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E Series
Arc Welding
Operation Manual
90203-1036DEA
E Series Controller
Kawasaki Robot Arc Welding Operation Manual
PREFACE
This manual describes operating instructions for arc welding specification of the Kawasaki Robot
Controller E series. This manual is supplemental for standard Operation Manual. Read
thoroughly the Safety Manual and other relevant manuals such as the Connection and Installation
Manual for arc weld robot controlled via E series controller. Once the contents of these manuals
are thoroughly read and understood the robot can be used.
This manual provides as much detailed information as possible on the standard operating methods
for arc welding specification of the Kawasaki robot. However, not every possible operation,
condition or situation that should be avoided can be described in full. Therefore, should any
unexplained questions or problems arise during robot operation, please contact Kawasaki Machine
Systems. Refer to the contact information listed on the rear cover of this manual for the nearest
Kawasaki Machine Systems office.
The explanations in this manual include information on optional functions, but depending on the
specification of each unit, not every optional function detailed here may be included with the robot.
Also, note that figures given here may differ partially from actual screens.
1. This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damage, and/or problems relating
to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching, maintenance
or inspection of the robot attend the necessary education/training course(s) prepared by
Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the right to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot is reinstalled
or moved to a different side or sold off to a different use, attach this manual to the robot without
fail. In the event the manual is lost or damaged severely, contact Kawasaki.
Copyright © 2011 Kawasaki Heavy Industries Ltd. All rights reserved.
i
E Series Controller
Kawasaki Robot Arc Welding Operation Manual
SYMBOLS
The items that require special attention in this manual are designated with the following symbols.
Ensure proper and safe operation of the robot and prevent physical injury or property damage by
complying with the safety matters given in the boxes with these symbols.
! DANGER
! WARNING
Failure to comply with indicated matters may possibly lead to
injury or death.
! CAUTION
Failure to comply with indicated matters may lead to physical
injury and/or mechanical damage.
[ NOTE ]
! WARNING
ii
E Series Controller
Kawasaki Robot Arc Welding Operation Manual
INTRODUCTORY NOTES
E series controller provides hardware keys and switches on the operation panel and the teach pendant
for various kinds of operations. In this manual the names of the hardware keys and switches are
enclosed with a square as follows. The terms “key” or “switch” which should follow the relevant
names are sometimes omitted for simpler expression. When pressing two or more keys at the same
time, the keys are indicated by “+” as shown in the example below.
EXAMPLES
E series controller provides softw are keys and switches which appear on the screen of the teach
pendant for various kinds of operations depending on specifications and situations. In this manual,
the names of software keys and switches are enclosed by “< >” parentheses. The terms “key” or
“switch” which should follow the relevant names are sometimes omitted for simpler expression.
EXAMPLES
<ENTER>: expresses an “ENTER” key that appears on the teach pendant screen.
<NEXT PAGE>: expresses a “NEXT PAGE” key on the teach pendant screen.
3. SELECTION ITEMS
Very often an item must be selected from a menu or pull-down menu on the teach pendant screen.
In this manual the names of these menu items are enclosed in brackets [XXX].
EXAMPLES
[Auxiliary Function]: Expresses the item “Auxiliary Function” in a menu. To select it, move the
cursor to the relevant item by the arrow keys, and press the ↵ key. For
detailed description, this procedure should be described every time, but “select
[XXX] item” will be used instead for simpler expression.
iii
E Series Controller
Kawasaki Robot Arc Welding Operation Manual
CONTENTS
1.0 Overview of Arc Welding Control·······················································································1-1
1.1 Configuration of Arc Welding Robot System ·····································································1-1
1.2 E Controller Specifications for Arc Welding·······································································1-2
5.0 Teaching································································································································5-1
5.1 Overview of Teaching Operation·························································································5-2
5.1.1 Basic Flow of Teaching Operation·······················································································5-2
5.1.2 Type of Teaching Points and Auxiliary Data·······································································5-3
5.1.3 Weld Condition·····················································································································5-4
5.1.3.1 How to Set Weld Condition ·································································································5-4
5.1.3.2 Types of Weld Conditions····································································································5-5
5.2 Teaching for Arc Welding····································································································5-6
5.2.1 Creating a Program Sheet·····································································································5-6
5.2.2 Preparation for Teaching ······································································································5-7
5.2.3 Configuration of Teach Screen·····························································································5-8
5.2.4 Teaching Operation ············································································································5-10
5.3 Setting Other Auxiliary Data······························································································5-17
5.3.1 Setting Option Switches ·····································································································5-18
iv
E Series Controller
Kawasaki Robot Arc Welding Operation Manual
vi
E Series Controller 1. Overview of Arc Welding Control
Kawasaki Robot Arc Welding Operation Manual
The standard E series controller has been incorporated with control functions specific to arc
welding. With these functions, the robot can be programmed to work flexibly and efficiently
with weld machines to produce variety of high quality welds.
Arc welding robot system consists mainly of the following components. See the figure below.
This manual mainly focuses on No.2 above, regarding items relating to E Series Controller for arc
welding. For details about other materials, see the standard operation manual, specification
sheets, etc.
Wire feeder
E Series Controller
for arc welding
1-1
E Series Controller 1. Overview of Arc Welding Control
Kawasaki Robot Arc Welding Operation Manual
Specifications for arc welding control are as follows. For details about other standard
specifications, refer to the Operation Manual for E series controller.
2. Arc welding control functions: Command of arc welding voltage/current to the weld power
supply, motor control for wire feed (including inching/retract),
gas supply ON/OFF, weld stuck detection
1-2
E Series Controller 2. Hardware Keys on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
This chapter describes hardware keys on teach pendant specially for arc welding specification.
For details about other standard keys, refer to Operation Manual for E series controller- 2.4
Switches on Teach Pendant and Functions of Hardware Keys.
Figure 2.1 shows the arrangement of the hardware keys on arc welding teach pendant.
Figure 2.1
2-1
E Series Controller 2. Hardware Keys on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
This chapter describes the function of each of the hardware keys for arc welding closed by
in Figure 2.1
Keys Function
Feeds weld wire when pressed. See 4.2 Inching Operation for Weld
Wire for more details. Pressing F key <Wire Inching> changes the speed
at which wire is fed.
Manually turns ON shield gas supply when pressing A + GAS ON. The
gas is turned ON only while the key is pressed.
Retracts weld wire when pressed. The wire is retracted only while the
key is pressed. See 4.2 Inching Operation for Weld Wire for more
details. Pressing F key <Wire Inching> changes the speed at which wire
is pulled back. Pressing A + CND.CHG. displays Real Time Condition
Modify screen in C area.
A + WELD ON/OFF selects weld ON and OFF during repeat/check
operations.
A + WELD CND. selects the weld conditions (Spd Amp Vlt Tmr Amp
Vlt) set for the weld condition number on block teaching screen. See
5.2.3 Configuration of Teach Screen for picture.
A + SPEC.CND. selects the special condition column on block teaching
screen. See 5.2.3 Configuration of Teach Screen for picture.
2-2
E Series Controller 3. Instructions for Operating Screen on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
This chapter describes the screens on the teach pendant used for operating the arc welding
functions. For details about other standard operating screens, the functions available on each
screen and their operation procedures refer to Operation Manual for E series controller-2.4
Switches on Teach Pendant and Functions of Hardware Keys.
3-1
E Series Controller 3. Instructions for Operating Screen on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
When weld is set ON by pressing A + WELD ON/OFF, the following icon is displayed in the
status (F) area as shown below.
3-2
E Series Controller 3. Instructions for Operating Screen on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
The chart below shows the functions of the arc weld specification F keys (shown as 1 to 3 in
figure below), displayed on teach mode screen. For other F keys, see the Operation Manual for
E series controller 2.6 Operation Keys on Teach Pendant Screen.
2 3
3-3
E Series Controller 3. Instructions for Operating Screen on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
In arc welding specification, the items below are added to the standard specification menu.
1. PC program (Monitor function no. 27)
2. Arc status (Monitor function no. 82)
3. Step information (Monitor function no. 83)
Figure 3.1
For details on other monitor functions on the menu, see the Operation Manual for E series
controller 2.9 Monitor Screen.
3.3.1 PC PROGRAM
Selecting [PC Program] in Figure 3.1 displays the screen in C area similar to Figure 3.1
Figure 3.2
3-4
E Series Controller 3. Instructions for Operating Screen on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
Selecting [Arc Status] in the screen shown in Figure 3.1 displays current robot status, arc weld
conditions, etc. as shown in Figure 3.3.
Figure 3.3
The following items are shown highlighted when the I/O signal is ON.
Input Signal: Current Detect, Pole Stuck, Torch Interfere, Wire Touch, Wire Stuck
Output Signal: Arc ON, Wire Inching*, Wire Retract*, Gas ON, Touch Sensor ON, Weld ON
NOTE* For Wire Inching or Wire Retract, only one output signal can be ON. They cannot be
ON simultaneously.
In Curr. Comm. and Volt. Comm., the current command values are displayed.
Current Command: 0.00 - 15.00 V
Voltage Command: 0.00 - 15.00 V
3-5
E Series Controller 3. Instructions for Operating Screen on Teach Pendant
Kawasaki Robot Arc Welding Operation Manual
Selecting [Step (Aux)] in Figure 3.1 displays the screen in C area as shown in Figure 3.4.
Figure 3.4
This screen displays all the auxiliary data for the selected step in the selected program. During
repeat operation, etc., when a step moves forward, the contents of the currently running step are
displayed.
3-6
E Series Controller 4. Manual Operation of Robot
Kawasaki Robot Arc Welding Operation Manual
When wire feeder or shield gas supplying unit are connected to E series controller, the teach
pendant can be used to manually inch/retract weld wire or turn ON/OFF gas supply in addition to
the normal robot operations by teach pendant. For details about connecting devices, see
Installation and Connection Manual for arc welding E series controller.
Same as standard specification robots, the arc welding robot can be driven manually in the
desired mode: joint, base coordinate based, or tool coordinate based. For more details, see
Operation Manual for E series controller- 4.0 Manual Operation of Robot.
This section describes the align operation, a function useful for arc weld teaching. Instructions
are also given for setting the robot installation posture in Aux. Function 0505 Robot Installation
Posture. In addition, the fixing of the +Z base axis in vertical direction regardless of the posture
set in Aux. 0505 is explained in detail.
Aligning function rotates the tool to make the Z axis of the tool coordinates parallel to the nearest
base coordinate axis during teaching. This is convenient for aligning the tool direction with the
Z axis of the base coordinates (especially when teaching downward welds) before teaching a weld
line.
Base coordinate
system
4-1
E Series Controller 4. Manual Operation of Robot
Kawasaki Robot Arc Welding Operation Manual
2. While pressing down the TRIGGER, press A + JT6 +/- for aligning at 45°, and A + JT7 +/-
for aligning at 90°. For 90° alignment, robot arm stops and align is complete when Z axis of
the tool becomes parallel to the base coordinates Z axis.
Z
X
45° Z
X
45° Base coordinates Base coordinates
Y system Y system
[ NOTE ]
Aligning operation can also be used for aligning the tool coordinates with
the base coordinates X or Y axes. Before aligning, move the tool near the
desired base coordinates axis and then execute the procedure described
above.
4-2
E Series Controller 4. Manual Operation of Robot
Kawasaki Robot Arc Welding Operation Manual
The +Z direction of the base coordinate motion can be set perpendicular upwards during teaching,
once the actual installation posture is made to match the posture set in the controller.
