Professional Documents
Culture Documents
Description of application
2/78 Bosch Rexroth AG | Electric Drives PSx 6xxx | R911172825 / 02
and Controls
Contents
Contents
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Program execution . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1 Programmable times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 Current blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3 Electrode force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1 Schedule modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.1 Single spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.2 Repeat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.3 Seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2 Impulse mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.3 Slope (current increase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.4 Welding modes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.4.1 Phase angle (PHA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.4.2 Constant-current regulation (KSR) . . . . . . . . . . . . . . . . . . . . . 30
7.4.3 UI regulation (UIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5 %I prewarning and limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5.1 %I limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5.2 %I warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5.3 Lower %I warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.6 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.6.1 Current monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.6.2 Time monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.6.3 Monitor stepper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.6.4 Measuring loop test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.6.5 Minimum current verification . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.7 Latching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.8 Automatic reweld by timer active . . . . . . . . . . . . . . . . . . . . . . . . 40
7.9 1. Halfcycle limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4/78 Bosch Rexroth AG | Electric Drives PSx 6xxx | R911172825 / 02
and Controls
Contents
8 List of tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9 List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 5/78
and Controls
Danger levels? The safety instructions are classified into danger levels (danger
classes). The signal word represents the danger level.
DANGER
Type and source of danger!
Consequences of failure to observe!
" Action for averting danger.
WARNING
Type and source of danger!
Consequences of failure to observe!
" Action for averting danger.
CAUTION
Type and source of danger!
Consequences of failure to observe!
" Action for averting danger.
NOTICE
Type and source of danger!
Consequences of failure to observe!
" Action for averting danger.
8/78 Bosch Rexroth AG | Electric Drives PSx 6xxx | R911172825 / 02
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1.3.2 Icons
The following icons are used to mark text passages specifically.
Symbol Meaning
This icon indicates a tip or an information. It helps use
and operate the product optimally or understand the
context better.
" This icon indicates the need to observe/perform certain
things.
• This icon indicates an (unsorted) list.
1. This icon indicates a (sorted) list or specific procedure
2. steps where a certain sequence has to be observed.
3.
1.3.3 Designations
The following designations may appear in our documentation:
Table 6: Designations
Name Meaning
BOS Welding user interface
PE Protective Earth. PE conductor.
PG Programming terminal/welding computer
PSG Transformer-rectifier unit for PSI types.
Medium-frequency welding transformer 1000 Hz
PSI Programmable weld timer with inverter.
PSQ 6000 Plug-in module for PSI with UI controller functionality.
XQR Is not needed for PSI 6xCx types.
PST Programmable weld timer with thyristor power unit.
PLC Programmable Logic Controller.
WT Weld timer.
Also referred to as timer or resistance weld timer.
1.3.4 Abbreviations
Refer to Section 10 on page 71 et seq.
R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 9/78
and Controls
Safety instructions
2 Safety instructions
" Please note the section with the identical name in the operating in
structions for the PSI 6xxx and PST 6xx0 product families
(for information on document numbers, refer to table 1: page 5).
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and Controls
Safety instructions
Notes:
R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 11/78
and Controls
Notes:
R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 13/78
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Scope of delivery
4 Scope of delivery
" Please note the section with the identical name in the operating in
structions for the PSI 6xxx and PST 6xx0 product families
(for information on document numbers, refer to table 1: page 5).
14/78 Bosch Rexroth AG | Electric Drives PSx 6xxx | R911172825 / 02
and Controls
Scope of delivery
Notes:
R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 15/78
and Controls
PSx 6xxx
Force control variable
Start O
I
Force feedback Gun
I
I
PLC or Prog. No./
robot spot No.
(WLD) Trans
Electrodes
former
O Internal
WC
current
sensor
I: input optional external current sensor
O: Output
WC: Weld complete
WLD: Weld time
The weld timer ensures the controlled performance of the actual weld
ing process. For this purpose, it must provide open- and closed-loop
control of many functions and physical quantities. Its main tasks in
clude, e.g.
• Communication with a higher-level PLC or robot controller via I/O
signals.
• Control of a welding gun for influencing the electrode force.
• Ensuring the proper welding schedule by different, technologically
required time intervals (e.g. pre-weld, main weld, post-weld time
etc.) or regulation methods.
