Automation

Global1+ and Global 2

Robot Setup Manual
for Tool Changer Equipment

Version 1.4
May 2018
Opel Automobile GmbH
OV ME Strategy

Author(s):
Andreas Gilles — Opel Automobile GmbH
Fernando de Pablo — Opel Automobile GmbH

Forward questions and comments to:

Opel Automobile GmbH
Bahnhofsplatz I
Mail Code IPC 42-74
D-65423 Ruesselsheim am Main
andreas.gilles@opel.com

Document revisions:
Date Revision By Revision history
2018-05 1.0 AG Init Document

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Table of Contents

1 GENERAL ................................................................................................................................. 3
1.1 Scope ............................................................................................................................................................................... 3
1.2 Purpose ........................................................................................................................................................................... 3
1.3 Deviations ...................................................................................................................................................................... 3

2 SETUP STEPS........................................................................................................................... 3
2.1 Step 1: Wizard................................................................................................................................................................3
2.2 Step 2: DeviceNet Scan ............................................................................................................................................... 3
2.3 Step 3: Setup Program................................................................................................................................................. 3
2.4 Step 4: Delete TP Program.......................................................................................................................................... 4
2.5 Step 5: Load TP Programs........................................................................................................................................... 4
2.6 Step 6: Toolchanger Application Type .................................................................................................................... 5
2.7 Step 7: Setup 2nd Servo Gun ........................................................................................................................................ 5
2.8 Servo Gun Setup............................................................................................................................................................6
2.9 Teach Docking Position ............................................................................................................................................... 6
2.10 TCP ................................................................................................................................................................................... 6

3 ISB200 FAULT RESET ............................................................................................................. 6

4 CAP CHANGE PROCESS ........................................................................................................ 7

5 TOOL CHANGER INTERFACE ............................................................................................... 7

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1 General
1.1 Scope
This manual applies to Global 2 Fanuc robots with Stäubli OV customized MPS630 tool changers with
ISB200 safety box and rack locking.

1.2 Purpose
This manual provides technical requirements for the commissioning of robots with tool changers.

1.3 Deviations
Deviations from this specification require written approval of the responsible GM ME PPA Automation
Engineer. Deviations made without approval are subject to rework at the expense of the supplier. Ap-
proved deviations apply to the specific instance only and shall not be considered a change to the speci-
fication. The responsible GM ME PPA Automation Engineer has the final decision making authority for
all deviations.

2 Setup Steps
2.1 Step 1: Wizard
Run the wizard as required for tool changing.

2.2 Step 2: DeviceNet Scan

Scan and add tool changer DeviceNet device:

MENU/IO/TYPE/DeviceNet/Board 2/Next/DIAG/MacId/BROWSE/F4/Poll/Add Definition/Add Scan

TC Robot Side => MAC 54
Nest 1/2/3/4 => MAC 56/57/58/59

2.3 Step 3: Setup Program

Load and run the setup program Setup_Tool_Changer/ WIZ_TC.PC to perform the following steps and
reboot the robot:

1. Sets IO comment and IO assignment for Stäubli tool changer

2. Deletes IO comment and IO assignment for node#55 “TC Tool Side”
3. Deletes IO comment and IO assignment for GI[17: giRobotNumber]
4. Sets IO comment and IO assignment for GI[15: giToolNumber]
5. Sets IO comment and IO assignment for GI[17: giTCAppType]
6. Sets Interconnections for PLC Tool Number
7. Sets MENU/SYSTEM/CONFIG/COLD Start Autoexec program: TCPWRON
8. Sets MENU/SYSTEM/CONFIG/HOT Start Autoexec program: TCPWRON
9. Sets Register comment for R[109: CNTR POWERED ON] and value=0

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2.4 Step 4: Delete TP Program

Delete the following program:

Program Comment
TCLTCHTL TC LATCH TL V1.0

2.5 Step 5: Load TP Programs

The following programs need to be loaded (Folder Programs_Tool_Changer):