The direction of robot’s base coordinates is set as shown in the figure below. However, the
value of the base coordinates must have O, A, and T set to 0(zero) in Aux. Function 0506 Base
Coordinates.
Floor Ceiling
Wall Wall 2
4-3
E Series Controller 4. Manual Operation of Robot
Kawasaki Robot Arc Welding Operation Manual
Setting procedure
Press WIRE INCHING or WIRE RETRACT to feed or withdraw weld wire. Inching operation
is possible when both weld power supply and controller power are ON regardless of ON/OFF
status of TRIGGER, TEACH LOCK, RUN/ HOLD, etc. However, inching operation for servo
torch spec. (Option) is possible only when TRIGGER, TEACH LOCK and MOTOR ON are ON
and RUN/ HOLD is set to RUN in teach mode.
Press A + GAS ON to turn ON/OFF shield gas supply. Gas ON/OFF operation is possible
when both weld power supply and controller power are ON regardless of ON/OFF status of
TRIGGER, TEACH LOCK, RUN/ HOLD, etc.
4-4
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
5.0 TEACHING
This chapter describes procedures for teaching and editing programs via the teach pendant using a
simple arc welding program as an example. For details on programming via AS language, refer
to Arc Welding AS Language Reference Manual for E series controller.
5-1
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
First enable manual operation of the robot, then start teaching by the following procedure with
teach pendant.
Air Cut (AC) Weld Start (WS) Weld Continue Weld End (WE) Arc Spot (AS)
point (P0/P3) point (P1) (WC) point point (P2) point
No Set standard
auxiliary data to the
point?
Change auxiliary data. Yes
Press ↵ to
confirm.
Yes
Final point?
No
To next point. End
5-2
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
The table below shows the types of teaching points and auxiliary data which are set/modified for
arc weld teaching. Set the teaching points with auxiliary data, instructions (Mtd).
5-3
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
By itself pose data for P0 to P3 is insufficient for operating the robot arc welding functions.
Additional data must also be taught to the robot, for example the speed for moving from P0 to P1,
how closely the torch tip comes to the taught point when arriving at P1 (accuracy), etc. This is
called auxiliary data. Furthermore, data specifying the weld quality such as weld speed, weld
current, weld voltage, etc. is also needed, which is called weld condition.
Two methods for setting the weld conditions are available during teaching.
5-4
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
The following weld conditions are available as shown in the table below.
(Unit: cm/min)
Weld current Sets weld current.
(Unit: Ampere (A))
Weld voltage Sets weld voltage.
(Unit: Volt (V))
Weaving width Sets amplitude in weaving.
(Unit: mm)
Weaving Condition
5-5
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
This section describes teaching operations specific to arc welding application. For standard
teaching methods, refer to Operation Manual for E series controller- 5.0 Teaching.
Once the teaching contents are determined, fill in the auxiliary data on program sheet.
The following sheet shows a sample program for teaching horizontal fillet welding. Teaching
operation of this program is explained in 5.2.4 Teaching Operation. A blank program sheet is
attached in Appendix 1. Program Sheet; make copies of use for when planning programs.
11 P0 AC JOINT 9 2 0
22 P1 WS LINEAR 9 - 0
3 P2 WC LINEAR - - - 0
4 P3 WE LINEAR - - - 0
5 P4 AC LINEAR 9 2 0
6 P5 AC JOINT 9 2 0
[ NOTE ]
5-6
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
To teach a program, first determine the work to be performed, then create a program sheet.
Before starting the teaching process, check the following two items.
Set the tool transformation value for the torch. When using a standard torch, refer to Aux.1405
in 8.0 Auxiliary Functions.
[ NOTE ]
When executing arc welding, set the wire extension length (mm) according to welding posture
and leg length. For details, refer to Aux.1405 in 8.0 Auxiliary Functions.
5-7
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
The configuration of the teach screen for arc welding is as shown in the figures below. To
switch between screens, press A + → or ←. For more details about using teaching screens,
refer to Operation Manual for E series controller- 5.0 Teaching.
* *
5-8
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
5-9
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
This section describes how to teach the robot to perform horizontal fillet welding via the five
points shown in Figure 5.1 below.
P4
Escape point
(Air cut point)
P0
Work start point
& P2
P5 (Weld continue
Work end point point)
P3 (Weld end point)
P1
(Weld start point)
Figure 5.1
Teaching procedure
1. First, set the program name to be edited. The teach screen in Figure 5.2 below displays the
setting of program pg10.
Figure 5.2
5-10
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
[ NOTE ]
3. Teach step1.
P0
P5
P2 ・P
4
P1 P3
5-11
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
(2) Set the auxiliary data, the instruction* to AC, the interpolation to joint, the speed to 9, the
accuracy to 2 and the timer to 0.**
Move cursor to the auxiliary data title row by pressing either A + INSTR. or by → or ←.
⇓
Pressing ↵ changes the instruction setting on the edit row as “AC (Air Cut point (point not
welded)) → WS (Weld Start point) → WC (Weld Continue point) → WE (Weld End point) →
AS (Arc Spot point)”.
⇓
When the desired instruction appears (in this case, AC), then the instruction setting is complete.
NOTE** To set the interpolation, speed, accuracy and timer, refer to Operation Manual for E
series controller- 5.3 Element Instruction and Their Parameters. Note some
interpolation modes may not be available for an instruction as shown below.
(3) Press RECORD to teach the pose and the auxiliary data of step1 at the same time. The teach
screen will appear as shown in Figure 5.3.
Figure 5.3
5-12
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
4. Teach step2.
Switch to inching
Set torch angle (θ1) mode when torch
approx. 45° at P1. is set close to P1.
P1
θ1= approx. 45°
Keep approx. 1mm
from corner.
(1) Press INTER and select base mode, then TEACH SPEED to select desired speed.
(2) Move torch tip near P1 by +/-. Then press TEACH SPEED to select the inching mode
(Speed 1), and move the robot at very slow speed to set the torch tip to P1 accurately.
(3) Set the auxiliary data, the instruction to WS, the interpolation to linear, the speed to 9, and the
timer to 0.
(4) Press RECORD to teach the pose and the auxiliary data of step2 at the same time. The teach
screen will appear as shown in Figure 5.4.
Figure 5.4
5. Teach step3.
P’2
Approx.
P’1 θ1=approx. 45°
1mm
P2 At P2, set torch posture by
torch angle θ1 and angle with
θ2=approx. 45° vertical plate θ2 to be approx.
P1 45° respectively.
Approx.
1mm
5-13
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
(4) Move the torch tip to P’2 near P2 by +/-. Then press TEACH SPEED and select the inching
mode (Speed 1). Move the robot at very slow speed to set the torch tip to P2 accurately.
(5) Set the auxiliary data, the instruction to WC, the interpolation to linear, and the weld condition
number* to 0. (In this example, weld condition No. 0 contains the data for welding
horizontal fillet with leg length/thickness of 5mm. For more details, refer to Aux.1401 (Arc
Weld Condition in 8.0 Auxiliary Functions).)
Move cursor to Weld Condition Number on the auxiliary data title row by pressing either A +
CND.NUM. or by → or ←. The screen below appears, so input the desired weld condition No.
and press ↵. Input range for weld condition No. is from 0 to 99. Input 100 to directly specify
the weld condition. (In this example, 0 is specified).
Pressing <Setting> in the above screen changes the display to screen for Aux. 1401 Arc Weld
Condition. The weld conditions can be set in that screen.
(6) Press RECORD to teach the pose and the auxiliary data of step 3 at the same time. The
teach screen will appear as shown in Figure 5.5.
Figure 5.5
5-14
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
6. Teach step4.
θ1=approx. 45° P3
Approx. 1mm
(1) Set the auxiliary data, the instruction to WE, the interpolation to linear, and the weld condition
number to 0. (In this example, weld condition No. 0 contains the data for welding horizontal
fillet with leg length/thickness of 5mm, and crater condition. For more details, refer to
Aux.1401 (Arc Weld Condition).)
Weld condition numbers are the same for P1→P2 and P2→P3, thus step4 is automatically set
with the same conditions as in step3. Take note that crater treatment condition is only
reflected in weld end step.
(2) Press RECORD to teach the pose and the auxiliary data of step4 at the same time. The teach
screen will appear as shown in Figure 5.6.
Figure 5.6
5-15
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
7. Teach step5.
P3
P4
(1) Set the auxiliary data, the instruction to AC, the interpolation to linear, the speed to 9, the
accuracy to 2 and the timer to 0.
(2) Press RECORD to teach the pose and the auxiliary data of step5 at the same time. The teach
screen will appear as shown in Figure 5.7.
Figure 5.7
8. Teach step6 by following the same procedure used in 3. above where P0 is taught. (See page
5-10 for procedure No. 3.)
5-16
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
In arc welding specification, the following auxiliary data can be set in addition to those described
above.
5-17
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
When Option functions are installed, option switches can be set in AC, WS and WE steps. For
details about the setting of these switches, refer to related option manual and 9.0 Touch Sensing
Function (Option).
1. In WC or WE steps press <Setting> in the screen that appears after pressing A + WELD CND.,
or move cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*) on the auxiliary
data title row by pressing → or ←, and press ↵. Aux. Function 1401 Arc Weld Condition is
displayed. For details about making settings on this screen, refer to Aux.1401 in 8.0
Auxiliary Functions.
2. In AS (Arc Spot) steps, press <Setting> in the screen that appears after pressing A +
WELD CND., or move cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*) on
the auxiliary data title row by pressing → or ←, and press ↵. Aux. Function 1402 Arc Spot
Weld Condition is displayed. For details about making settings on this screen, refer to Aux.
1402 in 8.0 Auxiliary Functions.
In WC or WE steps, move cursor to Special Condition on the auxiliary data title row by pressing
either A + SPEC.CND. or by → or ←, and press ↵. Aux. Function 1401 Arc Weld Condition
is displayed. For details about making settings on this screen, refer to Aux. 1401 in 8.0
Auxiliary Functions.
5-18
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
Using the real time weld condition modification function, weld speed, current, and voltage can be
changed during check operation. Any changes made to the weld conditions can then be
overwritten onto taught data in check mode. This function is also available in repeat operation
although overwriting is not allowed.
2. In WC or WE steps, press A + CND.CHG. or F key <Real Time Condition> to display the real
time condition modify screen in C area as shown in the figure below.
5-19
E Series Controller 5. Teaching
Kawasaki Robot Arc Welding Operation Manual
[ NOTE ]
1. During weld ON, weld speed, current, and voltage can be modified. To
overwrite weld condition data with the current changes, press <Data Set>.
During weld OFF, weld conditions cannot be modified.
2. When the taught data is overwritten in this manner, the weld condition is
considered to be direct setting even though it was originally indirect setting.
3. Real time condition modification for crater treatment and arc spot welding
is not possible at WE step.
! WARNING
If you watch the weld bead while using the real time weld
condition modification function, use face shield without fail,
and avoid looking directly at the arc.
5-20
E Series Controller 6. Repeat Operation
Kawasaki Robot Arc Welding Operation Manual
Repeat operation plays back and executes the contents of a program that was taught to the robot.
This chapter describes the functions available for arc welding application during repeat operation.
For details about standard repeat operation procedure, refer to Operation Manual for E series
controller- 6.0 Repeat Operation.
Using the real time weld condition modification function, weld speed, current, and voltage can be
changed during repeat operation. However, the changed weld conditions cannot be overwritten
onto taught data. Overwriting is possible in check mode. Refer to 5.4 Real Time Weld
Condition Modification Function for more details.