• Driving the power unit to generate the proper welding heat.
• Signalling a correct or incorrect weld at the end of the welding pro
gram schedule.
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Current I Time
Transformer
Start
PreSQZ
Secondary circuit + WLD HLD
SQZ
SQZ: Squeeze time (for explanations, refer to Sect. 6.1 starting on page 17)
WLD: Weld time
HLD: Hold time (for explanations, refer to section 6.1)
Program execution
6 Program execution
A total of 256 separate welding programs (prog.no. 0 to 255) are avail
able.
Each welding program contains all of the parameters that are required
for the precise definition of a weld. Basic parameters include, e.g.
• times that are to be subsequently processed
(refer to Section 6.1)
• %I values that are to be effective in different current blocks
(refer to Sect. 6.2 starting on page 20)
• electrode force
(for a description, refer to page 21 et seq.).
MainWLD
PreSQZ SQZ PreWLD PstWLD HLD
1.CT
3.CT
Current
Time
Fig.3: Example: Time diagram of a welding program execution without impulse operation in 2nd current block
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and Controls
Program execution
1.CT
3.CT
UST DST Time
Current
Time
Fig.4: Example: Time diagram with all programmable periods of time (incl. impulse mode with 3 impulses)
At the end of SQZ, some timer types check the signaled force / pres
sure for tolerance (”Tolerance force monitoring”) if the correspond
ing function has been selected via BOS within the electrode
parametrization under ”Pressure/force monitoring”. In case of a
fault, the message ”Welding fault force monitoring: Force too low/too
high” will be generated at the end of SQZ.
At the end of the SQZ, some timer types check whether a high level is
present at the digital input X2/4. Otherwise, the timer extends the
SQZ by max. 5 seconds before the schedule is aborted and a fault
message is output.
R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 19/78
and Controls
Program execution
Program execution
SQZ: Squeeze time (For description refer to Sect. 6.1 on page 17 et seq.).
WLD: Weld time
HLD: Hold time (For description refer to Sect. 6.1)
%I: Power/Heat (%I)
Program execution
Program execution
Notes:
R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 23/78
and Controls
Functions
7 Functions
Several functions or partial functions described in this section are
only available in certain timer types.
The implementation of some function may vary in detail in the differ
ent timer types.
" Therefore please always also note the type-specific operating in
structions of your timer.
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Functions
Start
WC
7.1.2 Repeat
Suitable for manual electrode guns and manually operated welding ma
chines.
The weld timer initially responds to the start signal as in single spot
mode and starts the welding schedule with the PreSQZ.
If the corresponding start input is still high after the end of the hold time
(HLD), the solenoid valve signal will be switched off via discrete output
signal, if available.
The welding gun is opened.
The Off time (OFF) runs. During this time, the operator can pull on the
welding gun towards the next spot.
After the end of the OFF time, the solenoid valve will be energized
again, and the welding schedule will be restarted - this time beginning
with the SQZ. This sequence will be repeated for as long as the relevant
start input is high.
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and Controls
Functions
When the start signal becomes low, the timer will terminate the actual
current cycle and start the hold time (HLD) instead of the OFF time.
Start
Solen
oid
7.1.3 Seam
Suitable for roll seam systems.
The parts to be welded are joined by individual spot welds while rolling
electrodes are moved along.
The weld timer initially responds to the start signal as in single spot
mode and starts the welding schedule.
The weld time (MainWLD) and a cool time (2.CT), if programmed, will be
repeated for as long as the start input remains high.
When the start signal becomes low, the timer will cancel the actual cur
rent cycle and start the hold time (HLD).
In seam operation, a distinction is made between a stitch weld and a
seal weld.
Stitch seam: A series of weld times is separated in time by sufficiently
long cool times (2.CT) so that subsequent spot welds
neither touch nor overlap.
Seal weld: The cool time (2.CT) is configured very short so that sub
sequent spot welds overlap.
ÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ
ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ
ÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ
2.CT MainWLD
CT very short or 0
Functions
2. current block
Example: Impulse mode OFF MainWLD
IMP = 1
MainWLD = 60 ms
2.CT (not relevant because 1 impulse only)
2. current block
Example: 2 Impulses
MainWLD MainWLD
IMP = 2 2.CT
MainWLD = 60 ms
2.CT = 40 ms
2. current block
Example: 3 Impulses
IMP = 3 MainWLD MainWLD MainWLD
2.CT 2.CT
MainWLD = 60 ms
2.CT = 40 ms
Functions
2. current block
Functions
Functions
Mains
Welding trans
Electrodes
former
Programming:
Commanded %I value
in %I
Power unit
kA actual current
mean phase angle
in %I
Current monitoring
-Status
- Tolerance band -Error
programmable refer
ence current (in kA)
Functions
Programming:
Commanded current Mains
value in kA Welding trans
former Electrodes
-
Controller
Power unit
Current sensor
(only required for
Measured value Actual current value measurement on the
preparation
secondary side)
kA actual current
mean phase
angle in %I
Current monitoring
-Status
- Tolerance band -Error
programmable refer
ence current (in kA)
Functions
The U/I controller measures not only the welding current, but also the
voltage at the electrodes. In this way, more profound information can be
obtained with respect to the welding process, and an adaptive interven
tion by the controller can be achieved if influencing variables are
present.
For detailed information refer to description of application „PSI 6xxx:
UI regulation and monitoring“.
7.5.1 %I limitation
The "%I Limitation" parameter is used to define the maximum permitted
%I value that may be generated by the inverter.
If the %I limitation responds, the timer will output the message "Max
imum phase angle".
The input value for %I limitation has an absolute effect!
The "%I correction" (refer to page 60) and "%I stepper" (refer to page
46) functions can trigger a %I limitation response for this reason.
In some timer types, this value cannot be changed in BOS. In these
cases, it is internally fixed to 100 %I.
7.5.2 %I warning
%I values generated which are higher than the ”%I warning” parameter
will trigger the ”Phase angle warning reached” message.
As a result, the timer may draw the operator's attention to an imminent
%I limitation - due to, e.g., line losses in the secondary circuit - in KSR
regulation mode.
The parameter value must be lower than the value for the %I limita
tion.
Functions
7.6 Monitoring
The timer is capable of monitoring the weld for the following quantities:
• current (refer to section 7.6.1 on page 33 et seq.)
• time (refer to section 7.6.2 on page 38 et seq.).
Functions
Tolerance ranges
In current monitoring, the actual current determined by rms value meas
urement is compared to the "tolerance band".
Whether or not the timer interprets a measured actual current as "ac
ceptable" depends on the programming of the tolerance band. The fol
lowing values are decisive for the definition of the tolerance band:
• Reference current in kA
• positive tolerance in % of the reference current
(upper tolerance band).
Actual values above the upper tolerance band generate the mes
sage type ”High current ...”.
• negative tolerance in % of the reference current
(Lower tolerance band).
Actual values below the lower tolerance band generate the message
type ”Low current ...” or "No current ...".
ÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎ
High current ...
upper tolerance band
(in %)
ÎÎÎÎÎÎÎÎÎ
Low current... / No welding current...
Functions
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
High current ...
upper tolerance band
(in %)
Reference current in kA
with respect to a
single measurement:
Current ok
Conditional tolerance
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
Conditional toler band (in %)
ance range
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
lower tolerance band
(in %)
Low current... / No welding current...
"Series of welds below lower
spots welded threshold point" message
Fig.14: Example: principle of the conditional tolerance band with a Reweld factor = 4
• Standard mode:
The entire current profile (1st, 2nd and 3rd current block including
cool times) is included in rms value measurement.
The complete current profile is represented by a single actual value,
and monitored by a single tolerance band.
Although this simple and often sufficient monitoring mode keeps the
amount of data to be processed low, any cool times that may have
been programmed and different amounts of current in the individual
blocks alter the measured result.
The reference current to be indicated should be determined by test
welds in this case. If you only use the MainWLD without impulse or
slope operation, you can specify the commanded current pro
grammed for regulation as reference current as well.
R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 35/78
and Controls
Functions
Tolerance band
Reference
current
1st * * 3rd
block block
PreWLD 3.CT PstWLD
1.CT 2nd block
*: 2.CT
Measuring time
• Mixed mode:
The rms value is measured separately for each current block and
monitored by individual tolerance bands (for 1st, 2nd and 3rd current
block).
The programmed cool times are not accounted for in the determina
tion of the actual value for the individual current blocks.
