Posts by retobor

    Coated material will create higher resistance in the circuit, resulting in lower current and poor weld quality. If another cell is able to weld the part ok, you may want to check the weld location and fitup.

    Which way are you orienting your calibration grid relative to the camera? The process detects how it is oriented using the 4 large dots.

    I usually use a joint position check with a .5 degree tolerance as a disabling input for the joint speed check. I've had issues in the past; this way when I am at the commanded position I do not receive nuisance DCS faults like this.

    From what I understand, DispenseTool uses Job programs and Process programs. If you have 2 or more arms on a controller, I believe you need a process program for each arm. You then define which equipment is used in each program under 'detail' when creating the program. You can then use a 'run' command to execute the Process1 program, and a 'call' command to execute Process2 program. Those instructions would go in the Job program.

    I am not familiar with DispenseTool, but I believe ArcTool commands for multiple equipment should be similar:

    1. 1:
    2. 2:L P[1] 100mm/sec FINE Arc Start E1[1]
    3. 3:Arc Start E2[1]
    4. 4:

    Are you starting and ending your second equipment like line 3 above?

    Per the HandlingTool manual, calibration applies to axes 5 and 6 and accounts for differences in the servo motors and gearboxes, etc. from one robot to the next. Assuming you have the auto payload ID option on this robot, you need to run calibration before any payload schedules are set up. With no tooling or dressout on the end of arm, set calibration status to ON and execute. The robot will move J5 and J6 through some simple motions to perform the calibration. When it is done, calibration status will change to done. Read up on this in the manual before you get started so you know how to position the robot before you start and how it will move during calibration.

    The reason I ask is because I find a lot of times I will be working on a cell where the previous integrator has not setup payload information. It is not practical to remove tooling & dressout on a robot that has been running production for 5+ years. I guess it is better to have payload values rather than nothing; but I will keep this in mind for new builds.

    Payload setup is covered in the HandlingTool manuals. One thing that is easily overlooked: Be sure to run calibration first with no tooling, etc. on the end of arm. After this is complete, the payload schedules can be set up.

    Is calibration always required on new robots? When switching calibration from (no) to (yes), a prompt appears that says '...only required when there has been a mechanical replacement'. The manual states to run payload calibration if status is not set to DONE. I only see astrisks under status, so I assume this means calibration has not been done?

    I've had issues connecting to welders using ArcTool before. Try this procedure I had in my notes to reset the comm settings.

    "In order to delete a connected welder, navigate to $BOOTP_TAB and delete the IP and MAC address for the first selection. This will clear the comm. Configuration. Then run the controlled start guide below."

    Figure 14 in the ArcTool manual explains how to connect a PowerWave over ethernet in controlled start menu.

    I've never experienced a warning or alarm reducing speed. You probably have an external device or some sort of logic that is changing the override value. I would check BGlogic or Override setting under setup.

    As for the warning, you may want to reduce the programmed speed or change motion as that move is aggressive on one or more of your axis. This will likely cause wear over time.

    I can't tell you why it is rotating that third group without seeing the system or a backup; my only suggestion would be to make sure that the program is masked to the only motion groups that are needed in the program. The only other way I can see the third group moving is through a macro or a RUN command in an upper level program.

    I am working on a multi-group controller R-30iB V8.0 and I am trying to locate the setup for DI/O feedback based on the selected group when in teach mode. DI-101-105 and DO-185-189 are turning on based on the selected group (1-5) and are overwriting inputs from my HMI device. It is not mapped in digital or cell I/O, I'm assuming there is a variable somewhere that sets this?


    I am currently working with a customer with this setup (R-30iA V7.7), it is an arc welding cell. The only limitation I have come across is mapping DI/O because the Fronius power source uses 300 I/O points x 4 robots is 1200, but the max is 1024 points for R-30iA. Each arm is its separate motion group, so you switch motion groups like a tool frame or user frame to select each robot. This cell does not have DCS, but it works the same as I just described; each CPC, JPC etc. needs to have it's own motion group defined. If you want to have a fence line for all 4 robots, you need to have 4 CPC's. I haven't really run into any issues, the programming is a little more complicated, it's more of an inconvenience if anything. That has been my experience anyway.

    The entire model is inside the cube (including the Z height)? Do you have more than one motion group on this controller? If the status is unsafe, the target model is outside of the cube. I'm assuming this is your fence line for the cell?

    Try looking at the 4D DCS graphics to help you diagnose the problem. If you need further help a screenshot would be helpful.