[ NOTE ]
1. During weld ON, weld speed, current, and voltage can be modified.
During weld OFF, only the weld speed can be changed.
2. Real time condition modification for crater condition and arc spot
condition is not possible at WE step.
! WARNING
If you watch the weld bead while using the real time weld
condition modification function, do not fail to use face shield,
and avoid looking at the arc directly.
6-1
E Series Controller 6. Repeat Operation
Kawasaki Robot Arc Welding Operation Manual
6-2
E Series Controller 7.0 Program Modification
Kawasaki Robot Arc Welding Operation Manual
This chapter explains about the program editing screen for arc welding specification. For general
operations of the program editing screen, see the Operation Manual for E series controller- 7.3
Edit on the Program Edit Screen.
The taught data are modified via the edit screen as follows:
1. Pressing A+←/→ scrolls the page and displays the data as shown in the figures below.
7-1
E Series Controller 7.0 Program Modification
Kawasaki Robot Arc Welding Operation Manual
3. Modify each data using the Number keys. Modification procedure differs according to the type
of data as 1 and 2 below.
1. Entering values other than for option switch, weld condition, WV, special conditions , Output(O),
input (I), and comment:
1) Move the cursor to the desired item.
2) Enter the necessary values according to the explanation in the chart below.
Item Explanation
Instruction Specify the instruction. (0:AC, 1:Start, 2:Midpoint, 3:End, 4:AS)
*
Interpolation Specify the interpolation mode. Refer to the Operation Manual for E Controller
7.3.3 Step Data Modification on Edit Screen.
No Specify the weld condition number. 0 – 99: Condition number, 100:Direct
input.
Speed Specify the speed. Refer to the Operation Manual for E Controller 7.3.3 Step
Data Modification on Edit Screen.
Accuracy Specify the accuracy. Refer to the Operation Manual for E Controller 7.3.3
Step Data Modification on Edit Screen.
Timer Specify the timer. Refer to the Operation Manual for E Controller 7.3.3 Step
Data Modification on Edit Screen.
J/E Specify the J/E instruction. Refer to the Operation Manual for E Controller
7.3.3 Step Data Modification on Edit Screen.
Pose data Specify the pose data. Refer to the Operation Manual for E Controller 7.3.3
Step Data Modification on Edit Screen.
3) Press ↵ after entering each value. When all the necessary items are input, press <ENTER>
to register.
NOTE* Interpolation setting that can be used depend on the instruction mode, as shown below.
2. Entering values for option switch, weld condition, WV, special conditions , Output(O), input (I),
and comment:
1) Move the cursor to the desired item and press ↵.
7-2
E Series Controller 7.0 Program Modification
Kawasaki Robot Arc Welding Operation Manual
2) The screen for data setting is display, so enter the values and comments to modify. See the
table below for how to input the values.
Item Explanation
Option Switch See 5.3.1 Setting Option Switches.
3) Press ↵ after entering each value. When all the necessary items are input, press <ENTER>
to register.
7-3
E Series Controller 7.0 Program Modification
Kawasaki Robot Arc Welding Operation Manual
Using this function enables modification of programs that are in repeat operation, although with some
restrictions. This section explains about the online editing function for arc weld specification. For
online operations common to all specifications, refer to the Operation Manual for E controller 7.3 Edit
on the Program Edit Screen
The following screens can be edited via the online editing function.
1. Editing
Basically is the same as explained in 7.1 Program Editing Screen, but there are few data that
cannot be changed in online program editing. For details, see “2. Save as” below.
2. Save as
In online program editing, the following data cannot be modified: instruction. Interpolation,
No, option switch, weld condition, WV, special condition, pose and comment. (Weld
condition may be changed when specified in the program as weld condition number and not
specified by direct number). When any of these are changed, save the program with a new
name following the procedure described in the Operation Manual for E Controller 7.4.2 Functions
on Online Edit Screen.
7-4
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
! WARNING
Use auxiliary functions for arc welding specification in the following cases.
Only auxiliary functions related arc welding are described here. For other auxiliary functions,
refer to Operation Manual for E series controller- 8.0 Auxiliary Functions, and for methods on
calling up the auxiliary function screen, see 8.2 How to Use Auxiliary Functions.
Select [14. Arc Weld] in the auxiliary function screen to call up the arc welding auxiliary function
list as shown below.
8-1
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
1401 ARC WELD CONDITION Displays and sets arc weld condition data.
ARC SPOT WELD Displays and sets arc spot weld condition data.
1402
CONDITION
ARC WELD CONDITION Displays and sets arc weld condition database.
1403
DATABASE
1404 ARC WELD SETTING Displays and sets various kinds of data for arc welding.
ARC WELD TORCH Displays and sets arc weld torch dimensions.
1405
DIMENSION
ARC WELD CONDITION Changes arc weld conditions for specified steps. (direct
1406
MODIFY teaching method)
ARC SPOT WELD Changes arc spot weld conditions for specified steps.
1407
CONDITION MODIFY (direct teaching method)
8-2
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
8-3
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
[ NOTE ]
1. [Pole Ratio] and [Weaving Data- Pattern] are displayed only when Option is installed.
2. Direct setting screen for arc weld conditions is not displayed. To specify or display the arc
weld condition of direct setting, see 3. below and set by Aux.1401 or Aux.1406.
3. In WC or WE steps, move cursor to “No.” on auxiliary data title row and press ↵ to display
the weld condition number input screen as shown in 5.2.4 (5) . Enter 100 and press
<Setting> to display the screen above. Directly input the condition number in this screen.
To select the weld condition No., refer to 5.2.4 Teaching Operation. (This method is also
available for indirect setting.) (Auxiliary function screen is also called up by moving
cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*) WV (Wid Freq Pat*),
and then pressing ↵.) At this time,
(1) the screen can be called up only in teach mode with teach lock ON.
(2) arc weld condition data set by direct method cannot be seen in repeat mode.
8-4
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
[ NOTE ]
1. [Pole Ratio] is displayed only when Option is installed.
2. Direct setting screen for arc spot weld condition is not displayed. To specify or display the
arc spot weld condition of direct setting, see 3. below and set by Aux.1402 or Aux.1407.
3. In AS (Arc Spot) steps, move cursor to “No.” on auxiliary data title row and press ↵ to
display the weld condition number input screen as shown in 5.2.4 (5) . Enter 100 and
press <Setting> to display the screen above. Directly input the condition number in this
screen. To select the weld condition No., refer to 5.2.4 Teaching Operation. (This
method is also available for indirect setting.) (Auxiliary function screen is also called up
by moving cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*), and then
pressing ↵.) At this time,
(1) the screen can be called up only in teach mode with teach lock ON.
(2) arc spot weld condition data set by direct method cannot be seen in repeat mode.
8-5
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
In the arc weld condition database, weld data (speed, current, voltage, polarity ratio*), crater
treatment data (time, current, voltage) and weaving data (width, frequency, pattern*) can be set
and modified for each weld joint shape and leg length/thickness. This database provides a
convenient means of calling up data when setting weld conditions by either the direct or indirect
teaching Aux. screens.
As shown in the figures below, move cursor to [Big Category] to display big category items and
to [Small Category] to display small category items which correspond to the selected big category
items. Select the desired item for each category by Number (0-9).
Pressing <Display> displays the weld condition data for the selected big/small category items on
the right half of the screen. In the figures above, weld condition data is for [1. H FILLET] of
[Big Category] and [1. 3mm] of [Small Category].
8-6
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
NOTE* [Pole Ratio] and [Weaving Data- Pattern] are displayed only when Option is installed.
! CAUTION
8-7
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
This function sets various kinds of data for arc welding operation.
Move the cursor to [1404. Arc Weld Setting] in the auxiliary function screen to display the
auxiliary function list as shown in the figure below. Some menu items are Options and may not
be shown depending on robot specification.
Overview of each function is shown in the table on next page. The subsections hereafter
describe each of these functions.
8-8
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
Weld machine
command
Set current/voltage
Weld Start Sequence Sets various kinds of data for arc weld sequence and enables
changing of the weld sequence.
Software Slow Down Sets weld conditions for the time up until arc is generated at arc
start. Enables superior arc start settings.
Weld Stuck Cancel Sets various kinds of data to automatically release when weld
Sequence wire is stuck.
Arc Spot Sequence Sets various kinds of data for arc spot weld sequence.
Preflow/Afterflow Sets time for preflow/afterflow.
Wire Inching/Retract Sets speed for inching/retracting weld wire.
Weld ON/OFF in Check Sets weld ON/OFF at check operation.
Touch Sensing (Option) Sets various kinds of data for touch sensing function. For more
details, see also 8.0 Touch Sensing Function (Option).
Special Pattern Weaving Enables registration of special weaving patterns for reference
(Option) during program execution. For more details, see also 9.0
Special Pattern Weaving Function (Option).
Servo Torch (Option) Sets various kinds of data for servo torch function. For more
details, see also 10.0 Servo Torch Function (Option).
8-9
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
AUX.1404-1 LINEARIZATION
This function calibrates the absolute values for current/voltage for each weld method, wire
diameter, wire extension length, wire type, and weld machine with the voltage that is actually
commanded to weld machine.
! CAUTION
8-10
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
Weld current
1. Move cursor to each item and
input required data by Number
(0-9). If the setting is correct,
press ↵.
Weld voltage
1. Move cursor to each item and
input required data by Number
(0-9). If the setting is correct,
press ↵.
Once setting is complete, weld current/voltage values are sorted in ascending order when the
setting screen is displayed again.
8-11
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
When current/voltage are set for the weld condition, the voltage value to be sent to weld machine
is then determined by linearization as per the linearization data. For example, the command
value to weld machine is as follows when setting the weld current/voltage value in the figure on
the previous page (outputs 4.74V by 224A and 7.967V by 19.2V, and outputs 3.53V by 192A and
6.639V by 16V) and executing welding of 210A and 18V.
8-12
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
Aux.1404-2 OFFSET/GAIN
In order to realize the specified current/voltage during actual welds, this function sets offset and
gain values for adjusting the standard linearization characteristics.
! CAUTION
[ NOTE ]
8-13
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
8-14
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
To start welding more smoothly, the following two types of weld start sequences have been
provided.
Robot moves to the next teach point from weld start point during which time arc is generated.
This is called scratch start as it looks like the torch scratches the work, and it is used mainly for
welding a long weld line. This robot motion is further classified into two types depending on
the distance between taught weld start point and the point the arc is actually generated.
1) Distance from start point to arc generating point is less than [Keep Welding Distance (A)]
If arc is generated within (A) distance, welding continues toward the next weld continue (end)
point.
8-15
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
2) Distance to arc generating point after passing (A) is less than [Turn Back Distance (B)]
If arc is generated within (B) distance, robot welds moving backwards to the weld start point, and
continues welding toward the next weld continue (end) point. When no arc is generated even
after passing (B) distance, error occurs.
Arc generating point
Robot stops at weld start point until arc is generated. After arc generation, welding continues
toward the next weld continue (end) point. Standstill time is variable and when arc is not
generated within the set time, an error occurs.
2. Restart sequence
This sequence is used for restarting the welding after robot stops welding for some reason.
e.g.) After arc deficiency by tip friction, etc. After holding.
