ArcTool - FANUC Robotics

1 Basic DescriptionThe ArcTool application softwarepackage, integrated with a FANUCR obot and SYSTEM R-J3 Controller, provides the user with aunique process solution to roboticarc welding ArcTool Application Softwarepackage is designed to simplify and standardize the setup andoperation of FANUC robot arcwelding applications. Built-in arcwelding functionality and point-and-shoot position teaching allow theoperator to program the robot ArcTool , the operator has full control over the welding welding instructions are writtenin easy to understand English rather than coded functionality is provided at theteach pendant for welding processsetup, operation and trouble-shooting, including diagnostics,status reporting and error recovery Full interface and controlthrough an arc welding specific,easy-to-read teach pendantwith large display for full view of programs and data allowstotal application functionality.

2 Plug and play simplicity withLincoln Electric s PowerWave455 , 450 , or STT (SurfaceTension Transfer) powersources. Multi-tasking capability reduces execution time andallows control of externaldevices usually controlled by a programmable logic cell controller. Arc process and motion controlimproves weld process qualitywith the ability to look ahead,resulting in faster arc starts and increased productivity. Power fail recovery capabilityincreases production byallowing program and datarecovery in the event of powerloss. Configurable to work with allmajor brands of weldingequipment. Interfaces with most types ofservo driven or indexingpositioners. TurboMove advanced servocontrol features allow quick,smooth point-to-point motion,which increases arc on-timeand cycle speeds. Independent control of up tofive motion groups supportsoverlapping motion of servocontrolled peripheral Scratch start function reducesarc start faults with anautomatic recovery process.

3 Easy-to-load software is pre-packaged to match the robotconfiguration for ease of setup. Arc welding specific softwaremakes it quick and easy forusers to setup, teach andoperate their system. Easy-to-use teach pendanteditor allows quick setup andprogramming using commonwelding terminology. Arc and weave schedule datacan be entered directly at theinstruction or in an easy-to-useschedule data table; users areprovided the most appropriatelevel of flexibility for their needs. Hot edit of positional data allows program positionadjustment while production isrunning; this results in morerobot uptime and partthroughput. The on-the-fly feature permitschanging of weld process datawhile the program is runningproduction; operators can finetune process data on-the-fly,improving weld quality withoutunnecessary downtime. I/O menu utilizes English labelson dedicated weld process I/Oand peripheral device controlI/O; this capability speeds uptroubleshooting and Application SoftwareRobotics Sinusoidal, circular and figure8 weave patterns improveweave performance, weldability and quality.

4 Process feedback (voltage,current and wirefeed speed) is displayed in large characterson the teach pendant. Thisallows more flexibility in weldequipment OptionsThru-Arc Seam Tracking (TAST)tracks weld seams by monitoringchanges in welding signals andautomatically adjusting the robotpath to improve finished partquality. TAST can be used tocompensate vertically and/orlaterally to maintain the desired arc length and wire enhances the TAST package by providingadditional setup and diagnosticinformation to increase trackingspeeds and track on thinner Sensingquickly locateseach part (up to 75 mm/sec search speed), stores positioninformation and offsets the robotpath. The ability to search for part movement in 1, 2, or 3dimensions allows compensationfor part variation and reduces the need for trimmed parts orexpensive fixtures. Easy to usesearch patterns find parts shiftingwith parallel and rotational Sensing is highly accurateby quickly stopping the robotmotion upon completion of asearch and therefore reduces wire II builds on the highly dependable TorchMate option by reducing the cycle time and increasing the accuracyof each adjustment II automatically adjusts for changes in the toolcenter point, improving systemuptime.

5 Works with all majorbrands of torches to compensatefor bent torch barrels and worncontact tips. It also reduces weld repair Voltage Control (AVC) tracks voltage duringwelding and adjusts the robot path to compensate for partdistortion or irregularity. Designed for GTAW or PAWwelding. The AVC option can be used with constant or pulsed current EYE is a laser-based trackingsensor designed specifically for arcwelding metal stampings. MIG EYEprovides real time control of therobot path, maximizing weld travelspeeds and quality. MIG EYEfeatures include: adaptive bias,adaptive weld schedules and ROOTPass Memorization (RPM).Motion OptionsCoordinated Motionsimplifiessetup and reduces expense whenapplying auxiliary axis Coordinated Jogging featureallows quick program creation byenabling the programmer to jog the robot and positionersimultaneously, maintaining relative gun angles and travel speedremains con-stant while the robotmoves in conjunction with theauxiliary Motion works with mostmulti-axis positioner configurations,eliminating the need for specializedor standardized mechanisms.

