If this happens occasionally then this error can be caused by the wire touching the work piece (or being extremely close to the work pice) at arc start.
It can also be caused by too rappid chain welding.
If it happens all the time and you can not weld anymore there is a short between the power source plus-output and ground or your power source is broken.
Posts by robotwelder2
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Question1
This means something goes wrong in communication between G4 and the robot controller, it is saying the external axis is doing something which it has not been told to do.
probable causes
1 accumulation of dirt around the encoder board in G4.
There are three covers on de G4 housing, underneath one of them is the encoder board, clean this area with compressed air in case there is dirt around this board.
2 a contact problem, use contact spray to clean the connectoers on this board.
NOTE: if you disconnect the encoder you have to calibrate G4 again.
Best thing to do, apply some contact spray and move the connectors just a little bit so they do not disconnect.Question 2;
Do you mean the E-Stop on the teach pendant does not work in teach mode?
If so check the wiring of the TP cable inside the controller cabinet because somone has been screwing around and changed the standart wiring in a very stupid way. -
Dariobot,
I'am sorry to say but my scedule has changed, it will be two more weeks until I will be in the office, i did not forget about you!
best regards,
Robotwelder2. -
Yea, I already stated I would not be right.
My offer still stands, I will be back in the office in about three weeks.
I will check if I still have a manual, if so I will scan it and mail it to you.
Regards,
robotwelder2 -
Note: the change I am being right with this answer is very slim, I have not seen this robot anymore in the last 7 years, especially the error number is unknown to me right now.
A calculation error can be generated by an error in circle or weave motion programming.
If this is the cause of the error press CLR (clear) on the TP, then the monitor will give you a message "start from the beginning" you have to confirm with "yes".
You then will be back in the progam which caused the error, the part of the program which caused the error is deleted, close the program and your robot will start-up again.
I will monitor this conversation and if you did not recieve a better answer within aboud three weeks I will investigate further when I am back at the ofiice where I still may have (?) a AW8010 manual.best regards,
robotwelder2 -
In case you have to re-teach positions you have a big problem, it means something is wrong with the calibration of the external axis G1.
If calibration has not been done, it is impossible to program positions outside the working range of any axis.
In case you ran into this problem during programming, jogging the external axis, then there may be no problem at all, you just moved the axis too far.
Another possibility is using calculated shift functions or tactile search functions which may produce shifts beyond the working range.
regards,
robotwelder2 -
I can't imagine why you need those files, I can assure you data like this is not leaving the Panasonic factory in any form and will be marked as confidential and secret.
The only chance to obtain these files will be directly addressing Panasonic headquarters in Osaka with a good story.
The chance of getting these files are nevertheless almost zero.Maybe the word “almost” should not be in the previous sentence.
regards,
robotwelder2 -
Heri,
sorry for the late reply, I have been out of the office for a while.
The only conclusion I can draw is that your I/O board is malfunctioning and needs to be replaced.
regards,
robotwelder2 -
It is better to note the axis angle (AGL) value, it is then more clear to see which axis has a problem.
And you really need to add a second reference point to rule out the torch (the grease nipple on the TW axis).
then you will be able to tell for sure if the problem is in the robot or in the torch. -
You do not state which robot or controller or process you are using so I am shooting in the dark here.
Some common steps you could consider;
1 Release the brakes of all axis (one at the time) and check for backlash.
This means you should be able to move the axis and feel the same (constant) amount of torque (resistance) when doing this.
If you feel a low resistance at first changing into higher resistance when you rotate further you have a worn or faulty transmission.
Also you should feel a more or less constant resistance all the way, if you are not sure compare it with the other robot.(if you are not experienced with this is not a bad idea at all to check the “good” robot first so you know what to expect.
2 When you are correcting the welds try to do this with jogging axis and not Cartesian or tool coordinates. If one axis is bad you will notice that you can regain the right position by moving one (or two) the same axis, this will indicate a problem in one (or two) axis.(TW and BW are the most vulnerable axis)
3 Check motor mountings, once I had a similar problem and it turned out the bolts for fixing the BW axis motor where lose.
4 When you are correcting the same weld over and over again write down the position of that point.
View, display change display position agl (angel).
If this position changes back and forward the problem may be external, in case the position changes in one direction it may indicate a robot problem.(vague indication, depends on robot type).
5 Make some reference point(s) on your jig.
The easy-est way to do this (when MIG or MAG welding) is by welding at least 3 wire contact tips (threaded part welded) on the jig, make a program which positions the torch over the contact tips in such a way you can inch and retract the wire in an out of the welded tip without any friction.
Try to keep the torch orientation as fixed as possible to rule out the robot.(TCP / Calibration errors).