Scratch start or standstill start can be executed in restart sequence. However, in order to bury the
crater caused by the weld stop, robot moves back to the point where welding stops after arc
generation and to restart welding with an overlap welding.
e.g.) After calculating remaining distance and restarting by a scratch start
Weld start point Arc generating point
Normally when No. of times for retry is not set, an error occurs if arc is not generated. However,
if set, the weld start sequence (scratch start/standstill start) will be attempted the set No. of times.
Wire can be retracted before the retry, and retract time and No. of times for retract can be set or
modified.
8-16
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
This function changes weld conditions for the time up until arc is generated. For example, when
the base metal surface is resistant to current flow and generation of arc is difficult, weave for
increased generation until the arc is actually applied to the surface.
8-17
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
After crater treatment or arc spot welding at weld end point, weld stuck detecting is executed
automatically. When wire is stuck, this condition is automatically released by arc generation
under the crater/arc spot conditions (Weld Stuck Cancel Sequence). When weld stuck cancel
does not succeed after attempting sequence set No. of Detecting Times, error occurs. Note
that cancel sequence is not possible if crater treatment was not executed.
Weld stuck? No
(Detecting)
Yes To next step
No
Error
Arc ON
8-18
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
8-19
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
AUX.1404-7 PREFLOW/AFTERFLOW
This function inches/retracts wire during air cut operation. This is executed in 0.5 sec
increments as robot moves per the air cut instruction taught this setting.
8-21
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
8-22
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
(1) In the setting above, distances between B’ and B, and B and B’’ are both 20mm.
(2) The faster the sensing speed, the greater the weld wire bends at touch and then correcting
accuracy becomes decreased. However, wire bend varies depending on sensing direction,
wire diameter, material, etc.
(3) These parameters are provided for the work detection and work position compensation
functions. For more details, see 8.3 Work Detection Function and 8.4 Compensation
Function for Work Deviation.
8-23
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
8-24
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
This function sets various kinds of data for servo torch function.
Select [16. Servo torch] in [1404. Arc Weld Setting] to display the auxiliary function list shown in
the figure below.
Overview of each function is shown in the table below. The subsections hereafter describe each
of these functions.
Linearization Sets the relation between weld current command values (A) and wire
feeding speeds (rpm).
Torch data Sets the speed reduction ratio, number of bits changed per encoder
rotation and direction of motor rotation for the servo torch.
Servo adjustment Adjusts the servo parameters that control the feeding.
Inching speed Registers the wire inching/retract speed that corresponds to each
teach speed, set by pressing TEACH SPEED.
Start/End sequence Sets the parameters that control the wire feeding at weld start/end.
8-25
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
AUX.1404-16-1 LINEARIZATION
This function sets the relation between weld current command values (A) and wire feeding
speeds (rpm) for each weld method, wire diameter, wire extension length, wire type, and weld
machine.
! CAUTION
8-26
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
When current/voltage are set for the weld condition, the rotation speed to be sent to servo torch
motor is then determined by linearization as per the linearization data. For example, the
command rotation speed to servo torch is as follows when setting the weld current value in the
figure on the previous page (outputs 102rpm by 250A and 81rpm by 200A) and executing
welding of 210A and 18V.
Note that max. command rotation speed cannot exceed the max. value set in this linearization
table.
8-27
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
This function sets the speed reduction ratio, number of bits changed per encoder rotation and
direction of motor rotation for servo torch.
8-28
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
This function adjusts the servo parameters that control the wire feeding. The following three
setting items can also be set in Aux.2007-2 External Axis Servo Parameter- Full Spec Tuning.
In that auxiliary function screen, Servo gain is KVP, Torque limit (plus direction) is IQCLP, and
Torque limit (minus direction) is IQCLM.
8-29
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
This function registers the wire inching/retract speed that corresponds to each teach speed, set by
pressing TEACH SPEED.
8-30
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
This function sets the parameters that control the wire feeding at weld start/end.
8-31
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
Wire feeding
speed at welding
Weld in progress
Time (t)
Wire feeder Waiting WCR Hot start 1 Hot start 2
on delay detection
WCR
Arc ON signal
At start of welding
8-32
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
Wire feeding
speed at welding
Arc ON signal
Time t
Wire feeder off delay Flare up time
Speed
Time t
Time1 Time2 Time3 Time4
Detecting weld
stuck
Arc ON signal
8-33
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
When using a standard arc weld torch as shown below, tool transformation values can be set by
registering length of the weld torch, torch installation angle and wire extension length.
! CAUTION
8-34
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
This function changes the weld conditions for a block of weld continue or weld end points that
were taught by direct teaching method. To change the weld conditions for a range of points
taught by indirect method, use Aux.1401.
[ NOTE ]
8-35
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
NOTE* From the range of selected steps, the data of the step first taught by direct teaching
method is displayed in this screen.
Press <Auto Set> to refer to the arc weld condition database screen. For details about
this screen, refer to Aux.1403.
[Pole Ratio] and [Weaving Data- Pattern] are displayed only when Option is installed.
[ NOTE ]
1. Changes apply only to the weld continue or weld end points in the specified
range that were taught by direct teaching method. Data of other steps in
the range are not affected.
2. To change weld conditions in weld continue or end points taught by indirect
method, see Aux.1401 Arc Weld Condition.
8-36
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
This function changes the weld conditions for a block of arc spot weld points that were taught by
direct teaching method. To change the arc spot weld conditions for a range of points taught by
indirect method, use Aux.1402.
[ NOTE ]
8-37
E Series Controller 8. Auxiliary Functions
Kawasaki Robot Arc Welding Operation Manual
NOTE* From the range of selected steps, the data of the arc spot step first taught by direct
teaching method is displayed in this screen.
[ NOTE ]
1. Changes apply only to the arc spot points in the specified range that were
taught by direct teaching method. Data of other arc spot steps in the range
are not effected.
2. To change AS (Arc Spot) weld conditions in arc spot points taught by
indirect method, see Aux.1402 Arc Spot Weld Condition.
8-38
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
This chapter describes touch sensing function by optional specification and the teaching
operation.
When using the robot to weld, good positioning accuracy is required for both workpiece and for
arc torch relative to the workpiece. However, at the weld production site, perfect accuracy
cannot always be guaranteed. Thus, to achieve better, more consistent accuracy, use the touch
sensing function in the following situations.
9-1
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
When planning a weld operation, determine beforehand the direction in which the workpiece may
deviate. In addition, one must be considered the kind of workpiece to be welded, and workpiece
deviation amount.
This section describes seven kinds of sensing patterns by which workpiece deviation
compensation are made. Sensing patterns can be used alone or in combination (max. of three
patterns).
9-2
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Types of sensing
Relation between
workpiece deviation No need to be No need to No need to No need to be No need to
Vertical Vertical
direction and control vertical be vertical be vertical vertical be vertical
surface
Relative relation of 2
control surfaces 2 orthogonal 3 orthogonal orthogonal 2 orthogonal
⎯ ⎯ ⎯
flat surfaces flat surfaces flat flat surfaces
surfaces
Order of teaching
⎯ ⎯ ⎯ Specified Specified Specified Specified
points
9-3
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
9-4
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Direction of
workpiece deviation (1) Condition of workpiece
Control
surface 2 1) Workpiece moves parallel in space (in
three directions).
A2 2) Control surfaces (1, 2 and 3) are flat
Control
surface 3
and orthogonal to each other.
BB22 B
9-5
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
conditions.
1) Lines A1B1, A2B2, and A3B3 are
B B B
9-6
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
B1
left figure.
Set surface
following conditions.
1) Lines A1B1 and A3B3 are parallel to the
B B
(90° is desirable).
3) Distances between B1 and B2/B3 and B4
are 10 mm or more.
9-7
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
conditions.
1) Lines A1B1, A2B2, and A3B3 are
B B B
(90° is desirable).
9-8
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
A2
B2 (2) Sensing point
B3 1) Execute sensing of two points on one
Control sensing surface and one point on the
surface 1
other surface, B1, B2, and B3 in left
A3 Control Deviation
figure.
surface direction
Control B1 2) B1 and B2 are on the same surface.
surface 2
Set surface
(3) Teaching point
Teach the points in order of A1, B1 →A2,
B2 → A3, B3 with the following
B
conditions.
1) Lines A1B1, A2B2, and A3B3 are
B B B
[ NOTE ]
9-9
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
! WARNING
1. To keep a constant wire extension length without using wire cutter devices, etc.
2. At pre welding points, set the wire to the desired length in 1. above.
The following subsection describes the teaching operations. For standard teaching methods,
refer to 5.0 Teaching and Operation Manual for E series controller- 5.0 Teaching.
Point A
Workpiece
9-10
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
[ NOTE ]
1. Only air cut points can be taught the wire check function.
2. Teach the wire check to the point where the wire is inched to the desired
length (Point B in figure on previous page).
Work
Nozzle
Tip
Wire
Extension
length
To set the desired wire
Workpiece extension length, use a scale
as shown here.
9-11
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
The setting screen appears as in Figure 8.1. Select [3. Wire Check] to [Touch Sensing] and
press ↵.
Figure 9.1
Press RECORD to teach the wire check in the Option Switch field. The teach screen appears as
in Figure 9.2.
Figure 9.2
Work
9-12
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
! CAUTION
Wire check function is possible only when repeat mode and continuous step
are selected. Wire check function does not operate under any other
conditions. (Doing so only plays back taught contents.)
Robot moves as shown below when the program taught in 9.2.1 Teaching for Wire Check
Function is executed in repeat mode.
Point A Point C
Point B
1. When [Wire Check] is taught at point B, wire is retracted for 0.5 sec when robot starts moving
from point A to point B.
2. When arriving at point B, robot stops and inches the wire for 5 sec at a constant speed.
3. When wire tip touches the workpiece during wire inching, robot stops inching the wire and
starts moving to point C.
4. If wire tip does not touch the workpiece within 5 sec, robot outputs error- E6516 Wire check
failure.- and stops.
5. The speed for inching/retracting wire can be changed. (The time cannot be changed.) For
more details, refer to Aux.1404-8 in 8.0 Auxiliary Functions.
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
! WARNING
Workpiece detection function can check for presence of a workpiece on the set table thus
eliminating the need for sensors, switches, etc.
The following subsection describes the teaching operations. For standard teaching methods,
refer to 5.0 Teaching and Operation Manual for E series controller- 5.0 Teaching.
Point A
Point C
Point B’
Workpiece
Point B
Touch the
workpiece here.
9-14
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
[ NOTE ]
1. Only air cut points can be taught the workpiece detection function.
2. Teach the workpiece detection to the point where the wire touches the work
(Point B in figure on previous page).
B
As exact positioning is required to point B,
Extension length set the accuracy to 1. Then move cursor
(Needs to be accurate)
under Option Switch on the auxiliary data
title row by pressing A + OPTION or by
Case C
Extension length (Needs to be accurate) → or ←, and press ↵. The setting screen
appears as in Figure 8.1. Select [4.
B
Workpiece Detect] to [Touch Sensing] and
press ↵. Press RECORD to teach the
workpiece detection in the Option Switch
field. The teach screen appears as in
Figure 9.3.
9-15
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Figure 9.3
Workpiece
9-16
E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
! CAUTION
Robot moves as shown below when the program taught in 9.3.1 Teaching for Workpiece
Detection Function is executed in repeat mode.
B’’’
Work
Point A Point B
B’ B’’
Detection range
1. Register beforehand the distances between points B and B’ and points B and B’’ by
Aux.1404-10 in 8.0 Auxiliary Functions.
2. When [Workpiece Detect] is taught at point B, robot moves from point A to point B’ at the air
cut speed.