This results in higher transparency of the individual current blocks,
however, the amount of data to be processed is larger.
In mixed mode, you can generally use the commanded currents pro
grammed for regulation as reference currents as well.
Reference current
Refer
ence Refer
current ence
1st current
block 3rd block
t1 t2 t3
Measuring time 1 2nd block Measuring time 3
Functions
Current
Irms_1
Irms_2
Time
Weld time
Irms_1: Fade out time accounted for
Irms_2: Fade out time not accounted for
Functions
Current
Time
2nd block
1st
block 3rd block
The programmed fade out time is identical for all weld times and for
all welding programs.
Therefore, you should make sure that the fade out time is always
shorter than the shortest programmed weld time!
The programmed trail current is identical for all weld times and for all
welding programs!
If the only quality criterion for your application is the amount of heat
applied to the spot weld (amount of heat: Q ≈ i2 x t x R), you should
program "0" for the fade-out time and switch the trail current ON.
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Functions
In this way, it can be ensured that no excessive weld time changes can
be made manually in the individual welding programs.
The following values are decisive for programming time monitoring:
• Time monitoring ON/OFF
• Reference time.
• Permitted time tolerance with respect to the programmed reference
time.
Actual times above the permitted time tolerance generate the mes
sage type ”Weld time too long ...”.
Actual times below the permitted time tolerance generate the mes
sage type ”Weld time too short ...”.
1st * *
block 3rd block
*: 2.CT
Reference time
Functions
If a fault has been detected, the weld timer will abort the running welding
program before initiating the first programmed weld time, the timer will
be inhibited and generate the "Measuring circuit open" or "Measuring
circuit shorted” message.
To activate the function, switch the "Measuring loop check" parameter
"On".
Conditions:
• Parameter "Inhibit monitoring" has been switched off and
• ”Current monitoring” function (refer to page 33) has been switched
on.
NOTICE
Incorrect declaration of process-critical messages
Excessive weld current possible!
" Make sure that the messages "Measuring circuit open" or "Mea
suring circuit shorted" are defined as "faults" in any case.
The controller receives incorrect actual value information, or no
information at all. As a result, the controller may fully activate the
power unit initially.
The point of time in which the timer eventually cancels the welding
schedule with a fault message depends on the "Minimum current
verification" function (refer to Sect. 7.6.5).
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Functions
7.7 Latching
When the SQZ has elapsed, the timer will start to be latching in the weld
ing mode "single spot". In latched condition, the PreWLD to PstWLD in
cluding HLD will continue to be executed even when the start signal has
been reset.
Signal latching can only be cancelled by opening the stop circuit.
Functions
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
High current ...
upper tolerance band
(in %)
: Weld triggered by
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
lower tolerance band
(in %)
automatic reweld
by timer. ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
Low current... / No welding current...
NOTICE
Incorrect declaration of process-critical messages
Defective welds may remain undiscovered!
" Make sure that the messages ”Low current ...”, ”No current ...” and
”Series of welds below lower threshold point” are always defined
as "fault".
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Functions
The first current half-cycle value can be limited in order to protect the
welding transformer and thyristor unit.
Example: Input value of 55 %I means
• the 1st half-cycle will not be influenced by welds with low pro
grammed %I (0 to 55 %I).
• for higher programmed %I values (> 55 %I), the 1st half-cycle will be
limited to 55 %I.
Two parameters are available for programming:
• "1st half-cycle limit":
Parameter acting globally for the weld timer.
Only the first half-cycle of a weld will be limited.
• "1. half-cycle after cool time":
Can be separately set for each welding program.
The first half-cycle of each weld time or each pulse is limited if a cool
time greater than 0 has been programmed before.
Monitoring of PstWLD
In addition to the inputs and definitions of the known limit values for
lower, upper and (lower) conditional tolerance, it is possible to define an
”Upper tolerance band” incl. the corresponding repeat factor specific
ally for PstWLD:
ÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎ High current ...
Upper tolerance (in %)
Upper tolerance band PstWLD (in %)
Reference current in kA
ÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎ
Cond. tolerance band (in %)
Lower tolerance (in %)
ÎÎÎÎÎÎÎÎÎÎ
Low current... / No current
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and Controls
Functions
NOTICE
Incorrect declaration of process-critical messages
Defective welds may remain undiscovered!
