OVRS-3 Global Robot Integration Specification

Automation
OVRS-3
Global Robot Integration Specification
Version 1.0
February 2018
Opel Automobile GmbH
OV ME Strategy
Author(s):
Andreas Gilles — Opel Automobile GmbH / ME PPA Automation
Fernando de Pablo — Opel Automobile GmbH / ME PPA Automation
Forward questions and comments to:

Bahnhofsplatz I
Mail Code IPC 42-74
D-65423 Ruesselsheim am Main
Andreas Gilles
Document revisions:
Date Revision By Revision history
2018-02 1.0 AG
February 2018 OVRS-3 4 of 52

Version 1.0 General OVRS3 Global Robot Integra-
tion Specification.docx
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Table of Contents
1 GENERAL .................................................................................................................................................. 8
1.1 Scope ........................................................................................................................................................................................... 8
1.2 Purpose ........................................................................................................................................................................................ 8
1.3 Audience ..................................................................................................................................................................................... 9
1.4 Deviations ................................................................................................................................................................................... 9
1.5 Normative References .............................................................................................................................................................. 9
1.6 Definitions ................................................................................................................................................................................... 9
1.7 Resources .................................................................................................................................................................................. 10
2 ORDER ROBOTS .................................................................................................................................... 10

2.1 Robots........................................................................................................................................................................................ 10
2.2 Cables ........................................................................................................................................................................................ 10
3 ROBOT PROGRAMMING SAFETY ....................................................................................................... 10

3.1 Verify Correct Teach Pendant Cable Length ....................................................................................................................... 10
3.2 Verify that Robots Lag Bolts are installed............................................................................................................................ 11
3.3 Verify Advanced DCS Deliverables from Simulation ........................................................................................................... 11
3.4 Verify SMC Cylinder Locks ...................................................................................................................................................... 12
3.5 Bypass DCS CIP Safety............................................................................................................................................................. 12
3.6 Verify Presence of Light Screens ........................................................................................................................................... 12
3.7 Robot Programming SOP’s ...................................................................................................................................................... 12
4 CONFIGURATION OF ROBOT ............................................................................................................. 12

4.1 Verify/Load Latest Software .................................................................................................................................................. 12
4.2 Run the Setup Wizard .............................................................................................................................................................. 13
4.3 Set Controller Date and Time ................................................................................................................................................. 13
4.4 Load Offline Programs ............................................................................................................................................................ 13
4.5 Run Offline Program Setup Utilities ....................................................................................................................................... 13
4.6 Configure Ethernet I/P Address & Parameters ..................................................................................................................... 13
4.7 Configure Device Net Node Parameters .............................................................................................................................. 13
4.8 Configure Material Handling Software ................................................................................................................................. 13
4.9 Verify Operation of EOAT....................................................................................................................................................... 13
4.10 Set Payload and Armload Data ............................................................................................................................................. 14
4.10.1 Manual Load Definition ............................................................................................................................................14
4.10.2 Payload Naming Convention ....................................................................................................................................14
4.11 Verify Robot Mastering ........................................................................................................................................................... 14
4.12 Create MASTERPS .................................................................................................................................................................... 15
5 SETUP WELD GUN ................................................................................................................................. 15

5.1 Setup Servo Weld Gun ............................................................................................................................................................. 15
5.2 Setup Pneumatic Weld Gun..................................................................................................................................................... 15
5.2.1 Pressure Control ............................................................................................................................................................15
5.2.2 Equalization Control .....................................................................................................................................................15

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6 ACCESSORY WELD EQUIPMENT SETUP AND FUNCTIONALITY.................................................... 15

6.1 Setup Water Saver ................................................................................................................................................................... 15
6.2 Setup Tip Dresser ..................................................................................................................................................................... 15
6.3 Verify Tip Dress Motor Functionality ..................................................................................................................................... 15
6.4 Verify Tip Dress Blow Off......................................................................................................................................................... 16
6.5 Verify Dress Verification Gauge (DVG) ................................................................................................................................. 16
6.6 Verify Auto Cap Changer ........................................................................................................................................................ 16
7 PROGRAMMED PATHS ......................................................................................................................... 17