3. The wire tip moves detecting the workpiece at a constant speed from the point B’ to the point
B’’. Set this speed by Aux.1404-10 in 8.0 Auxiliary Functions.
4. When wire tip touches the workpiece (that is, workpiece detection) at point B’’’ during motion
from B’ to B’’, the robot moves to point C at the air cut speed.
5. When workpiece detection did not succeed even after arriving at point B’’, robot outputs error-
E6509 No work detected.- and stops.
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
When compensating for deviations in workpiece position, the deviation amount must be acquired
correctly. In arc weld specification robot, sensing patterns for compensation are classified into
seven types as in the table below depending on shape of workpiece, deviate direction, etc. For
details on each pattern, see 9.1.2 Sensing Patterns for Compensation of Workpiece Deviation.
It may be necessary to use a combination of two or three of the patterns above in order to
correctly acquire the deviation amounts. Apply any combination (max. of three patterns) as
needed to accommodate workpiece shape/size.
1. Case 1
(2)
Executes circumferential fillet weld of the cylinder pipe to the Cylinder pipe (1)
Compensating procedure
Working table
(1) Compensate the deviation (height of square pipe) by pattern 1.
(2) Compensate the deviation (height of cylinder pipe) by pattern 6.
(3) Execute welding.
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
2. Case 2
Using multiple patterns to compensate for workpiece deviation as above is called compensation
by combination of sensing patterns. The relation between patterns is explained below.
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
As shown in figure above, the workpiece to be welded can be compensated only after the
deviation of mother workpiece, daughter workpiece and baby workpiece are compensated in this
order.
[ NOTE ]
Compensation by combination
Z
Compensation by combination of sensing
patterns can be mathematically explained as
follows. To compensate the deviation of
coordinates systems, assume mother work
coordinates system (XM, YM, ZM) relative to
the robot base coordinates system (X, Y, Z),
daughter work coordinates system (XD, YD,
Y
ZM ZD) relative to the mother work coordinates
Mother work coordinates
YM
system (XM, YM, ZM), and baby work
Base coordinates
X ZD coordinates system (XB, YB, ZB) relative to
Daughter work coordinates
XM YD the daughter work coordinates system (XD,
XD ZB
YD, ZD) shown on left. Then obtain the
Baby work coordinates deviation of the coordinates systems and
YB
XB
compensate the deviation.
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
! WARNING
This section describes the teaching operations. For standard teaching methods, refer to 5.0
Teaching and Operation Manual for E series controller- 5.0 Teaching.
(5)
(6)
(2) (4)
(1) (3)
Cylinder work
(Mother work)
Part to be welded
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
[ NOTE ]
1. Only air cut points can be taught the deviation compensation function.
2. Teach points in order of (1)→(2)→…→(6)→(7). Execute the sensing to the
mother workpiece (cylinder workpiece) by pattern 6.
3. Teach angle made by lines (1)(2) and (3)(4) to be 30° to150° (90° is desirable).
[ NOTE ]
When torch direction is parallel to the sensed surface, wire extension length need not be
accurate. However, when it is oblique or vertical, wire length must correctly match the
set length.
Teach the following data. (Weld conditions, OX, WX, etc. are omitted.)
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Kawasaki Robot Arc Welding Operation Manual
Note that point (1) defines the sensing direction to the sensing point (2) where compensation
deviation is taught (that is, robot moves (1) to (2) when sensing). Recommended distance
between (1) and (2) is 100mm or more.
Then move cursor under Option Switch on the auxiliary data title row by pressing A + OPTION
or by → or ←, and press ↵. The setting screen appears as in Figure 8.1. Select [6. Workpiece
Reset] to [Touch Sensing]. Then move cursor to [Work] by → to display the setting screen as in
Figure 8.4. Select [1. Mother] and press ↵. Press RECORD to teach the workpiece reset
(Mother) in the Option Switch field. The teach screen appears as in Figure 8.5.
Figure 9.4
Figure 9.5
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
! CAUTION
Teach air cut (AC) for instruction, linear for interpolation, 9 for speed. As exact positioning is
required to point (2), set the accuracy to 1. Then move cursor under Option Switch on the
auxiliary data title row by pressing A + OPTION or by → or ←, and press ↵. The setting
screen appears as in Figure 9.1. Select [5. Work(piece) Modify] for [Touch Sensing]. Then
move cursor to [Work] by → to display the setting screen as in Figure 9.6. Select [1. Mother].
Move cursor to [Pattern] by → to display the setting screen as in Figure 9.7. Select reset pattern
[6] and press ↵. Press RECORD to teach the workpiece modify (Mother, 6) in the Option
Switch field. The teach screen appears as in Figure 9.8.
Figure 9.6
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Figure 9.7
Figure 9.8
3. Continue teaching points (3) to (7) following the same procedure described above. Note that
points (3) and (5) define the sensing direction to the sensing points (4) and (6) respectively
where deviation compensation is taught (that is, robot moves (3) to (4) and (5) to (6) when
sensing). Be sure to teach “workpiece mother, pattern 6” to points (2), (4), (6).
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Kawasaki Robot Arc Welding Operation Manual
! WARNING
This section describes the teaching operations. For standard teaching methods, refer to 5.0
Teaching and Operation Manual for E series controller- 5.0 Teaching.
(9)
Deviation direction of cylinder workpiece (7)
(8)
(6)
(4)
(3) Cylinder (5)
(1) workpiece
(Daughter Deviation direction of square pipe
workpiece)
Square workpiece
(Mother workpiece)
Working table
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
[ NOTE ]
1. Only air cut points can be taught the deviation compensation function.
2. Teach points in order of (1)→(2)→…→(8)→(9).
3. Execute the sensing to the mother workpiece (square workpiece) by pattern 1.
4. Execute the sensing to the daughter workpiece (cylinder workpiece) by pattern
6.
5. Teach angle made by lines (3)(4) and (5)(6) to be 30° to 150° (90° is desirable).
[ NOTE ]
Cylinder pipe
Deviation
Square pipe
Up down deviation occurs in the square Horizontal deviation occurs in the cylinder
pipe. Compensate the height by pipe. Compensate the deviation by pattern
pattern 1. Height compensation of a 6. The square pipe on which cylinder pipe
square pipe should be executed first, is placed is compensated as mother
thus select [Mother work]. workpiece, thus the cylinder pipe becomes
the second compensation, then select
[Daughter work].
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Kawasaki Robot Arc Welding Operation Manual
Teach the following data. (Weld conditions, OX, WX, etc. are omitted.)
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Then move cursor under Option Switch on the auxiliary data title row by pressing A + OPTION
or by → or ←, and press ↵. The setting screen appears as in Figure 9.1. Select
[6. Workpiece Reset] for [Touch Sensing]. Then move cursor to [Work] by → to display the
setting screen as in Figure 9.4. Select [1. Mother] and press ↵. Press RECORD to teach the
workpiece reset (Mother) in the Option Switch field. The teach screen appears as in Figure 9.5.
! CAUTION
Direction to
touch the 2. First create mother workpiece coordinates
workpiece
(square pipe) by sensing pattern 1.
is (1)→(2).
(2)
Square pipe
Teach air cut (AC) for instruction, linear
for interpolation, 9 for speed. As exact
positioning is required to point (2), set the
accuracy to 1.
Then move cursor under Option Switch on the auxiliary data title row by pressing A +
OPTION/C or by → or ←, and press ↵. The setting screen appears as in Figure 9.1. Select [5.
Work(piece) Modify] for [Touch Sensing]. Then move cursor to [Work] by → to display the
setting screen as in Figure 9.6. Select [1. Mother]. Move cursor to [Pattern] by → to display
the setting screen as in Figure 9.7. Select reset pattern [1] and press ↵. Press RECORD to
teach the workpiece modify (Mother, 1) in the Option Switch field. The teach screen appears as
in Figure 9.9.
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Figure 9.9
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Then move cursor under Option Switch on the auxiliary data title row by pressing A + OPTION
or by → or ←, and press ↵. The setting screen appears as in Figure 9.1. Select
[5. Work(piece) Modify] for [Touch Sensing]. Then move cursor to [Work] by → to display
the setting screen as in Figure 9.6. Select [2. Daughter]. Move cursor to [Pattern] by → to
display the setting screen as in Figure 9.10. Select reset pattern [6] and press ↵. Press
RECORD to teach the workpiece modify (Daughter, 6) in the Option Switch field. The teach
screen appears as in Figure 9.11.
Figure 9.10
Figure 9.11
5. Continue teaching points (5) to (9) following the same procedure described above. Note that
points (5) and (7) define the sensing direction to the sensing points (6) and (8) respectively
where deviation compensation is taught (that is, robot moves (5) to (6) and (7) to (8) when
sensing). Be sure to teach “workpiece daughter, pattern 6” to points (4), (6), (8).
The procedure is now complete. The teaching performed here creates the mother workpiece
coordinates by sensing pattern 1 and the daughter workpiece coordinates by sensing pattern 6.
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Kawasaki Robot Arc Welding Operation Manual
! CAUTION
Robot moves as shown below when the program taught in 9.4.2 Teaching- Compensation
Function for Workpiece Deviation- 1 (Teaching for Each Sensing Pattern) is executed in repeat
mode.
Point (3)
Point (1)
Sensing the
workpiece
Cylinder
workpiece
Point (2)
1. Register beforehand the touch sensing distance by Aux.1404-10 in 8.0 Auxiliary Functions.
2. The wire tip moves detecting the workpiece at a constant speed within the touch sensing
distance (sensing range). Set this speed by Aux.1404-10 in 8.0 Auxiliary Functions.
3. When wire tip touches the workpiece (that is, sensing) within the touch sensing distance
(sensing range), the robot moves to the next teaching point (point (3) in the figure above).
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
The difference between continuation and reset of compensation are described in this section by
Figures 9.12 and 9.13 which demonstrates the welding a pipe on an iron plate. In Figure 9.12,
pipes are placed on the same iron plate and are considered to deviate in one direction on the plate.
In Figure 9.13, each pipe is on a separate iron plate but deviates in the same direction.
In the case of Figure 9.12, execute one direction compensation by pattern 1 before welding pipe
No.1, then weld No.1 → No.2 → No.3 in that compensated state. In the case of Figure 9.13, on
the other hand, weld pipe No.1 by executing one direction compensation by pattern 1, and reset
the compensation (that is, reset compensation when robot moves to next teaching point.).
Execute compensation by pattern 1 again before welding pipe No.2, and then execute the same
procedure to pipe No. 3.
Based on these examples, the compensation function can be performed once, compensating the
same deviation distance on multiple workpieces – “Continuous Compensated” state, or
compensation can be performed independently for each workpiece – “Reset Compensation” state.
(See program examples on next page.)
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Kawasaki Robot Arc Welding Operation Manual
Guide
Work reset mother … Sets initialization Work reset mother … Sets initialization
(Same state at (Same state at
teaching) teaching)
Work mother pattern 1 Work mother pattern 1
…Compensated state
Weld pipe No.1. Weld pipe No.1.
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Cases for using continuous or reset compensation are classified in the table below.
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
This section describes precautions when teaching a program that uses the touch sensing functions,
wire check, workpiece detection, and compensation for workpiece deviation. Note that incorrect
operation causes sensing error or defect.
! WARNING
1. If tool dimensions are registered incorrectly, error results from the workpiece coordinates
acquired by sensing, even if workpiece is set correctly with no deviation. For more details,
see Aux.1405 in 8.0 Auxiliary Functions.
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Different!
E.g.
