Posts by 89Seth

Hi,

Sorry I’ve been meaning to reply for a while...

I’m located in Australia, are the Kawasaki distributors linked? Are you able to reference which one is in Australia?

I get two pop up, one is diverseco and the other is robot technologies-systems Australia

Gone with ditching the 1GN board and just using the 1TW and running a output to a relay which is being used as the welder hand piece switch.

Working far easier!

I am not great with the coding side, but I am curious, is there are way to code in when the e-stop on the robot is pushed, it stops the outputs until the cycle is started again?

Also with the plasma, it was wired into the 1GN board, used like that at a different site, they just gave us the drawings for it.

Again thanks heaps for your help!

Yes, we understand the issues with butchering the code and you holding no liability for what we are doing.

Is there a way to add a step in that depresses and holds in the ‘Gas on’ button on the TP?

Example, welder moves to position, next step, ‘gas on’ is pushed (physically on the TP, so a wait command) and it latches that button until it gets to its finally position then stops latching.

I will do some digging on the welder unit comms features!

With those issues you mentioned, there will be a boiler maker standing by making minor adjustments if required and stopping the robot if there is a weld issue (cordless robot remote),the welding requirements don’t need 100% correct settings (fair bit of wiggle room).

Would it be possible to...

use the ‘gas on’ on the 1GN board and run that straight into the WCR inputs? (Currently the ‘gas on’ Is not being used as it is not required), but just for a temp measure, could it be used to activate the WCR?

There is a 24Vdc supply inside the controller, so I believe it would be possible to run a wire to the gas on contacts, than in series it to the WCR (which I’m am really hoping is plug CN4 pins 5-6, just found a wiring diagram for the plasma that was connected to this robot, and the description for those pins is “Arc est” Which I believe is ‘arc established’), So fingers crossed it is the WCR Input we require.

Very sorry if some of this does not make much sense, I’ve just finished a night shift, if it is really bad I will edit it after a sleep.

The TIG welding unit we have is pretty amazing, it has a wire feed attached to it, so all you need to do with the hand piece is toggle/hold the trigger downwards to start the arc and it will continue to weld, no expect input needed just continue moving.

The robot model we are using is:

Kawasaki RS015XA

I will check with the supervisor where the manual is located.

Thank you heaps for all your help you are confirming and parting more of this together in my head.

We are trying to use a Tig welder with the robot.

The machine we are trying to use (and I bet could be wired into the robot but we lack the cabling... but I haven’t checked yet) is:

Brand EWM

Power source - Tetrix 351 AC/DC smart FW

Wire feeder - tigspeed drive 45 hot wire

The welding unit that came with the robot is:

Brand EWM

Power source - Alpha Q 552 RC

I suspect it was added onto the robot at a later date, not sure at all. We are using weld code only because it is the only one we know of at the moment.

So you are saying if we used standard BLOCK or AS, but I’m assuming I won’t be able to connect the tig Trigger for the welder To the 1TW CN2 plug in Either NPN or PNP because the voltage required is 24VDc +\-10% (so about 20-26Vdc) because the welder voltage is about 9VDc?

Is it possible (but I’m assuming not advised) to parallel any other input into the 1GN board that’s for the WCR input?

How do I locate where the WCR input physically is? Is it a point you allocate? Or a set pins on the board?

Thanks very much for the information Kawkisaki!

The robot controller does have the 1GN board and I was able to use the Arc Start contacts on CN3 plug pins 2 and 3.

I’ve ran into another issue tho!

First off, the robot controller is:

Kawasaki robot controller

Model: E42F-A002

(Sorry Lemster68, I forgot to mention at the start)

You may have guessed this, The error we keep getting is “Arc failure” (E6502) as the controller has not received a signal to indicate welding has started.

Is there any way to turn this input off?

The welder is set up and automatically welds once the ‘Arc Start’ Contacts close (on the 1GN board, CN3 plug) but it does not have any ports to connect to the controller, plus the control voltage on the welder is 9V.

I’ve been looking through the external I/O manual (Kawasaki robot controller E series) but with no luck...

the couple of points I’ve seen which I thought would work were...

If inputs are set to 1000 (outputs to 0) they are unused and not worried about, so in my monitor screen I can see a ‘I002_EXT_WCR_INDIVI’ input and when I change its setting to 1000 (was 1153) it no longer appears on the input monitoring screen but the fault still occurs when I start a cycle (it starts welding great, but stops once the scratch distance is reached and goes back to original position and starts again - it did this 4 times before the fault would occur, I was able to change it so it did not keep repeating it).

I also noticed in the manual the input is a software dedicated signal, so is this something in the TP I can remove or do I need to look at the coding of the program on a computer and possibly remove the need for WCR signal?

Hi,

I’ve just been requested to wire a welding hand piece into the robot and just wondering if there is usually any dry contacts on the cards?

I was hoping to use some of the spare outputs on the 1TW card but noticed they have a 24vDc supply on them (which I’ve heard makes them known as ‘wet contacts’ please correct me if I’ve got something wrong)

All I need to two contacts/switches from the robot to the welding unit (example: robot will be controlling the buttons on the welder hand piece)

the buttons on the hand piece are just normal open contacts, that have 9vDc across them, just waiting to be closed. This is why I don’t believe I can use the outputs on the 1TW card, as they have voltage on them already and most likely will damage something on the welder.

I am hoping there is something I can do, as my other option is installing a couple of 24vDc Relay.

Thank you heaps for the information above.

I am currently stuck to searching threads with my phone and not having much luck, so please forgive me for the next few questions if they have been answered before.

I am very new to this, is there any training modules you can recommend that would help me learn and program the robot?

Where do I find the WHERE 5 in the TCP?

Does the encoder model numbers need to match as well? (I have pulled them apart to have a closer look to see if I could spot the fault on joint 3, and worked out very quickly these are put together in a clean lab...)

When we get the other motor, I recalled reading that you need to change the serial numbers in the controller so the controller knows what it is looking at and telling what to do etc, is this correct? (and can it be adjusted/changed in the TCP?)

Hi,

I am hoping maybe someone can shine some light or advise on a issue with the robot we have.

We have:

Kawasaki robot: RS15X A

Kawasaki robot controller: E42F-A002

Joint 3 encoder is not registering, when we Manually release the brakes and move joint 3 we can see on the TCP (hand controller, forgive me if I get anny terms wrong) that the encoder is not changing state.

So!

Question I have, can we swap this motor out with another one?

We have 4 rotator tables that came with the robot and they have the same motor specs and brand (only difference is the last digit on the model numbers is different, one joint 3 is ‘S’ and rotator motor is ‘R’), I am suspecting the only difference with these motors is the drive shaft, because the drive shaft on the rotator motor does look quite long, but it also looks removable too (haven’t tired to remove yet)

These are the details of the motors:

Motor manufacturer: Sanyo Denki

Joint 3 motor:

2KW

2000min-1

Model: R2AA13200LCP2S

Part no: 50601-1460

Encoder details:

Model: PA035-017BC00S

And

Rotator Motor:

2KW

2000min-1

Model: R2AA13200LCP2R

Part no: 50601-1490

Encoder details:

Model: PA035-017BC01H

I have contact Sanyo Denki to get the motor details but they have informed me these are Kawasaki custom motors and they have zero information and I need to contact them, which I have and 3-4 weeks and still no reply.

I have plugged the rotator motor using the joint 3 cables, and released the brake, the encoder information changes, so I highly doubt it is a cable issue