1 November 2004

TRAINING REPORT
COMPANY: - FANUC INDIA LTD.

PLACE: - ELECTRONIC CITY, BANGALORE

PERSONS :

Mr. N. S. Raut- Deputy Manager.

Mr. S. R. Firange-Engineer.
Mr. R. G. Bhilare Engineer.
Mr. A. M. Rampure-Engineer.
Mr. V. Nanekar-Engineer.

FACULTY: - Yaseer Wajahet

PURPOSE: - Training Program on Fanuc Robot, Controller Operation, Programming and
Maintenance.
DATE: - 26~29 October 2004
TIMING: - 9.30am to 4.30 pm

DATE: - 26/10/2004
Following points and Activities are done on this day.
INTRODUCTION
In morning Peoples from BFL and FANUC introduced each other. After
introduction the purpose of training and schedule of training is given.
VIDEO PRESENTATION ON FANUC, JAPAN.
They give us Video Presentation on the company profile of Fanuc, Japan. In
this video they had shown the facilities of robot manufacturing, servo Control factory,
various R & D projects and CNC manufacturing. Total manufacturing and assembling
of robot and servomotors is robotized. Fanuc India has facility of sales and service in
India.
ROBOT CLASSIFICATION:
1. Work Envelope
The Work Envelope depends on the degree of freedom or no of axis. Work
envelope varies from 0.5 to 2.6 m/ 3.2 m
2. Payload
Payload capacity of robot is load carrying capacity at J6 in work envelope. Fanuc
makes the robot from 5 Kg to 450Kg payload capacity robots. Recently they have
made the robot with payload capacity of 650 kg. The capacity of model R200i A/F 165
which is ordered by BFL is 165 Kg.
3. Application
The robots are also classified on application as follows

Spot welding robot

Material handling robot

Arc welding robot

Plasma cutting robots

Spray painting robots

4. Degree of Freedom.

In this class robots are available from 4 DOF to 6 DOF.

ROBOT: Robot can be divided in to two Parts:

Mechanical parts: In this the main parts are Manipulator Body (yellow), Motors, Base, Balancing

cylinder. The manipulator body is made of light metal i.e. Al alloys. The base of robot
is made of heavy casting. Balancing cylinder is used for balance the robot while
operation.

Electrical Parts: This contains Controllers, Amplifier, CPU, and Power Supply Unit (PSU). The

main controller is used to get signals from the system and gives the signal to robot to
operate. Amplifier is used to convert the 415 Volt, 50 Hz supply to 200 Volts, 60 Hz
because all the design of the robot is manufactured as per Japanese standards. The
CPU contains the main processor, FRAM in which all data is saved
ROBOT PROGRAMMING: Robot programming is nothing but a teaching a path, which should be followed
by the robot by using the TEACH PENDANT. Then by selecting auto mode we can
obtain the same motion repetitively.
While teaching the robot the robot is kept in STEP mode and Speed of 10
%(by default). This is for safety point of view. After getting experience one can
increase the speed.

MODES OF MOTION OF ROBOT

For movement of robot four modes are used, they are as follows:
1. JOINT
In This mode we can get motion of every joint independently i.e.J1, J2,
J3, ----, J6.
2. JGFRAM
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In JOGFRAM mode the robot moves with reference to Cartesian coordinates with zero reference at middle of robot base.
3. TOOL
In TOOL frame mode we can define coordinates of tool for reference.
We can move axis according to tool reference position. For this we
define zero reference at tool tip.
4. USER
In this mode we can define the coordinates as per user requirement.

INTERPOLATION
In robot we can move to different points by three methods:

1. J (Arial / Joint)
2. L (Linear)
3. C (Circular)
P1 *

JOINT

P2

P3

CIRCULAR
P5

P4

LINEAR

1: J P [2] 10% (Shortest path with min. energy consumption)

2: C P [3] FINE / CNT 100
P [4] 100 mm/sec

(touch up)

3: L P [5] 100 mm/sec

(Circular path)
(Linear path)

We can change the recorded point by selecting new point and pressing
(SHIFT + TOUCH UP) keys.

TEACH PENDANT
On teach pendant there are following options
1. Menu: In this option all menus are displayed like Alarm, Tool frame setup,
I/Os, etc.
2. Select: All programs in the teach pendant are displayed using this option. We
can create, delete, copy program in this option.
3. Edit: Using this option we can go to program editing screen
4. Data: In this we can get the data regarding the registers, position registers,
timer and I/Os.
5. Function: this contains aux. Options like program abort, wait release, load,
save, print etc.