6 Withthis option, users can achieve highquality welds with minimal Setup and Teaching:Arc welding specific teachpendant hard keys provide single key stroke access to most frequentlyused Pendant3 ScreenAccess KeysArc WeldingApplicationKeys3 ArcweldingstatusindicatorsALARMHOLDSTEPB USYRUNNINGWELD ENBLARC ESTABDRY RUNJOINTXYZTOOLOFFONWIREINCHKEYSMANFCTNS STATUSPOSNWIREINCHKEYSDISPLAYWELDSTATUSE NABLE/DISABLEWELDINGPROCESSW eaveVertical trackingTorchLateral trackingStickoutResistanceArcGrooveMetal TAST FunctionExample of Search OffsetCollision Guard protects not only end-of-arm-tooling, but alsoprotects part tooling and the entire robot arm. It does this byinstantly stopping robot motionwhen a collision is detected,reducing downtime associated with collisions. Collision Guardalso minimizes the costsassociated with tool, part and torch replacement. Process OptionsBumpbox provides operators aneasy way to adjust weld placementto match minor intermittent changesin joint position.

7 Each adjustmentcan be maintained for a batch ofparts. The operator can shiftspecified welds within pre-determined limits, during productionon the robot teach pendant or aseparate interface option providessystem flexibility by allowing onerobot to work with two weldingprocesses, such as Tandem MIG or switching between two differentwelding processes such as MIGand TIG. Using this option for aTandem MIG application has shown higher deposition rates,allowing a cycle time reduction of up to 50%. By allowing twocomplete welding systems to be setup, the operator can easily switch between the twoprocesses, reducing down timebetween Electric PowerWave455/Rwelding power source issupported through a DeviceNetCommunications integration time isachieved from the DeviceNetinterface, which performs all setup, scaling and initialization. All weld procedure setup isremoved from the power supply sfront panel and moved to the robot teach pendant.

8 A weldprocedure database on thePW455/R can be queried from the robot teach pendant to selectthe correct waveform. Additional process welding I/Ointegrates multi-channel weldingequipment such as 4 channel TIG and 3 channel OptionsError recoveryoffers the userseveral options for arc faultrecovery. User-defined programsenable the robot to move to a repair position then return andresume welding after repairshave been made, reducing system downtime and scrap. The operator does not have to jog the robot to protectionrestrictsuser access beyond designatedareas, preventing unauthorizedusers from modifying critical control data. Password protectionoffers four levels of protection and can accommodate up to 100 users with text strings for each user name. Remote accessis also available through anEthernet event loggingrecordsoperational changes made to the teach pendant programs and system data structure.

9 Userlogin/ logout time is recorded along with any changes each user has made to the system. This information allows systemmanagers to track changes thataffect production MachineController (PMC) providescapability to execute Ladder Logic on the robot controller,eliminating the need for someexternal PLC s. PMC logicexecutes on the robot processorwithout any additional boards or hardware and interacts with all robot I/O and system cost andcomplexity can be achieved byeliminating extra enclosures,wiring, and PLC trackingadds two newvariable structures that captureinformation about arc starts, arcends, failed starts, scratch starts,aborted welds, burn back events and other pertinent weldinginformation. These statistics can then be displayed on the teachpendant or pulled offline to a PC to give a simplified production status report. Available in both standard and long-armversions, FANUC Robotics ARC Mate120irobot sets the standard in roboticarc TorchMate II software allowsusers to redefine the tool center point(TCP) of a welding torch that has becomedamaged or I/O DI/DO: 40 points and analog in/output (welding interface).

10 EA BoardBoard is mounted in the operation power : 440, 460, 480, 500, 550, 575 VAC inputWeightApprox 100kg (220 lbs) Installation Ambient temperature: 0-45 CenvironmentAmbient humidityNormal75% RH or less(No dew or frost allowed)Short termMax 95% RH(within one month) or lessNo corrosive gas allowedR-J3 Controller and Teach Pendant SpecificationsStandard Integrated and Optional Remote ControllerMonitoring functionsTAST Welding restartSuper TAST Scratch startAVCOn-the-fly weld adjustmentTouch sensingWeld from teach pendantMIG EYE RuninTorchMate II BurnbackCoordinated motion32 weld schedulesError code outputWeave instructionsExtended axes10 weave schedulesMulti-group motionProgram shift utilityDetached jogging of auxiliary axesReference position utilityPLC I/OMulti-tasking utilityKAREL Command Language (KCL)Mirror image utilityGE FANUC Genius I/O interfaceRegistersAllen Bradley I/O interfacePosition registersRoot pass memorizationMACRO functionsMultipass weldingTest cycle functionsAnalog rampingPlug and play capabilityPassword protectionOriginal path resumeFTPDry run modeTPP condition monitorJog speed controlCollision Guard Path joggingEvent loggingOverride selectError recoveryPower fail recoveryWrist axis weaveUser frameSmall circleTool offsetData monitorI/O interconnect menusProgrammable Machine Controller (PMC)UNDOD omain Name Service (DNS)