TC_ALL/ TCPICKH1.LS PICK HEAD1 OV => User program
TC_ALL/ TCDROPH1.LS DROP HEAD1 OV => User program
TC_ALL/ TCLATCH.LS TC LATCH OV
TC_ALL/ TCULATCH.LS TC PREUNLTH OV
TC_ALL/ TCUNLTCH.LS TC UNLTH OV
TC_ALL/ TCCKTOOL.LS TC CHK TL OV
TC_ALL/ TCGETNUM.LS TC GET NO. OV
TC_ALL/ CAP_WEAR.LS SGTC CAPWR OV
TC_ALL/ HMIOCST.LS CUST HOMEIO OV
TC_ALL/ TCPWRON.LS TC POWER ON
TC_ALL/ TCPWRRST.LS TC POWER CYCLE
TC_ALL/ TCOUTSZ.LS TC OUT SAFEZONE
TC_ALL/ TCAFTERD.LS CHECK AFTER DROP
TC_ALL/ TCAFTERP.LS CHECK AFTER PICK
TC_ALL/ TCOPNLID.LS TC OPEN LID OV
TC_ALL/ TCCLSLID.LS TC CLSE LID OV
TC_ALL/ TCEMPTY.LS TC NST EMTY OV
TC_ALL/ TCINNEST.LS TC TLinNST OV
TC_ALL/ TCNESTLO.LS CHECK RACK AND TOOL SIDE LOCKED
TC_ALL/ TCNESTUL.LS CHECK RACK AND TOOL SIDE UNLOCKED
TC_ALL/ TC_CAPW TC CAP WEAR OV
TC_ALL/ TIP_RST TIPRESET OV
TC_ALL/ STPR_CHK STEPER CHK OV
TC_ALL/ CAP_WEAR SGTC CAPWR OV
TC_ALL/ TW_SETG2 SETUP TW G2 OV=> Load if required
TC_ALL/ TW_SETG3 SETUP TW G2 OV=> Load if required
TC_ALL/ TW_SETG4 SETUP TW G2 OV=> Load if required
TC_TIPDRESS/ TD_PROC1.LS TC TD GUN1 OV => Load if required
TC_TIPDRESS/ TD_PROC2.LS TC TD GUN2 OV => Load if required
TC_TIPDRESS/ TD_PROC3.LS TC TD GUN3 OV => Load if required
TC_TIPDRESS/ TD_PROC4.LS TC TD GUN4 OV => Load if required

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2.6 Step 6: Toolchanger Application Type TCApplType

The tool changer application type and tool number need to be

set for each tool side of the tool changer.

Available applications types:

1 = MH / Clinching
2 = Carried Gun
3 = Carried Gun & MH
4 = Carried Stud Tool Number

2.7 Step 7: Setup 2nd Servo Gun

Selecting the tool changer option in the Fanuc wizards only the first servo gun is set up. All other servo
guns need to be configured manually:
Start the robot in controlled start
MENU/MAINTENANCE/
Select Servo Gun Axes
MANUAL
Add Servo Gun Axis
Select Complete
Select Other
Select Direct Entry Method
Select = Motor ID from list below
Enter amplifier number = 2
Enter Tip Displacement Ratio = Label on gun
Enter Servo Gun 2 Motion Sign = TRUE
Select gun close direction = Positive
Enter Open Limit (mm) = Label on gun
Enter Close Limit (mm) = 20mm or 22mm dependent on plant
Enter Max gun pressure (nwt) = Label on gun
Enter Brake Number = 0
Enter Max Gun Speed (mm/sec) = Def. Max Gun Speed (mm/sec)
FUNCTION/Cold Start

A list with motor types and motor IDs is distributed in a separate document.