15mm 10mm
3. Confirm wire touches the control surface correctly and that there is conduction.
4. When condition of wire tip is not good, wire check, workpiece detection, compensation for
workpiece deviation may not be performed correctly.
The tip is cut by wire cutter, Wire tip has a lump, or spatter,
etc. and there is a good etc. adheres to the wire.
electrical contact.
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
5. In order to compensate correctly, execute touch sensing to the surface which deviates the same
as the weld line.
6. When sensing pattern and sensing order are not matched, an error occurs.
1 2 1 2
[ NOTE ]
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
This section describes errors occurring during touch sensing operation and the error handling.
Error
Error message Main cause
code
E6509 No work detected. When sensing for workpiece detection or
compensation, wire did not touch the workpiece
after moving the touch sensing distance.
E6510 Undefined sensing When sensing for workpiece detection or
direction. compensation, no point was taught prior to the
sensing point, or Air Cut (defining the sensing
direction) was not taught in the prior point/step.
E6511 Insufficient sensing Weld was started before acquiring the No. of
points. sensing points specified by the pattern.
E6512 Undefined mother or Attempted to execute daughter or baby workpiece
daughter work. before mother workpiece was specified. Or,
attempted to execute baby workpiece before
daughter workpiece was specified.
E6513 Too many sensing Without reset, executed the same sensing to
points. workpiece for which sensing was already complete.
Or, executed sensing at more points than the No. of
sensing points specified by the pattern.
E6514 Work specification Before completing sensing of all the sensing points
incorrect. of the specified pattern, a different sensing pattern
was processed.
E6515 Incorrect sensing point During deviation compensation, sensing order or
specified. sensing locations were incorrect.
E6516 Wire check failure. During wire check, wire did not touch the
workpiece after inching the wire for 5 sec.
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
If the program taught with the touch sensing function suffers an error while it is running, execute
the recovery procedures detailed here and on the following pages.
When an error occurs, robot holds detection of the workpiece and stops at the place the error
occurred.
Main cause:
1. Workpiece deviated more than touch sensing distance registered in Aux. Function 1404-10.
2. Workpiece is not set.
Countermeasure:
Touch sensing distance may be short, set again with a longer touch sensing distance in Aux.
Function 1404-10. (Beware that setting a longer distance lengthens the touch sensing time.)
Or, when workpiece deviates too much, reset it to its set place.
Trajectory of robot torch tip from time of error occurrence to error handling
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Remarks: If robot is stopped by turning RUN /HOLD to HOLD during sensing, the trajectory
of the robot torch tip is as shown below when restarting.
Pausing A
Cycle start
z A
z
A
z
! CAUTION
When an error occurs, robot holds detection of the workpiece and stops in that step.
Main cause:
For example, when the error occurred in step 4 of the program below, the following are
considered probable causes.
1. The previous step (step 3) is not an air cut point, which is necessary for using the workpiece
detection function in step 4.
2. When selecting a particular step as the start step wherein the sensing function is specified, for
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Kawasaki Robot Arc Welding Operation Manual
Countermeasure:
1. In the case of the program above, inset a new step containing an Air Cut point before step4
(which includes workpiece detection). (Sensing direction is determined by the point taught
sensing function and the air cut point.)
2. When selecting a particular step for execution, specify the step that precedes the step taught
workpiece detection function as a start step. For programs that frequently use touch sensing
functions, be sure to execute the program from the first step.
When an error occurs, robot holds creation of the workpiece coordinates and stops in that step.
Main cause:
For example, when the error occurred in step2 of the program below, the following are
considered probable causes.
1. Although pattern 2 (with 2 sensing points) was set in step2 above, sensing was executed for
only one of the two sensing points, also a non-Air Cut instruction was specified in the next step
(step3).
Countermeasure:
1. In the case of the program above, insert new steps (steps 3, 4) for sensing the second of the two
sensing points as below. Ensure the number of steps used to execute workpiece deviation
compensation corresponds with the number of sensing points. (As in program example each
sensing point is taught by two steps, the first being an Air Cut step and the second being
MOTHER_WORK#, DAUGHTER_WORK#, etc.)
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Kawasaki Robot Arc Welding Operation Manual
When an error occurs, robot holds creation of the workpiece coordinates and stops in that step.
Main cause:
For example, when the error occurred in step2 of the program below, the following are
considered probable causes.
1. Attempted creation of daughter workpiece coordinates in step2 without first making the mother
workpiece coordinates. Or, although mother workpiece is taught in the previous step,
attempted to start execution in repeat mode from the step containing daughter workpiece.
Countermeasure:
1. In the case of the program above, edit the step so as to ensure mother workpiece coordinates
are created first. Or, insert a new step creating mother workpiece coordinates.
When selecting a step from which to begin in repeat mode, avoid starting from step with
daughter workpiece or baby workpiece.
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E Series Controller 9. Touch Sensing Function (Option)
Kawasaki Robot Arc Welding Operation Manual
When an error occurs, robot stops in the place the error occurred.
Main cause:
For example, when the error occurred in step7 of the program below, the following are
considered probable causes.
1. Although workpiece coordinates have already been created (step 2), the workpiece coordinates
were to be created again (step 7). Or, the sensing was to be executed at a higher No. of
sensing points than specified in sensing pattern.
Countermeasure:
1. In the case of the program above, reset the workpiece coordinates (step6), and edit the step so
as to create the workpiece coordinates again. See below.
Main cause:
For example, when the error occurred in step4 of the program below, the following are
considered probable causes.
1. After specifying the first point of two point sensing pattern in step3, different sensing pattern
was specified in step4.
Countermeasure:
1. In the case of the program above, specify the same sensing pattern to complete the workpiece
coordinates as below.
Main cause:
1. Teaching order was incorrect, for example did not follow A1→B1→A2→B2→A3→B3.
B B B
2. The distance between two points taught on the same control surface was less than 10mm. Or,
angle made from the sensing directions for two different control surfaces was not within
30°∼150°.
Countermeasure:
1. Clear the error cause and teach again correctly.
Main cause:
1. The workpiece was too far from the teaching point.
2. Wire feeder did not inch weld wire due to cut OFF of power supply in weld machine, etc.
Countermeasure:
1. When teaching point and the workpiece are located far apart, teach again with the position
closer to the workpiece.
2. When weld wire was not inched, adjust and check the devices and press CYCLE START
button. Then, confirm wire is inched for the full 5 sec.
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Kawasaki Robot Arc Welding Operation Manual
9-46
E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
By using this special pattern weaving function, weaving shapes which are normally simple
harmonic can be created or changed freely.
10-1
E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Simple harmonic
1
both ends stop
2 Triangular
Reciprocating
3
triangular
Circular
4
(Clockwise)
Circular
5
(Counterclockwise)
6 to 0 Unregistered ⎯ ⎯
10-2
E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
For weaving in a narrow groove, the torch posture often needs to be changed during weaving
operation. With the special pattern weaving function, torch posture can be changed a max. of
±10°. This is called pendulum weaving.
+10° -10°
+50% -50%
! CAUTION
Note that pendulum weaving sometimes induces large motions in the robot
even though the motion of the torch tip is small. Or, speed abnormality
may occur. In these cases, set pendulum angle smaller, or modify teaching
contents to make the motion of each robot axis smaller.
For weaving in a narrow groove, etc., weld current or weld voltage often need to be changed to
enable high quality penetrating at both ends of the weave. Via the special pattern weaving
function, weld current or weld voltage can be changed a max. of ±100%. This is called weld
current/weld voltage boosts.
(%)
200
+100%
100 Weld condition set value
-100%
0
10-3
E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
To use special pattern weaving function, follow the flow chart described below.
Use a standard pattern. Use a pattern example listed in Make and use a new
(See 10.2 Standard this manual. (See Aux.1404-11 pattern. (See 10.4.2
Weaving Patterns Special Pattern Weaving (Option) Creating Weaving
Registered for Robot.) in 8.0 Auxiliary Functions). Patterns.)
(Specify one pattern from the five kinds of weaving patterns.)
movement in created
pattern.
Determine weaving
pattern No. and register
required data.
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E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
The standard weaving patterns registered in this function include: simple harmonic both ends stop
weaving, triangular weaving, reciprocating triangular weaving, circular weaving, etc.
This section describes the motion using solid figures and the expansion patterns for the weaving
patterns in back/forth, lateral, and vertical directions.
Vertical direction
Vertical direction:
Lateral direction Torch direction
Motion direction (+ moves upwards.)
Vertical plate
Lateral direction:
Direction vertical to torch
Back/forth direction
and traveling direction
Amplitude (+ moves towards vertical
(WV)
1 cycle (sec) plate (left))
Back/forth direction:
Horizontal plate
Motion direction of weld
Motion of torch tip (+ moves forward)
1 sec
Frequency
f=0.5Hz 2 sec
1 cycle
1 sec
f=1Hz 2 sec
1 cycle
1 sec
f=2Hz 2 sec
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E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
1. Pattern No. 1 (PN=1): Simple harmonic both ends stop weaving pattern
Amplitude
(WV)
Motion direction
Forth
Lateral
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E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Amplitude
(WV)
Motion direction
Forth
Back
Lateral
10-7
E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
3. Pattern No. 3 (PN=3): Reciprocating triangular weaving pattern- both ends stop, center stop
Motion direction
Amplitude
(WV)
Forth
Lateral
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E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
4. Pattern No. 4 (PN=4): Circular weaving pattern (1)- from vertical plate direction
Amplitude
(WV)
Motion direction
Forth
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E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
5. Pattern No. 5 (PN=5): Circular weaving pattern (2)- from horizontal plate direction
Amplitude
(WV)
Motion direction
Forth
10-10
E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Weld line
Weld start point
When using registered weaving patterns, there is no additional teaching procedure to use special
weaving function. Simply set the desired weaving pattern No. in the weld conditions.
For example, to use weaving pattern 4 in the arc spot weld condition of direct setting, set the
pattern No. as in Figure 10.1. ([Pole Ratio] shown only when Option is installed.)
Figure 10.1
Weaving patterns can be also set in the weld condition by the following auxiliary functions. For
details about the setting procedures of each function, see 8.0 Auxiliary Functions.
10-11
E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
When creating a new weaving pattern, keep in mind the torch movements defined in the figure
below, and be careful when specifying the plus (+) and minus (-) directions on this coordinates
system. To register created weaving patterns, see Aux.1404-11 in 8.0 Auxiliary Functions.
Torch
Up+
Amplitude(WV)=100%
When defining an amplitude and setting the (0) point for
50% 50%
teaching origin as shown on left, motion amounts of points (1)
and (2) are as follows.
Left Up Right Amount of oscillation for point (1):
(1) (2)
upward direction 50%, left direction 50%
50%
Amount of oscillation for point (2):
upward direction 50%, right direction -50%
Down (0)
When registering weaving patterns, specify the motion amount in each oscillation direction by
percentage (%) to the amplitude.
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E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
As robot travels along weld direction, this weaving rotates the torch vertical to surface of weld
with torch tip set as center of rotation. For angle, minus (–) direction is toward the vertical plate.
⎯
+
Vertical
plate
Current and voltage values set in weld condition can be changed within a max. of ±100%.
(%)
200
+100%
100 Weld condition set value
-100%
0
10-13
E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
When creating a weaving pattern, follow the procedure described in the flow chart below. A
blank program sheet is attached in Appendix 3. Pattern Example of Special Pattern Weaving
(List); make copies and use when creating weaving patterns.
(2) Determine a position for defining teaching origin and weaving width.