" Make sure that the message: ”High current in consecutive welds”
is always defined as "Fault".
Functions
Wear
Functions
Example:
6 welds have to be performed on a part.
Every single spot (P1 to P6) is generated by a separate welding pro
gram (Prog1 to Prog6).
The upper 3 spots (P1 to P3) have to weld 2 sheets, the lower 3 spots
(P4 to P6) have to weld 3 sheets, each.
Consequently, electrode wear is higher for spot welds P4 to P6 (greater
material thickness). For this reason, the program-specific count factor is
defined by the value "1" for Prog1 to Prog3, and by 1.5 for Prog4 to
Prog6.
The resulting wear per component is 7.5.
The count factors in this example are of an exemplary nature only. In
practice, they are determined in advance with respect to the materi
als and thicknesses used.
Counts:
0 1 2 3
(new electrodes)
Functions
0% „Count (wear)“
parameter
Count (wear) = 0
Functions
Functions
Power (%I) in %
(with reference to the programmed base %I)
Count (wear) = 0
Functions
As feedback for the robot some timers reflect the status of the acknow
ledgment input to a dedicated output.
Functions
Functions
Functions
Functions
ÎÎÎÎÎÎÎÎÎÎ
Current ok
+toler. before tip
ÎÎÎÎÎÎÎÎÎÎ
dressing
is identified by the refer prohibited range
(in %)
ÎÎÎÎÎÎÎÎÎÎ
ence weld directly before
Reference current 1st test
a new required dressing
ÎÎÎÎÎÎÎÎÎÎ
in kA
prohibited range
-toler. before tip dress
ing
(in %)
ÎÎÎÎÎÎÎÎÎÎ Current ok
Fig.27: ”Tip dresser result monitoring” function: Effect of the tolerance bands -
Testing 1 (for prohibited range)
ÎÎÎÎÎÎÎÎÎÎ
Iact MON
ÎÎÎÎÎÎÎÎÎÎ
prohibited range
+toler. new electrode
(in %)
is identified by the Current ok
reference weld after Reference current 2nd test
dressing in kA
ÎÎÎÎÎÎÎÎÎÎ
Current ok
-toler. new electrode
(in %)
ÎÎÎÎÎÎÎÎÎÎ prohibited range
Fig.28: ”Tip dresser result monitoring” function: Effect of the tolerance bands -
Testing 2 (for permitted range)
The dressing operation is regarded as good when test 1 and test 2 dur
ing monitoring weld were successful.
Otherwise the timer sets the TIP DRESSING DEFECTIVE output (if
available).
Since phase angle values are programmed for reference and monit
oring welds as %I input, mains voltage fluctuations may influence the
actual current and thus the test result.
" Therefore the tolerance bands should be dimensioned so that they
compensate normal mains voltage fluctuations safely but do not
overlap!
Relevant signals for the ”Tip dresser result monitoring” function:
• Input REFERENCE WELD FOR NEW ELECTRODE
• Input REFERENCE WELD TIP DRESS
• Input MONITORING WELD
• Output REFERENCE WELD ACTIVE
• Output MONITORING WELD ACTIVE
• Output TIP DRESSING DEFECTIVE
Please refer to the type-specific operating instructions of your timer
for the addresses to which these signals are assigned in the I/O inter
face.
54/78 Bosch Rexroth AG | Electric Drives PSx 6xxx | R911172825 / 02
and Controls
Functions
Functions
Functions
" In order to ensure that the programmed force actually acts on the
electrodes in case of servo guns, a proper calibration of the servo
gun circuitry is necessary!
In the course of force calibration, the current values of the ”Conver
sion factor” and ”Zero adjust” parameters are overwritten!
Functions
7.16 Calibration
" Calibrate force first, and current afterwards!
NOTICE
Operating the timer without or with incorrect force calibration
Possibility of damage to the gun / defective welds!
" The base pressure value to be programmed must be determined
empirically - starting with "0" - for each electrode force required
and whenever guns have been replaced if force calibration is not
carried out!
If force calibration is not used, the timer cannot generate a proper
reference between the programmed force and the force actuating
variable to be output (for controlling the gun force).
Therefore, the actual force acting on the gun may differ consider
ably from the programmed force!