CREATE NEW PROGRAM

For creating new program following steps are followed
MENU
SELECT
CREATE
After this write program name and other details like type (sub), comment,

Group mask, write protection etc. Press END key.

By using group masking we can control maximum 16 axes in four groups.

DATE: - 27/10/04
INSTRUCTIONS (INST)

REGISTERS: Register is a variable for holding an integer or decimal fraction. There are 200
registers available and designated as R [i]; where i =1,2,3
Register instructions perform arithmetic operations on registers. The following
register instructions are available:
1.
2.
3.
4.
5.
6.
7.
8.
e.g.

Register Instructions
Registers
I/O
IF/SELECT
WAIT
JMP/LBL
CALL
PALLETIZING
----NEXT PAGE---R[1]= R[2]+R[3]

POSITION REGISTER: A position register is a variable for holding position data (x,y,z,w,p,r). Position
register instructions performs an arithmetic operations on position registers.
PR instruction can load position data, the sum of two values, or difference of
two values, into specified register.
There are 200 Position Registers available and designated as PR [i]; where i
=1,2,3

PALLETIZING REGISTERS: Palletizing Registers are used for automatic palletizing. It holds data regarding
rows, columns, and layers (1 to 127).

MENUS: 1. Utility-Displays information regarding FANUC robot model, software

version.
2. Test cycle-It contains fuctions like DRY RUN, Robot Lock etc.
3. Set Up-Using this fuction we can change language, offset, tool offset,
FRAMES, creating MACRO.
4. Reference Position-we can define a reference Position for robot

5. RSR/PNS- used to start the program automatically and operate a

production line.
6. User Alarm- Alarms can be set to display certain conditions.
7. FILE-using this function files from Memory card can be routed to Teach
Pendent vice versa.
8. User-we can create logins and passwords.
FRAMES: The frames instruction is used to change the settings of the Cartesian
coordinate system by which the robot works. There are two kinds in this instruction
1.

Frame setup instruction-The definition of the specified frame is

changed.

2.

Frame select instruction-the frame no being selected is now changed.

1.Tool frame (Tool Coordinate system)

A tool coordinate system is a Cartesian coordinate system that defines the
positions of the tool center point (TCP) and the attitude of the tool. On this zero point
is the TCP and Z-axis is tool axis.
There are 3 methods to set up tool frame as follows:
1.1 Six point method
1.2 Three point method
1.3 Direct List method
1.1 SIX POINT METHOD
MENU
SET UP
TYPE (F1 Key)
FRAMES
OTHER (F3 Key)
Tool frame screen is displayed.
Move the cursor to Tool frame number line you want to set.

Press DETAIL (F2 Key)

The Tool Frame setup screen is displayed.
Press F2, METHOD.
The Six-point screen is displayed.
Select any point Press Shift+F5 (RECORD)
Similarly record the same point by five times more by different orientation
Move the tool in X and Z direction and record the points at ends.
To make this Tool Frame effective; press F5 SETIND
Then enter frame no.
1.2 THREE POINT METHOD
This method has same procedure as of Six Point Method ;only difference is to
select three points. This method is less accurate than Six Point Method.
1.3 DIRECT LIST METHOD
Display Tool frame List screen (refer 6 point method)
Move the cursor to Tool frame number line you want to set.
Press DETAIL (F2 Key)
The Tool Frame setup screen is displayed
Press F2, METHOD.
Select direct entry. Tool frame set up is displayed.
Add a comment
Enter coordinates values of tool frame
To make this Tool Frame effective; press F5 SETIND
Then enter frame no.
2. USER FRAME (USER COORDINATE SYSTEM)
A User Coordinate system is a Cartesian system defined for each workspace by
the User. If the coordinate system is not defined, the world coordinate system
substitutes it.