7.1 Verify and Update TCP / RTCP ............................................................................................................................................... 17
7.1.1 Tool Center Point Naming Standards ...........................................................................................................................17
7.1.2 Tool Center Point Location and Orientation Verification ............................................................................................17
7.2 Verify TCP / RTCP Motion Instruction in all Paths ................................................................................................................. 19
7.3 Verify Motion, Speed, and Termination Types ....................................................................................................................20
7.4 Verify and Comment Path Segments ..................................................................................................................................... 21
7.4.1 Path Segment Numbering.............................................................................................................................................21
7.4.2 General Path Segment Rules.........................................................................................................................................21
7.4.3 Path Segment Example.................................................................................................................................................22
7.5 Comment MH Instructions ....................................................................................................................................................... 23
7.6 Verify and Comment Weld Spot / Joining Annotations ....................................................................................................... 23
7.7 Teach Home to Pounce and Pounce to Home Paths............................................................................................................24
7.8 Teach Pick and Drop Paths .....................................................................................................................................................24
7.8.1 Program Pick Paths .......................................................................................................................................................24
7.8.2 Program Drop Paths ......................................................................................................................................................26
7.8.3 Teach Common Drop Path (S01DROP1) .......................................................................................................................27
7.8.4 Teach Style Specific Drop Path (SXXDROPY)...............................................................................................................27
7.9 Program Fast Fault Recovery Paths ......................................................................................................................................27
7.10 Program Tool Changer Pick and Drop Paths ........................................................................................................................27
7.11 Determine Style and Option Coding......................................................................................................................................27
7.11.1 Style Code Usage ......................................................................................................................................................27
7.11.2 Option Code Usage...................................................................................................................................................29
7.11.3 Style Specific Paths ...................................................................................................................................................29
7.12 Program Process Paths ............................................................................................................................................................29
7.12.1 S01PROC1 ..................................................................................................................................................................29
7.12.2 SXXPROCX ................................................................................................................................................................29
7.13 Verify Decision Codes..............................................................................................................................................................29
7.13.1 Decision Code Usage ................................................................................................................................................30
7.14 Program Robotic Racking and Unracking Paths ..................................................................................................................30
7.15 Program Dispense Path ........................................................................................................................................................... 31
7.16 Program Dispense Verification “Show Me” Path ................................................................................................................. 31
7.17 Program Repair/Service Paths ............................................................................................................................................... 31
8 INTERFERENCE ZONES ........................................................................................................................32

8.1 Verify Interference Zones Numbering and Comments ....................................................................................................... 33
8.1.1 Interference Zone Numbering Convention ..................................................................................................................33
8.1.2 Comment Interference Zones .......................................................................................................................................33
8.2 Verify Interference Zones with PLC ....................................................................................................................................... 33

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9 VERIFY CYCLE TIME .............................................................................................................................34

9.1 Verify All Styles 100% with Metal ...........................................................................................................................................34
9.2 Verify and Record Cycle Time ................................................................................................................................................34
10 SOFTWARE HOUSEKEEPING ...........................................................................................................34

10.1 Delete Temporary Programs ..................................................................................................................................................34
10.2 Remove Unused Macros ..........................................................................................................................................................34
10.3 Remove Temporary UTOOLS and UFRAMES ........................................................................................................................34
10.4 Remove Temporary Payload Information ............................................................................................................................34
10.5 Enable Required Prompts and Alerts ....................................................................................................................................34
10.6 Backup Robots ..........................................................................................................................................................................34
10.7 Setup UD&C ............................................................................................................................................................................... 35
11 HARDWARE HOUSEKEEPING...........................................................................................................35
11.1 Verify Robot Dress ................................................................................................................................................................... 35
11.1.1 Robot Dress Requirements .......................................................................................................................................35
11.1.2 Robot Dress Rules ......................................................................................................................................................35
11.2 Stencil Robot Arm and Controller .......................................................................................................................................... 35
11.2.1 Robot ID .....................................................................................................................................................................36
11.2.2 Stencil ID Placement – Robot Arm ............................................................................................................................36
11.2.3 Stencil ID Placement - Robot Controller ...................................................................................................................36
11.3 Install Dust Covers ....................................................................................................................................................................38
12 ROBOT LIMITING HARDWARE AND SOFTWARE ..........................................................................38

12.1 Set Axis Soft Limits...................................................................................................................................................................38
12.2 Install Robot Hard Stops .........................................................................................................................................................38
12.2.1 Verify Hard Stops are Placed Correctly ....................................................................................................................38
12.3 Validate Operator Light Screen Placement .........................................................................................................................38
12.3.1 Operator Light Screen Placement Validation Procedure ........................................................................................38
12.4 Optimize Collision Guard Sensitivity ..................................................................................................................................... 39
13 ROBOT DOCUMENTATION ..............................................................................................................40

13.1 Electronic Documentation ......................................................................................................................................................40
13.2 Hardcopy Documentation.......................................................................................................................................................40
14 PREPARE ROBOT AND CONTROLLER FOR SHIPPING..................................................................40