Functions
• if possible, the higher value should generate the force that is max
imally used for welding (upper end of the force working range).
• The two values should differ by a minimum of 20 %.
• The force used for tip dressing should not be allocated to the nor
mal working range (because it is usually lower).
• If you do not know the values you have to enter for force calibra
tion, first perform force calibration using low values in order to
check the forces that are adjusted at the gun, and abort calibra
tion, if necessary. Thus, you avoid overloading or damaging the
gun during force calibration. Then, you should increase the input
values by new force calibration processes until the higher input
value generates the maximum force used for welding.
" Use the same reference force meter for all plants that should be com
parable.
" Perform calibration for each gun of the welding equipment and
whenever a gun has been replaced.
" Verify any calibration made by comparing the base pressure values
programmed for test welding programs with the actual values on the
gun.
When doing so, make sure that the test programs work without cur
rent and that no persons are at risk during the measurements (e.g.
as a result of robot movements).
" Repeat calibration whenever a component that is actively involved in
force generation has been replaced (weld timer, proportionate con
trol valve, gun, ...).
R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 59/78
and Controls
Functions
Functions
7.17 Corrections
Using the timer's correction function you can change
• the %I, and
• the pressure (electrode force).
Corrections are programmed as a percentage of the corresponding
base values.
Functions
KSR SELECTION 3
KSR SELECTION 2
KSR SELECTION 1
Secondary circuit 1
D
X3 external
Toroid input 1 change-
2 over box D
Toroid input
for KSR
Shield 3 D
changeover
4
Secondary circuit 2
5
D
Fig.29: Principle of KSR change-over; application with 3 separate welding circuits (transformers), for example
62/78 Bosch Rexroth AG | Electric Drives PSx 6xxx | R911172825 / 02
and Controls
Functions
Functions
Signals used:
• Outputs:
”WCD warning”
Upon delivery (or after deletion of the timer memory), the function is
deactivated, the "Max. reference current" parameter ("WC degrada
tion" parameter group) is preset to 3 kA and the WCD tolerance band
parameter to 100%.
64/78 Bosch Rexroth AG | Electric Drives PSx 6xxx | R911172825 / 02
and Controls
Functions
7.21.1 UI regulation
The UI regulation protects your welding process against interfering vari
ables much better than e.g. a constant-current regulation.
Higher process reliability and fewer user interventions in the system are
required as a result.
The function is described in detail in the manual „PSI6 xxx: UI regula
tion and monitoring“ (for document number refer to table 1: page 5).
Functions
Functions
Notes:
R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 67/78
and Controls
List of tables
8 List of tables
Table 1: Necessary and supplementary documents . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 2: Example for the structure of a safety instruction . . . . . . . . . . . . . . . . . . . . . 6
Table 3: Danger classes according to ANSI Z535.6-2006 . . . . . . . . . . . . . . . . . . . . . 7
Table 4: Examples for classification of safety instructions . . . . . . . . . . . . . . . . . . . . . 7
Table 5: Icons used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 6: Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 7: Abbreviations and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
68/78 Bosch Rexroth AG | Electric Drives PSx 6xxx | R911172825 / 02
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R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 69/78
and Controls
List of figures
9 List of figures
Fig.1: Main components of a welding plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fig.2: Physical basic parameters for influencing the weld . . . . . . . . . . . . . . . . . . . 16
Fig.3: Example: Time diagram of a welding program execution without impulse
operation in 2nd current block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fig.4: Example: Time diagram with all programmable periods of time
(incl. impulse mode with 3 impulses) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fig.5: Current blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fig.6: Single spot welding mode; signal sequence . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fig.7: Repeat welding mode; signal sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fig.8: Seam operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fig.9: Programming examples for impulse mode . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fig.10: Example: Slope in connection with impulse mode . . . . . . . . . . . . . . . . . . . . 27
Fig.11: Principle of open-loop PHA mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fig.12: Principle of KSR regulation mode with secondary current sensor . . . . . . 30
Fig.13: Principle: tolerance band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fig.14: Example: principle of the conditional tolerance band with a
Reweld factor = 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fig.15: Principle of "Standard" monitoring mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fig.16: Principle of "Mixed" monitoring mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fig.17: Effect of the fade-out time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fig.18: Trail current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fig.19: Start times of fade-out time and trail current . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fig.20: Principle of time monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fig.21: Example: Principle of automatic reweld by timer using
"Max. rewelds" = 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fig.22: Enlarged contact area through electrode wear . . . . . . . . . . . . . . . . . . . . . . 44
Fig.23: Example: Determining the count value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fig.24: Operating principle of stepping in the „Start“ function area . . . . . . . . . . . . 46
Fig.25: Operating principle of stepping in the „Stepper“ function area . . . . . . . . . 47
Fig.26: Operating principle in the „Dressing“ function area . . . . . . . . . . . . . . . . . . . 48
Fig.27: ”Tip dresser result monitoring” function: Effect of the tolerance bands -
Testing 1 (for prohibited range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fig.28: ”Tip dresser result monitoring” function: Effect of the tolerance bands -
Testing 2 (for permitted range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fig.29: Principle of KSR change-over; application with 3 separate welding circuits
(transformers), for example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
70/78 Bosch Rexroth AG | Electric Drives PSx 6xxx | R911172825 / 02
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R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 71/78
and Controls
Abbreviations
10 Abbreviations
Abbreviation Meaning
%I General abbreviation for heat (%I).