Define User coordinate system by (x,y,z) indicating the position of zero point
and (w,p,r) indicating the angular displacement around X,Y, and Z axes.
There are 3 methods to set up tool frame as follows:
2.1 Four point method
2.2 Three point method
2.3 Direct List method
The procedure for above methods is same as the setting tool frame only
difference is to select USER FRAME instead of TOOL FRAME.
REFERENCE POSITION
A reference position is a fixed (predetermined) position that is frequently used
in program or when the robot is moved by jog feed. The reference position is safe
position, which is usually distant from operating area of m/c tool. Three reference
positions can be specified.
MISCELLANEOUS INSTRUCTIONS.
INST
MISCELLENAEOUS
1. RSR: - This instruction is used for automatic program loading.
2. USER ALARM: - This instruction pauses program and displays alarm message as
set in the program.
3. TIMER: - This instruction is used to start stop and reset the timer as per
requirement.
4. COMMENT: - This instruction is used to write comment in the program. While
execution this lines are eliminated.
5. OVERRIDE: - Using this instruction we can reduce the speed of selected
movements.
6. MESSAGE: -The message instruction displays a specified message on the User
screen.

DATE: - 28/10/04
INPUTS AND OUTPUTS (INTERFACING): Input/Outputs signals are electric signals that allow the controller to communicate with
robot, end effector, external equipment, and other peripheral equipment of the system.
MENU
I/O
TYPE

LINK DEVICE: The I/O link screen is used to make setting related to FANUC I/O unit model

and displays the Configuration of the I/O link units. The I/o link screen displays a list
of I/O units in Slave Mode that are connected to the I/O link. It also displays the Rack
and Slot numbers of each unit.

DIGITAL I/O: It is a group of general-purpose signals that send or receive the data of the

peripheral equipment via process I/O printed circuit board (or I/O module)The Digital
signals is set ON or OFF.

RACK:
The rack indicates the kind of the hardware, which composes I/O module.
-

0= Process I/O PC board.

1 to 16= I/O unit

Rack 1,2, and so on are assigned to the base units of I/O model A and the interface
units of I/O unit model B in order, which they are connected.

SLOT:
The slot indicates the number of I/O module parts which Composes RACK.

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CONFIGURING I/O: MENU

I/O
TYPE
Digital
IN/OUT
CONFIG (F2 Key)
MONITOR (F2 Key)
Place the cursor on the Range and specify the range of signals to be assigned.
Line division is performed automatically according to the specified range.
Enter appropriate values for Rack and Slot and Start Point.
When entered values are valid, :PEND is displayed in status.
If entered values are invalid INVAL is displayed.
Press MONITOR
To set attributes of I/O , press NEXT, and DETAIL.
Press PREV to return to selection key.
TURN OFF CONTROLLER. TURN ON AGAIN.

GROUP O/P: -group I/O is a general purpose signals that send or receive the data
by using two or more signals lines as the same group.
To configure the GROUP I/O ; The procedure is same as the DIGITAL
I/O only difference is instead of selecting Digital; select Group.

ROBOT I/O: Robot input signal (RDI) and robot output signal (RDO) are
input/output signals that can be controlled by the user.

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AUTOMATIC SELECTION OF PROGRAM: Automatic operation is the function with which the remote controller starts a

program, using the peripheral I/O. The automatic operation includes the following
functions.
1. The Robot Service Request (RSR) function selects and starts a program according
to the robot service request signals (RSR1 to RSR8 inputs). When another program
is being executed or is temporarily stopped, the selected program enters the wait
state and is started once the program is currently being executed terminates.
MENU
SETUP
TYPE
RSR/PNS
CHOICE (F4 Key)
RSR
DETAIL (F3 Key)
Position the cursor to the target item and enter a value.
After changing PNS to RSR, to enable the change; turn the power off, then on again.
2. The Program Number Selection (PNS) function selects or examines program,
using the program number selection signals (PNS1 to PNS8) while a program is
temporarily stopped or being executed, these signals are ignored.
The procedure for setting PNS function is same as that of RSR.
Program will run automatically when: -Robot is not in step mode.
-Robot setup should be configured as REMOTE.
-User operated signal CMD_enable
-Teach pendant should be disable.

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MACRO: Macro instruction is a function for registering a program consisting of

sequence of instructions as one instruction and calling such a set of instructions for
execution as required. Macro can be set of motion instructions or any non-motion
instructions. The non-motion instructions consist of register instructions or any I/O
instructions.
These macros are called in main program by using CALL function whenever
required. This instruction is very useful for small repetitive set of instructions.
e.g. HOME POSITION
MENU
SELECT
DETAIL
SUBTYPE
CHOICE
MACRO
A group mask can be set (*, *, *, *, *) for a program not including motion instruction.
MENU
SETUP
TYPE
Macro.
Program
Choice
After program selected; assign a key from seven function keys provided on
Teach Pendent.