Run setup program GUN2/WIZ_G2.PC to perform the following step:

1. Set servo gun system variables for gun2

2. Set distance schedules for gun 2
3. Set pressure schedule comments for gun1 & gun2

Do the following setup steps:

1. MENU/UTILITIES/TYPE/Gun Setup/Set gun motion sign
2. MENU/UTILITIES/TYPE/Gun Setup/Set Gun specs, master gun
3. MENU/UTILITIES/TYPE/Gun Setup/Auto Tune
4. Load GUN2/TW_SETG2.LS
5. Perform Cap wear calibration running TW_SETG2.LS

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2.8 Servo Gun Setup

To perform the servo gun setup, auto tune and tip wear setup, the corresponding gun need to be at-
tached using the Fanuc attach TP program.

2.9 Teach Docking Position

During teaching the dock position, the floating position of the nest shall be blocked with two centering
pins. After teaching the dock position, the centering pins shall be removed.

2.10 TCP

To avoid confusion, reserve TOOL # 1- Tool # 4 for weld gun Utool’s since by default the gun attach rou-
tine will set the utool to the gun # it is picking. Set the dip switches representing gun number on the tool
of the tool changers, prior to start programming.

The Stäubli robot side shall have the following TCP:

3 ISB200 Fault Reset

After a power failure the Stäubli Intelligent Safety Box (ISB200) shows a hardware fault that need to be
reset. When the robot is powered on the robot remembers via TCPWRON.LS and R[109:CNTR POWERED
ON]=1 that it was powered on. Next time entering the safety area of the nest a fault reset is send via
DO[698: doResetError] if required.

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4 Cap Change Process

Before cap change the attached gun shall be tip dressed. This allows the operator to identify NOK tip-
dress resuls due to defect cuter etc.
During cap change all caps need to be changed at the same time.
The robot remembers the guns with new caps picking up a gun (R[121]-R[124]).
When a gun is picked up with new caps, a cap wear reset is executed (CALL TW_GUNS) and tip dress is
executed as well (TD_PROC1-4). Both tasks are done in TC_PICKxyz.

5 Tool Changer Interface

Group inputs:
15 Tool Number giToolNumber
17 TCAppType giTCAppType

Inputs:
697 Tool Number (bit 1) giToolNumber
698 Tool Number (bit 2) giToolNumber
699 Tool Number (bit 3) giToolNumber
700 Applikation Number (bit 1) giTCAppType
701 Applikation Number (bit 2) giTCAppType
702 TC Robot Side Node Applikation Number (bit 3) giTCAppType
703 #54 Docking System OK diDockSystemOK
704
705 Tool Plate Unlocked diToolUnlocked
706
707 Tool Plate Locked diToolLocked
708
721 Nest 1 Closed diNest1Closed
722 TC Nest 1 Nest 1 Open diNest1Open
723 Node #56 Head 1 In Nest diHead1InNest
724 Nest 1 Locked diNest1Locked

Outputs:
697 Unlatch Tool Plate doUnlatchTool
698 TC Robot Side Node Reset Docking System from Fault doResetError
699 #54 (Reserved) (Reserved)
700 (Reserved) (Reserved)
721 Close Nest 1 doCloseNest1
722 TC Nest 1 Open Nest 1 doOpenNest1
723 Node #56 (Reserved) (Reserved)
724 (Reserved) (Reserved)

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Register:
1= Controller powered on
109 0= After tool changer fault reset CNTR POWERED ON
121 1= Gun1 with new caps CapChanged G1
122 1= Gun2 with new caps CapChanged G2
123 1= Gun3 with new caps CapChanged G3
124 1= Gun4 with new caps CapChanged G4

Interconnections:
DI[697: giToolNumber] => DO[133: doTCToolNumBit1]
DI[698: giToolNumber] => DO[134: doTCToolNumBit2]
DI[699: giToolNumber] => DO[135: doTCToolNumBit3]
Via HMIOCST.LS DO[136: doTCToolNumBit3]=0

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