(3) Create expansion pattern diagrams for back/forth, lateral, vertical dir.
(4) Fill in sheet with the data from expansion pattern diagram in (3).
(5)
(1)
(2)
(4)
(3)
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E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
(2) Determine a position for defining the teaching origin and weaving width.
1) Teaching origin: Be sure to match the teaching point and the teaching origin.
Case 1
Up
B C
A During weaving
Lateral+ Lateral-
operation, torch tip
Teaching origin
moves as
Down
A→B→C→A.
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E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Case 2
Up
B C
Lateral+
During weaving
A D
operation, torch tip
moves as
Down Lateral- A→B→C→D→A.
Teaching origin
Case 3
Up
C D
During weaving
Lateral+ operation, torch tip
B A E moves as
A→B→C→D→E→
Lateral-
Down Teaching origin
A
2) Defining position for weaving width: Normally, weaving width (lateral direction) is set at 90°
to the torch axis. However, a root gap (or groove
dimension) can be used as basis for setting the weaving
width, as shown below right. Be careful as the
dimensions and directions set for the weaving width will
affect the weaving pattern that can be created.
Weaving width
(Groove dimension)
Left Right
Left
Right
10-16
E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
(3) Create expansion pattern diagrams for the back/forth, lateral, and vertical directions. See
diagrams at bottom.
Case 1
Up
Stop time on vertical plate=26%
2
Weaving width=6mm (0)
1 (1)
(1) 3
(2) (2)
(1) 3mm (0) (2) 5
4 Stop time on horizontal
(0) plate=26%
Lateral+ Lateral-
(0)
In the groove in the figure above, set weaving In the weaving pattern in the figure above, set time
width 6 mm (100 %) between (1) and (2). (0) is ratio between paths in the case where stop time on
teaching origin. Note if weaving motion vertical plate=26 % and stop time on horizontal
component in any one (+/-) direction exceeds plate=26 %. Weaving speed in each path is
±200 %, an error occurs. considered to be the same.
0 mm to vertical dir. .........................0 % 100 % - ( 26 % + 26 %)
(0) = 12 %
0 mm to lateral dir. ...........................0 % 4
Then, time ratio in each point is as follows.
3 mm(3 mm/6 mm) upward.......... 50 %
(1) Time ratio at point 1: .................................. 12 %
3 mm(3 mm/6 mm) to left............. 50 %
Time ratio at point 2: 12 % + 26 %............ 38 %
3 mm(3 mm/6 mm) upward........... 50%
(2) Time ratio at point 3: 38 % +12 %............. 50 %
-3 mm(-3 mm/6 mm) to right........ -50%
Time ratio at point 4: 50 % + 12%............. 62 %
Time ratio at point 5: 62 %+26 %.............. 88 %
Forth+
1 2 3 4 5
0 Time ratio
12 38 50 62 88 100%
Back-
50 50
Lateral+
0 0% Time ratio
0
Lateral-
-50 -50
50 50 50 50
Up+
0 Time ratio
0 0%
Down-
10-17
E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
Case 2
This example shows weaving with torch inclined 22.5° toward the groove: 45° horizontal and
bevel shape with 4mm root gap. Calculate the time, motion amount in vertical, lateral directions,
etc. in consideration of the 22.5° angle. When calculation seems too complicated, draw the
groove diagram in x10 scale, then use the expanded groove diagram to get the vertical, lateral
motion amounts.
When reading by scale
Approx. 6.9mm
(1) Up 2
(0)
22.5° Weaving width (2) (1)
=10mm 4 (3)
6 mm (3) 5
1 3
45°
Lateral+ (0) (3) (2)
(0)
Stop time=10%
4 mm Stop time=10%
Lateral-
Down
In the groove in the figure above, set weaving In weaving pattern above, set time ratio for each path
width 10 mm (100 %) among (0) to (3). (0) is assuming a 10 % stop time at bottom of each wall.
teaching origin. Note if weaving motion Weaving speed in each path is considered to be the
component in any one (+/-) direction exceeds same. Weaving motion is executed in 80% of
±200%, an error occurs. weaving cycle.
0mm to vertical dir. ...............................0% Time ratio at point 1: .............................................. 10%
(0) 6mm
0mm to lateral dir. .................................0% Time ratio at point 2: 10%+80%× 28.5m ......26.8%
6cos22.5° mm upward.........................55% 10mm
(1) Time ratio at point 3: 26.8%+80%× 28.5m ...54.9%
6sin22.5° mm to left............................23%
6cos22.5°+10sin22.5° mm upward.....94% 8.5mm
(2) Time ratio at point 4: 54.9%+80%× 28.5m ...78.8%
6sin22.5°-10cos22.5° mm to right......69%
4sin22.5°mm upward ..........................15% Time ratio at point 5: 78%+10% .....................88.8%
(3)
-4cos22.5°mm to right....................... -37%
Forth+
1 2 3 4 5
0 Time ratio
10 26.8 54.9 78.8 88.8 100
Back-
Lateral+
0 0%
23 Time ratio
0
-37 -37
Lateral- -69
Up+
94
55 15 15
0 0%
0 Time ratio
Down-
10-18
E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
(4) Fill in sheet with the data from the expansion pattern diagram created in (3).
Using the expansion weaving pattern diagram created in Case 1 in (3) above, the data will be as
follows. When filling in data for each point, do not fill in the last point or specify all 0%.
Back-
50 50
Lateral+
0 0%
0 Time ratio
Lateral-
-50 -50
50 50 50 50
Up+
0 Time ratio
0 0%
Down-
Time B&F [X] Lateral [Y] Vertical [Z] Angle Current Voltage
Point
(%) (%) (%) (%) (°) (%) (%)
←Do not fill in the
1 12 0 50 50 0 0 0
first point (prior
2 38 0 50 50 0 0 0
to point 1).
3 50 0 0 0 0 0 0
4 62 0 -50 50 0 0 0
5 88 0 -50 50 0 0 0
6 (0) (0) (0) (0) (0) (0) (0) ←Do not fill in
¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ the last point, or
specify all 0%.
10-19
E Series Controller 10. Special Pattern Weaving Function (Option)
Kawasaki Robot Arc Welding Operation Manual
For weaving patterns with stops at both ends or a center stop, do not fail to fill in the ratio of
stopping time.
(1) When specifying a big weaving width in a short time during weaving operation, an error
occurs. In this case, the torch tip speed became 100 mm/s or more, and error message
“(E1123) Speed error jtXX.” is displayed. (For some specific robots, this error may occur at
speeds less than100 mm/s.)
(2) In sequential steps, when time ratios of back/forth direction are the same, or when time ratio to
the next point is smaller than the time ratio to the last point, the last point becomes the final
point. (Point 3 is the final point in the following three examples.)
(3) When weaving motion component in back/forth, lateral, or vertical directions is 400 %
(200 % in either plus (+) or minus (-) direction) or more, an error occurs.
10-20
E Series Controller 11. Servo Torch Function (Option)
Kawasaki Robot Arc Welding Operation Manual
This chapter describes servo torch function by optional specification and the teaching operation.
Typically when a robot and weld machine are used together to perform arc welding, the weld
machine controls the wire feeding. However, this system may not be effective for welding all
types of works. This is especially true if the weld machine lacks the sensitivity for feeding the
wire on to delicate works such as thin aluminum plates which can damage easily. Using this
servo torch function makes the following possible:
1. By controlling the wire feeding servo motor as robot-controller controlled external axis,
detailed weld conditions can be set and the welding of thin works/plates becomes possible with
much greater accuracy.
2. Features of servo adjusted by feedback gain of wire feeding servo motor, etc. and sequence at
weld start/end can be changed depending on its application condition.
11-1
E Series Controller 11. Servo Torch Function (Option)
Kawasaki Robot Arc Welding Operation Manual
This section describes the procedure for registering a servo torch as an external axis. For more
details on the procedure for setting external axes, refer to External Axis Addition of E Series
Controller, a separate volume.
As described in the External Axis Addition manual, select Aux.2002 External Axis to display the
screen below.
! CAUTION
Be sure to set the servo torch with the highest axis number
in the system. Failure to do so may cause malfunction.
For settings made after pressing <Next Page>, see the External Axis Servo Parameter Setting
manual. Note that the number of setting items for [Servo torch] is smaller than those required
for [Linear Axis] or [Rotary Axis].
11-2
E Series Controller 11. Servo Torch Function (Option)
Kawasaki Robot Arc Welding Operation Manual
For details on auxiliary functions specific to the servo torch, see Aux.1404-16 in 8.0 Auxiliary
Functions.
The differences between the servo torch specification and standard arc specification are explained
below. Take these characteristics into account when planning you system and the work required
for your application.
11-3
E Series Controller 11. Servo Torch Function (Option)
Kawasaki Robot Arc Welding Operation Manual
This section describes errors occurring during servo torch operation and the error handling.
Error
Error message Main cause
code
E6559 Wire feeding speed deviation Difference between command speed and actual wire
error. feeding speed exceeds allowable range.
If the program taught with the servo torch function suffers error E6559 while it is running,
execute the recovery procedures below.
Main cause:
1. Difference between the command speed and actual wire feeding speed exceeds the allowable
range.
Countermeasure:
1. Check if the power cable to the servo torch motor is disconnected. If disconnected, speed
command will still be output even though robot does not actually work and thus result in error.
2. Determine why the actual wire feeding speed has decreased. Check the system for possible
causes: the wire is being supplied correctly, etc.
11-4
E Series Controller 12. Error Message for Arc Weld Specification
Kawasaki Robot Arc Welding Operation Manual
This chapter describes errors occurring in arc weld specification robot. Some errors only occur
if optional functions for arc weld application are installed.
12-1
E Series Controller 12. Error Message for Arc Weld Specification
Kawasaki Robot Arc Welding Operation Manual
Error
Error message Option
code
P6502 No weld database. Standard
P6503 Cannot change weld condition. Standard
E6500 No welding Interface board. Standard
E6502 Arc failure. Standard
E6503 Wire stuck. Standard
E6505 Arc weld insulation defect. Standard
E6506 Torch interference. Standard
E6509 No work detected. Touch sensing
E6510 Undefined sensing direction. Touch sensing
E6511 Insufficient sensing points. Touch sensing
E6512 Undefined mother or daughter work. Touch sensing
E6513 Too many sensing points. Touch sensing
E6514 Work specification incorrect. Touch sensing
E6515 Incorrect sensing point specified. Touch sensing
E6516 Wire check failure. Touch sensing
E6517 Incorrect weld condition number. Standard
E6518 No weld data set. Standard
E6519 Weld data is out of range. Standard
E6533 No RTPM board. RTPM
E6534 Too many taught points for RTPM. RTPM
E6535 RTPM arc sensor error. RTPM
E6536 RTPM current deviation error. RTPM
E6537 RTPM tracking value is out of range. RTPM
E6538 Out of RTPM tracking capacity. RTPM
E6539 Out of AVC tracking value. AVC
E6540 Out of AVC tracking capacity. AVC
E6541 No AVC board. AVC
E6542 AVC voltage deviation error. AVC
E6543 Too many taught points for AVC. AVC
E6559 Wire feeding speed deviation error. Servo torch
E6562 Electric pole stuck. TIG welding
12-2
E Series Controller 12. Error Message for Arc Weld Specification
Kawasaki Robot Arc Welding Operation Manual
This section describes troubleshooting for standard errors occurring in arc specification. For
errors which occur in optional functions for arc welding, refer to the related Option Manuals.