May be specified in %I (scale values) or kA.
%I Scale values (%I)
With thyristor power units: Measure for the electrical phase
value.
For MF inverters: Measure for the pulse width.
AC Alternating Current
BOS Welding user interface
BQR User interface for U/I controller
CAN Controller Area Network; data bus
CT Cool time
Time between the current impulses/blocks (1., 2., 3. CT)
Cyc Cycles. Refer to P.
Cyc. Refer to P.
daN Deka-Newton. 1 daN = 10 N
DC Direct current
dimmed The relevant object or its text is shown in grey color. In this
condition, the relevant functionality is inhibited, or cannot
be activated for reasons of the very system.
DST Downslope time.
Time in which the %I decreases until the end of the Main
WLD.
ELMO Electromotive.
EMC Electromagnetic compatibility
EOS End of Schedule. Refer to WC.
ESD ElectroStatic Discharge.
Abbreviation of all references to electrostatic discharge,
e.g. ESD protection, ESD hazard.
ESD-sensit Electrostatically Sensitive Devices
ive compon
ents
FPO Freely programmable output.
Is not offered for all timers.
FQF Force Quality Factor.
Value for the welding quality, derived from the character
istic of the counterforce to the electrodes during a weld.
HLD Hold time.
Time after the last weld time in which the parts to be wel
ded can cool down.
HSA (main Main switch trip.
switch trip)
Ignition Ignition.
Firing pulses for triggering the power unit are switched on
and off.
72/78 Bosch Rexroth AG | Electric Drives PSx 6xxx | R911172825 / 02
and Controls
Abbreviations
Abbreviation Meaning
IMP Number of impulses.
Number of impulses, impulses forming the MainWLD.
IP Internet Protocol
kA Kilo-Ampere (amount of current)
kN Kilo-Newton (force)
KSR Constant-current regulation (CCR).
Keeps the current in the welding circuit constant.
KUR Constant-voltage regulation.
Compensates line voltage fluctuations.
LT Power unit (thyristor or inverter)
MF Medium Frequency
ms Milliseconds.
NBS Mains load limitation control.
Monitors and influences the mains load.
NWI Post-warming pulse.
OFF Off time.
Time between two spot welds in which the solenoid valve
is not driven. Relevant for Repeat mode only.
Option button Round object on the user interface for toggling a function
on/off.
P Cycles (mains cycles)
With a line frequency of 50 Hz: 1 P -> 20 ms.
With a line frequency of 60 Hz: 1 P -> 16.6
PE Protective Earth. PE conductor.
PG Programming terminal/welding computer
PHA Phase angle.
PLC Programmable Logic Controller.
Post-Heat Post-heating time,
also referred to as PstWLD.
Pre-heat Pre-heating time,
also referred to as PreWLD.
PSF Process stability.
Value for the consistency between the current resistance
characteristic and the resistance characteristic of the refer
ence curve.
PSG Transformer-rectifier unit for PSI types.
Medium-frequency welding transformer 1000 Hz
PSI Programmable weld timer with inverter.
PST Programmable weld timer with thyristor power unit.
Radio Refer to "Option button".
button
REPEAT Repeat mode.