Do the same thing on a part which is not moving (torch cleaner, base of the robot).
If the first (moving) reference points are not ok but the fixed point are ok the problem is not in the robot.
If all reference points change the problem is in the robot.
6 Rule out the torch by making a reference point on a fixed position and use one of the grease nipples on the TW axis as reference on the robot. the fixed point could be as easy as the edge of the torch cleaner or somthing else stable.(depending of the adjustments you have to make to your program, if you are TIG welding this check may be too crude).
That is all I can think of right now.
Good luck and I hope to hear from you again, something like problem found / solved would be nice! -
did you check your 24 Volt power supply?
do you have any voltage at the i/o board output.
It is posible that one output on the i/o board is bad, try using another output, on the picture I see that output 3 is available, try that one.
use a 100mA fuse to protect your i/o board!! -
A7020 is a noise problem, check grounding all the way from power outlet to controller, robot and motor.
Also check the ground of the power outlet by measuring the voltage on your outlet and the ground of another outlet.
Always be very careful when working with high voltages, take no risk at all and use proper equipment!!!
(once I had a similar problem at the customers site, I temporary used the metal structure of the building as ground just to make my case.
This is not a solution of course.) -
see topic "signal output Panasonic GIII"
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write a simple program like this;
A: Label A
MOVEP P001 position does not matter, can be anywhere
OUT 1#(1:01#0001)=ON turn on the output
delay 0.5 wait for half a second
OUt 1#(1:01#0001)=OFF turn output 1 off
delay 0.5 wait again
jump A: jump to label ARun the program in test or auto mode.(to run the program in auto mode the robot probably has to be at a home position (P001 should also be there).
Now you will have a pulsating voltage on output 1, see if the relay recieves the same puls and check if the relay is toggling between on and off.
If there is no voltage on the the output check your power supply.
Warning: you can set a jumper to use the internal 24 voltage supply, never do this, it is very dangerous.allways use an external power supply!! -
Dear Heri
I stumbled over this post and looked at the picture of the TP screen;
Three remarks,
1 line 0005 should be MOVEP with welding.
2 line 0008 should be MOVEL without welding.
3 If you are using output #0001 (line 0004) to control a pneumatic device it will possibly not be closed (or opened) as the robot starts welding.
You want to wait for a return message from the pneumatic device or program a delay to give the pneumatic device enough time to close (or open). -
How much free memory space do you have?
I know in case the free memory space is critically low the program sometimes is saved and somtimes it is not, I can not explain this.
What happens if you open the program and save it as a copy (upper menu bar select file >> save as).
If the program is saved without any problem you have enough memory left and something else is going on.
Try to change a position in the copy and check whether is saves or not.
What happens when you do the same thing in another program?(try changing an aircut step).
Remark, when you run a program in test modus it is first saved and closed (together with all other opened programs) and reopened again, this explains the similarity in both cases.
Pls let me know how you are doing.
NB, which controller are you using G2 or G3? -
An other option could be the active wire process (does the same as CMT) which is supplyed by Panasonic, I am not sure wheater this is available for the G2 controller.
In this case you would have to buy some software and hardware (welding torch) and you have the advantage of working with the Panasonic integrated welding power source which works better (faster response and more accurate) than a serial link controlled welder. -
I do not understand the question, could you please submit the question in different words or in your own language so I can give google translate a try?
I guess you want to have the welding on signal for external use?
Or do you want to turn on / off welding from the outside world?In case you want an output to indicate welding is enabled / disabled (F3 in test mode).
In the upper menu bar click on “set”.
Goto “In / out”, “Status input output” and click on Weld off status output.
Check valid and select (browse) the output you want to use.In case you want to turn on or off welding by means of an input;
In the upper menu bar click on “set”.
Goto “In / out”, “Status input output” and click on Weld off status output.
Check valid and select (browse) the input you want to use.In case you want an output to indicate if welding is on (arc-on);
In the upper menu bar click on “set”.
Goto “In / out”, “Status input output” and click on arc-on output.
Check valid and select (browse) the output you want to use.
I hope this will help. -
Tried it, it is a lot of programming and does not reduce the cycle time much on a app 8 minute program the difference could not be measured.
If you want to reduce cycle time the best way to go is to optimize your weld settings, try to go faster with the same welding result.
Many leave the robot at the preprogrammed 50 or 60 cM/min, in many cases you can go much faster.
Till now i dont know of anybody using it. -
In the top menu bar click on set, go down to welding and select the power source you are using.
The first menu item lets you set the wire diameter.
If the diameter you want is not there you will have to buy this option.
If you do not want to buy the option you can use the wrong wire setting, the programmed weld current has to be recalculated because it will be different from the current in the arc start line.
(Make sure the robot is not in automatic mode.)