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FILE SAVE (LOADING AND BACKUP)

A program is a unit of data storage in the memory of the controller. This

program data can be copied to removal disks and used on computers for backup. This
backup data can be reloaded on controller whenever required.
MENU
FILE
TYPE
FILE
UTILITY.
SET DEVICE-1. Floppy Disk
2. Auto Back Up
3. Memory Card.
After selecting the device, press BACKUP.

LOADING OF FILES.
The files can be load externally through MEMORY CARD only.
The file input/output device is set correctly.
MENU
SELECT
LOAD (F3 Key)
NAME OF PROGRAM
To see all the files in the memory of controller use the function DIR

DATE: - 2910/04
SYSTEM VARIABLES: 14

All system variables can be seen with the system variable screen. Setting of the
system is stored in the system variables.
MENU
SYSTEM
TYPE (F1 Key)
VARIABLES
To change settings of system variables, move cursor to desired field and press
ENTER. After changing settings turn power OFF then ON again.
SOME IMPORTANT SYSTEM VARIABLES.

$ DMR_GRP
This variable shows the DMR values required for the mastering.

$ MASTER_DONE
This variable shows the mastering is done or not.

$ MASTER_COUN
Pulse coder count at zero degree position is stored. This value is calculated

from current count at mastering and current position.

MASTERING: Mastering associates with the angle of each axis of the robot with the pulse
count of the absolute pulse coder connected to motor of each axis. More specifically,
mastering is performed by obtaining the pulse cont read at zero degree position.
Mastering data is factory set but it may be lost due to voltage drop of back up battery
or any cable is cut etc. There are five types of mastering.

1. JIG MASTERING: -

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Mastering is performed by using a special Jig. Jig mastering is performed at

the factory.
MENU
SYSTEM
TYPE

(F1 Key)

Master/Cal
Move the robot by jog feed to the mastering position.
Then select the mastering type; press F4 key (YES)
Then select 6 CALIBRATE; press F4 key (YES)
Press F5 DONE.
Turn power OFF then ON again.

2. ZERO POSITION MASTERING: Mastering is performed with axis of robot aligned with the zero degree
position. The zero degree position mark attached to each axis of the robot is
referenced.
The procedure is same as for JIG MASTERING only difference is move the
robot by jog feed to the ZERO DEGREE POSITIONS and choose ZERO POSITION
MASTER; the rest of the same.
3. QUICK MASTERING: The mastering position can be set to any position. To do this reference points
must be set in advance.
Make System variable $MASTER_ENB ; 1 or 2.
Display Master/Cal screen.
Jog robot to quick mastering position and select QUICK MASTER.
Rest of the procedure is same as above methods.
4. SINGLE AXIS MASTERING: -

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Single axis mastering is that the mastering is performed at every one axis.
System variable $MASTER_ENB must be set to 1.
Display Master/Cal screen.
Select 4 SINGLE AXIS MASTER
Enter the 1 to SEL setting field of the axis that you want to perform mastering.
SEL can be specified for every one axis simultaneously. Press F5 EXEC.
This causes SEL is to set 0 and ST to 2 or 1.
Press PREV
Select6 CALIBRATE
Press F5 DONE.
5. SET QUICK MASTER REF: Mastering Data is set in Mastering counters directly.
Select 6 SYSTEM from MENU.
Select Variables.
Select $ DMR_GRP.
SELECT $MASTER_COUN. And Enter the mastering data.
Press PREV key
Set $MASTER_DONE to TRUE.
Display Master/cal screen and select 6 CALIBRATE.
Press F5 DONE.

MAINTENANCE OF ROBOT: -

17

CHANGING PCB CARD: In control cabinet there are slots for PCB cards. We can add one PCB card for

each added group. For changing the PCB card this card is pulled out of the slot
directly.

ALARM SCREEN: This screen shows faults occurred. This alarm screen can be reset after specific

time.

CHANGING BATTERY: A battery is located in the base of the robot. This is used to store the pulse

coder values when the robot power is OFF. If batteries of the robot get discharged it
can be replaced. The capacitor in the circuit will give supply for half hour after
removal of battery. So we get this time to change battery. If these batteries are not
replaced all data regarding the pulse coder values will be lost and robot will require
calibration.

GREESING: The Greasing points/openings are provided on the robot manipulator. The

Greasing gun is pressed at these points/openings until the new grease is come through
another point/opening on the robot body. This is very easy method and does not
require any adjustments to be done on the robot body.

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