Main cause:
Signal showing welding in process (current detection: WCR) was not returned from weld
machine 1 sec (or more) after robot attempted to weld.
Countermeasure:
Some insulating object may interrupt arc generation at arc start point. Check for and remove
any foreign object, insulating item, etc. If this error occurred during welding, check if wire feed
has run out or tip is stuck.
12-3
E Series Controller 12. Error Message for Arc Weld Specification
Kawasaki Robot Arc Welding Operation Manual
Main cause:
Wire is stuck to the base material when welding has completed.
Countermeasure:
If wire is stuck to the base material, cut the wire. When wire is often stuck at the same point,
reexamine the weld conditions.
Main cause:
When controller power was turned ON, interface board for arc welding was not detected.
Countermeasure:
Turn OFF the CONTROLLER POWER, and check whether weld interface board is mounted in
the card rack of the controller. When mounted, insert it correctly and firmly as the interface
board may be loose.
After error reset, robot can be moved in teach mode. In repeat mode, operation is only possible
after setting the torch back to its original state.
Main cause:
Torch interfered with something, and limit switch in the torch bracket came off.
Countermeasure:
Reset the error, and move robot in teach mode to set the torch back to its original state. (Set the
limit switch back to the original state.)
12-4
E Series Controller 12. Error Message for Arc Weld Specification
Kawasaki Robot Arc Welding Operation Manual
Main cause:
Torch short-circuited to the work when INSUL_CHK instruction was executed.
Countermeasure:
Check and make the insulation as needed.
12-5
E Series Controller 12. Error Message for Arc Weld Specification
Kawasaki Robot Arc Welding Operation Manual
12-6
E Series Controller Appendix 1. Program Sheet
Kawasaki Robot Arc Welding Operation Manual
Once the robot operation is determined, fill in the contents to teach the robot on the program
sheet.
Instruction Interpolation Speed Accuracy Timer Weld condition Arc Spot condition
1 Air cut Joint 9 4 0
2 Weld start Joint 9 0
3 Weld continue Linear Direct
4 Weld end Linear Direct
5 Air cut Linear 9 4 0
6 Arc spot Joint 9 1 0 Direct
A-1
SHEET OF
lding Condition
WeWeld Arc Spot Condition Option
Condition
E Series Controller
Typeofof Inter-
Step Teachcing Type Air
Speed Accu- Timer OX WX Jump
Point teaching
Teach polation Cut racy Direct Direct
/End In- In-
point
Point Speed direct
direct t
SP A V WV f PN Ct CA CV A V
Kawasaki Robot Arc Welding Operation Manual
A-2
Appendix 1. Program Sheet
E Series Controller Appendix 2. Weld Database
Kawasaki Robot Arc Welding Operation Manual
[ NOTE ]
Database provided at time of factory shipment contains weld conditions whose
contents were tested and confirmed by Kawasaki. Be advised these
conditions may not be best for the planned work. Kawasaki cannot guarantee
that this database will provide the best possible welding operation and quality
for every work.
Preconditions for using this database with the standard arc specification:
Weld gas ........................ CO2
Wire diameter ................ 1.2φ
Wire extension length .... 15mm
Wire type ....................... Solid wire “JIS YGW12 (equivalent to KC-50T KAWASAKI
STEEL)”
Weld machine ................ DAIHEN CPVB350, CPVP350, etc.
(For other weld machines, please contact Kawasaki.)
If conditions differ from those described above, no data is stored in weld database at time of
factory shipment.
A-3
E Series Controller Appendix 2. Weld Database
Kawasaki Robot Arc Welding Operation Manual
1. Horizontal fillet
2. Flat fillet
A-4
E Series Controller Appendix 2. Weld Database
Kawasaki Robot Arc Welding Operation Manual
3. Lap fillet
4. Corner fillet
A-5
E Series Controller Appendix 2. Weld Database
Kawasaki Robot Arc Welding Operation Manual
5. Butt I fillet
6. Downhill fillet
A-6
E Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Kawasaki Robot Arc Welding Operation Manual (List)
Weaving pattern for 1 cycle Weld gas: CO2, MAG Center stop time: 0%
Amplitude
Teaching origin
Back/forth direction:
Points for weaving pattern
100%
B&F Lat. Vert.
F + Point
Time
X Y Z
Ang. Cur. Vol.
(%) (°) (%) (%)
50 (%) (%) (%)
0 Time ratio 1 12 0 50 50 0 0 0
12 38 62 88 100%
-50 2 38 0 50 50 0 0 0
B - -100 3 62 0 -50 50 0 0 0
4 88 0 -50 50 0 0 0
Lateral direction: 5 … … … … … … …
100% 6 … … … … … … …
Lat. + 50 50
50 7 … … … … … … …
0 Time ratio 8 … … … … … … …
0%
-50
9 … … … … … … …
-50 -50
Lat. - 10 … … … … … … …
-100
11 … … … … … … …
Vertical direction: 12 … … … … … … …
100% 13 … … … … … … …
Up + 50 50 50 50 14 … … … … … … …
50
15 … … … … … … …
0 Time ratio
0%
-50
Down - -100
A-7
E Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Kawasaki Robot Arc Welding Operation Manual (List)
Weaving pattern for 1 cycle Weld gas: CO2, MAG Center stop time: 0%
Teaching origin
Back/forth direction:
Points for weaving pattern
100% B&F Lat. Vert.
Time Ang. Cur. Vol.
F + Point
(%)
X Y Z
(°) (%) (%)
50 (%) (%) (%)
0 Time ratio 1 25 0 50 50 0 0 0
25 50 75 100%
-50 2 50 0 0 0 0 0 0
B - -100
3 75 0 -50 50 0 0 0
4 … … … … … … …
Lateral direction: 5 … … … … … … …
100% 6 … … … … … … …
Lat. + 50
50
7 … … … … … … …
0
0 Time ratio
8 … … … … … … …
0%
9 … … … … … … …
-50
-50
10 … … … … … … …
Lat. - -100
11 … … … … … … …
12 … … … … … … …
Vertical direction:
13 … … … … … … …
100%
Up + 50 50 14 … … … … … … …
50
0 15 … … … … … … …
0 Time ratio
0%
-50
Down - -100
A-8
E Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Kawasaki Robot Arc Welding Operation Manual (List)
Weaving pattern for 1 cycle Weld gas: CO2, MAG Center stop time: 0%
Teaching origin
Amplitude
Back/forth direction:
Points for weaving pattern
100% B&F Lat. Vert.
Time Ang. Cur. Vol.
F + Point
(%)
X Y Z
(°) (%) (%)
50 (%) (%) (%)
B - -100
3 75 0 -46 19 0 0 0
4 … … … … … … …
Lateral direction: 5 … … … … … … …
100% 6 … … … … … … …
Lat. +
50
46 7 … … … … … … …
0
0 Time ratio
8 … … … … … … …
0%
9 … … … … … … …
-50
-46
10 … … … … … … …
Lat. - -100
11 … … … … … … …
12 … … … … … … …
Vertical direction:
13 … … … … … … …
50%
Up + 19 14 … … … … … … …
25
0 15 … … … … … … …
0 Time ratio
0%
-25
-19
Down - -50
A-9
E Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Kawasaki Robot Arc Welding Operation Manual (List)
Weaving pattern for 1 cycle Weld gas: CO2, MAG Center stop time: 0%
Teaching origin
Amplitude
Back/forth direction:
Points for weaving pattern
100% Point B&F Lat. Vert.
Time Ang. Cur. Vol.
F + 50 (%)
X Y Z
(°) (%) (%)
50 (%) (%) (%)
0 0%
0 Time ratio 1 25 50 0 0 0 0 0
25 50 75 100%
-50 2 50 0 0 0 0 0 0
-50
B - -100
3 75 -50 0 0 0 0 0
4 … … … … … … …
Lateral direction: 5 … … … … … … …
100% 6 … … … … … … …
Lat. +
50
7 … … … … … … …
0 Time ratio
8 … … … … … … …
0 0 0 0%
9 … … … … … … …
-50
10 … … … … … … …
Lat. - -100
11 … … … … … … …
12 … … … … … … …
Vertical direction:
13 … … … … … … …
100%
Up + 14 … … … … … … …
50
15 … … … … … … …
0 Time ratio
0 0 0 0%
-50
Down - -100
A-10
E Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Kawasaki Robot Arc Welding Operation Manual (List)
Weaving pattern for 1 cycle Weld gas: CO2, MAG Center stop time: 0%
45°
4mm
Teaching point
0 Time ratio
7 28 63 93 100%
1 7 0 18 -8 2.5 0 0
2 28 0 41 47 7.5 0 0
Back -
3 63 0 -50 86 -7.5 0 0
4 93 0 -18 8 -2.5 0 0
Lat. +
5 … … … … … … …
41
18
0 6 … … … … … … …
Time ratio 7 … … … … … … …
Lat. - -18
-50 8 … … … … … … …
9 … … … … … … …
Up + 47
86 10 … … … … … … …
8
11 … … … … … … …
0 Time ratio
-8 12 … … … … … … …
Down - 13 … … … … … … …
Angle + 14 … … … … … … …
7.5
2.5
15 … … … … … … …
0 Time ratio
-7.5 -2.5
Angle -
A-11
E Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Kawasaki Robot Arc Welding Operation Manual (List)
Weaving pattern for 1 cycle Weld gas: CO2, MAG Center stop time: 0%
Amplitude
Teaching origin
Lat. + 50 50
1 15 0 38 0 0.0 0 0
65 70 80 85 100% 2 20 0 50 0 0.0 20 0
0 Time ratio
15 20 30 35 50
3 30 0 50 0 0.0 20 0
-50 -50
Lat. - 4 35 0 38 0 0.0 0 0
5 50 0 0 0 0.0 0 0
Current + 20 30 20 20
6 65 0 -38 0 0.0 0 0
Time ratio
0 7 70 0 -50 0 0.0 20 0
8 80 0 -50 0 0.0 20 0
Voltage - 9 85 0 -38 0 0.0 0 0
10 … … … … … … …
11 … … … … … … …
12 … … … … … … …
13 … … … … … … …
14 … … … … … … …
15 … … … … … … …
A-12
E Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Kawasaki Robot Arc Welding Operation Manual (List)
Back/forth direction:
Points for weaving pattern
100%
B&F Lat. Vert.
F + Point
Time
X Y Z
Ang. Cur. Vol.
(%) (°) (%) (%)
50 (%) (%) (%)
0 Time ratio 1
50 100%
-50 2
B - -100 3
4
Lateral direction:
5
100%
6
Lat. +
50 7
0 Time ratio 8
50 100%
-50 9
Lat. - 10
-100
11
Vertical direction: 12
100% 13
Up + 14
50
15
0 Time ratio
50 100%
-50
Down - -100
A-13
E Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Kawasaki Robot Arc Welding Operation Manual (List)
Back/forth direction:
Points for weaving pattern
100%
B&F Lat. Vert.
F + Point
Time
X Y Z
Ang. Cur. Vol.
(%) (°) (%) (%)
50 (%) (%) (%)
0 Time ratio 1
50 100%
-50 2
B - -100 3
4
Lateral direction:
5
100%
6
Lat. +
50 7
0 Time ratio 8
50 100%
-50 9
Lat. - 10
-100
11
Vertical direction: 12
100% 13
Up + 14
50
15
0 Time ratio
50 100%
-50
Down - -100
A-14
Kawasaki Robot Controller E Series
ARC WELDING OPERATION MANUAL
90203-1036DEA