Operating mode for manually operated systems.
RO Relay output
SINGLE Single spot operating mode.
For automatic and manual systems
R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 73/78
and Controls
Abbreviations
Abbreviation Meaning
Slope Current increase.
Current increases/decreases from an initial to a final heat
value.
Solenoid Solenoid valve.
Drives the cylinders for closing the electrodes.
SQZ Squeeze time.
Time that runs before the weld time. The electrodes
squeeze the parts to be welded together.
Stepper %I stepping in order to compensate for electrode wear.
TCP Transmission Control Protocol.
TCP controls the way in which data is exchanged between
computers. It is a link-oriented, packet-switching transport
protocol and belongs to the range of Internet protocols
(IP).
Temp. Temperature.
Timer Weld timer.
Also referred to as timer or resistance weld timer.
Tool tip Explanatory text.
Appears when the mouse pointer remains on an input
field/object for a moment.
ÜK Monitoring contact
e.g. for monitoring the pressure cylinder that closes the
electrodes or monitoring of the electrode position (e.g. gun
closed”).
UIR UI regulation
UIP Process quality.
Value for the welding quality, derived from the resistance
characteristic of the current weld.
UST Up-slope time.
Time in which the %I increases from the beginning of the
MainWLD.
WLD Weld time.
A distinction is made between PreWLD (pre-heating time),
MainWLD (main weld time), and PstWLD (post-heating
time).
All 3 weld times can be programmed separately in terms of
duration and %I.
Impulses and slope values can only be programmed for
the MainWLD.
WC Weld complete (contact).
This signal is output when the schedule has been com
pleted.
WCD Weld circuit degradation
74/78 Bosch Rexroth AG | Electric Drives PSx 6xxx | R911172825 / 02
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Abbreviations
Notes:
R911172825 / 02 | PSx 6xxx Electric Drives | Bosch Rexroth AG 75/78
and Controls
Index
11 Index
% H
%I limitation, 31 HLD (Hold time), 19
%I stepping, 46 HSA (main switch trip), 71
%I warning, 31
%I warning, lower, 31 I
Icons, 8
1 Impulse mode, 26
1.CT (cool time), 19
1st half-cycle, 42 K
KSR, 30, 72
A KSR changeover, 61
Abbreviations, 71 KUR, 72
AC, 71
L
Automatic reweld by timer active, 40
Latching, 40
B Lower %I warning, 31
BOS, 8
M
C Manual electrode guns, 24
Calibration, 57 Measuring loop test, 39
Close weld contactor, 62 MF, 72
Conditional tolerance range, 33 Minimum current verification, 40
Constant-current regulation, 30 Minimum current, Verification, 40
Corrections, 60 Mixed mode
CT (cool time), 19 Monitoring, 35
Current blocks, 20 Regulation, 28
Current calibration, 59 Monitor stepper, 38
Current monitoring, 33 Monitoring, 32
Monitoring dresser change, 54
D Monitoring gun life, 55
Damage to products, 11 Monitoring modes, 34
Damage to property, 11
DC, 71 N
NBS, 72
Designations, 8
NWI, 42
Downslope time (DST), 27
Dresser change monitoring, 54 O
Dressing, 49 OFF, 72
DST (downslope time), 27
P
E PG, 8, 72
Electrode force, 21 PHA, 28
ELMO, 71 Phase angle, 28
EMC, 71 PLC, 8, 72
End of Stepper, 50 Post-heating time, 20
EOS, 71 Post-warming pulse (NWI), 42
ESD, 71 Pre-heating time, 20
ESD-sensitive components, 71 Pressure profile, 56
Pressure stepping, 56
F PSF, 72
Fade out time, 35 PSG, 8, 72
Force, 21 PSI, 8, 72
Force calibration, 57 PST, 8, 72
Force monitoring, 65
Q
G Q Stop, 64
Glue function, 64
Gun life monitoring, 55 R
Gun resistance compensation, 64 Repeat, 24
76/78 Bosch Rexroth AG | Electric Drives PSx 6xxx | R911172825 / 02
and Controls
Index
Notes:
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Tel. +49 9352 18 0
Fax +49 9352 18 8400
www.boschrexroth.com/electrics
DOK-PS6000-TECH*******-AP02-EN-P