those webinars actually secret......

KRI (Kawasaki Robotics Incorporated USA) were behind the Webinars and also the application KTOOLS from what I know and not Kawasaki Robotics Japan.
I am pretty sure those webinars you are referring to, were developed for those that applied for the trial licence (2 months/60 days) from KRI, in order to experience the full version, they also received access to the webinars too.
- Yes, so kind of secret.
- I believe KRI only implemented these webinars as a trial basis only initially, so I wouldn't be surprised if they're unavailable now.

Shame if that's the case, as I also viewed them and from a 'Seasoned KROSET user' perspective, some additional information was learned, and I can see from a newcomer's perspective just how much of a boost it would give them in comparison to just reading manuals.

So a 'niche' area for you to document/video your journey as a beginner maybe......?

1GE Board contains additionl Current Sense Module (1GM).
- This allows for current match for specific motor(s) fitted.

Usual issues are:
Faulty boards 9ZA or 1GE or 1GM - Replace.
Mismatch between 9ZA Software and actual hardware, Robot Model maybe incorrectly set or installed software for 9ZA is not of correct version.

See attached Troubleshooting flow.

Welcome to the forum..........

Kawasaki offer a dedicated OLP called KROSET.
This is a simulation tool offering 3D representation, motion, cell deisgn/layout, reach study analysis options as well as allowing the user to learn/program including using virtual teach pendant and evaluate Kawasaki Robots (see attached).

The application is available upon request from your local Kawasaki distributor which you can obtain via the link below.
- The Application can be used without license - called 'Lite', but has many limitations, but can suffice as an introduction to Kawasaki.
- Alternatively, you can also purchase a valid license (which is supplied via USB HASP Security Key), this allows for full application usage.

http://global.kawasaki.com/en/corp/profile/network/

Welcome to the forum...........

The optimal solution is to control the material flow by feeding back the actual TCP speed of the robot to a flow controller, therefore maintaining bead width/diameter uniformity throughout the process.

1. Are you using a flow controller or constant flow. (If constant flow, then it will be difficult to achieve).
2. Are you using the dedicated sealing commands. (GUNON/GUNPURGE etc) as this is recommended.
3. Is the sealing gun attached to the robot or are you moving a held work piece around a fixed/static sealing gun.
4. Is the TCP correctly configured.
5. Are you shaping the bead around the curve (rotating the nozzle during the radius motion).
6. Have a read about the SPEED command in the AS Manual - and try the DEG/S option for the CxMOVE
7. Can you provide a small example of your code.

Check ARC ON system switch is activated (you should be able to see this on Teach Pendant in Function Tab screen - See attached).
- If this is OFF (greyed out), the robot will run the program as intended without welding/sending the applicable signals to the weld set.

If this is ON, then you need to check dedicated signals are being sent to weld set to initiate weld.

1. What Controller/Arm and Weld Power Source.
2. Mapping, are you using fieldbus or standard IO.
3. What do you mean by 'call programs from welding machine'.
4. How is this programmed - BLOCK or AS.

Can you clarify/be a little more specific?

Have a look at the attached error code information.
From a hardware perspective, this is attributable to the mechanical contactors inside the MC Unit.
However, could be a control board within the MC Unit or harnessing issue.

MC Unit is the main control for power distribution for Fans, Brakes and Servo Amplifiers.