14.1 Block Robot Arm ....................................................................................................................................................................... 41
14.2 Band Robot Arm and Controller .............................................................................................................................................42
14.2.1 Band Robot Arm ........................................................................................................................................................42
14.2.2 Band Controller .........................................................................................................................................................42
14.2.3 Detached EOAT Shipping .........................................................................................................................................42
14.3 Palletize Robot Arm and Controller.......................................................................................................................................43
14.3.1 Robot Arm .................................................................................................................................................................43
14.3.2 Controller...................................................................................................................................................................43
14.4 Prepare Robot Transport Unit for Shipping .........................................................................................................................43

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Appendix A: 1. General .................................................................................................................. 1

Appendix A: 2. DCS End Effector Model ...................................................................................... 2
Appendix A: 3. Validate SafeIO Connect Mapping ...................................................................... 3
Appendix A: 4. Validate Operator Station Guarding.................................................................... 5
Appendix A: 5. Validate DCS Zones Protecting Cell Perimeter ................................................. 8
Appendix A: 6. Validate Guarding Between Cells........................................................................ 8
Appendix A: 7. Validate DCS Speed Zones ................................................................................. 9
Appendix A: 8. Validate Joint Position Checks ......................................................................... 10
1 General
Scope
The provisions of this document apply to the integration of robots for Opel Automobile GmbH. Robotic integration require-
ments in this specification supersede any requirements in the Global Common Controls Build specification (OVCB-1).
Robot programming standards established in this specification are applicable only to robots that meet minimum require-
ments listed in the 2014 version of the following specifications (Global 3): OVRS-4A, OVRS4-B1, OVRS4-B2, OVRS4B3, OVRS4-
C, OVRS4-D, OVRS4-E, DS-1, OVRS-1, and OVRS-FP
Robot programs, developed off-line with simulation software, shall conform to the programming standards defined in this
specification.
1.1 Purpose
The purpose of this specification is to provide common robot programming and integration requirements to the integrator
of Opel Automobile GmbH Body Shop or Metal Forming systems. This specification defines common requirements and
guidelines that encompass the construction and integration phases of a OV vehicle program; the period of time from when
robots arrive at the integrator to the time when the completed system is shipped from the integrator to the OV facility.
This document was created to define:
Acceptable use and handling of OV robotic assets throughout the integration process.
 Roles and Responsibilities of OV engineering contacts and integrator personnel as they relate to robot integra-
tion.
 Requirements and acceptable practices for primary robot dress.
 Requirements and acceptable practices for secondary robot dress.
 Proper implementation and documentation of the software for robots.
 Common procedure for documenting and reporting progress on robotic integration milestones.
 Common form and procedure for Vehicle Systems robotic buyoff.
This specification is coordinated with the Robot Integration Buyoff Checklist, which is also available on DocInfo. Every num-
bered item in the checklist matches a section in this document. It is intended that these sections explain the details for
each checklist item.

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1.2 Audience
This standard is primarily for use by robot engineers, skilled trades and other personnel involved with the integration of ro-
bots at an integration facility or a OV plant.
1.3 Deviations
Any deviations from this specification require the approval of the Vehicle Systems Lead Robot Engineer or the Vehicle Sys-
tems Robot Commodity Engineer. Any approved deviation shall not be considered a change to the standard.
1.4 Normative References

The following normative references contain provisions that, through reference in this text, constitute provisions of this
standard. The editions indicated were valid at the time of publication. All normative documents are subject to revision and
the most recent editions of the normative standards indicated below shall apply.
OVCB-1, ME Vehicle Systems Global Common Controls Build Specification
OV GTC-1, OV Tool Construction Standards
OVD-1, Global Mechanical Design Standards
GEP-1, Global Engineering Process Standard
1.5 Definitions
The following terms, or corresponding acronyms, are used throughout this document:
Bill of materials: BOM; a system parts list that generally accompanies the wiring diagrams
DCS: Dual Check Safety – Robot safety software option. Two components of DCS are used. Safe IO Connect, otherwise
known simply as “DCS” is used on every robot for safety signals and Speed and Position Check, otherwise known as “Ad-
vanced DCS” is used to replace robot light screens in certain stations.
End-of-arm tooling: EOAT; any process related or material-handling device attached to the robot faceplate
Bypass Process path: After running the Wizard on a new robot configuration, pedestal applications will have template pro-
grams for Bypass Process, which can be used to create paths that skip the pedestal process but continue to perform mate-
rial handling. Bypass Process paths are typically not programmed by the integrator. They are reserved for use by the final
manufacturing facility in conjunction with their plan to back up the missing process.
Fast fault recovery: FFR; a method of dealing with robot process faults which removes the need to enable the teach pen-
dant and manually jog the robot
Home Line Integration: Any line integration that is performed in the permanent production location of the system. When
shipping after on-line integration is not required, integration is considered Home Line
Maximum Space: Space which can be swept by the moving parts of the robot, end-effector and part MFD: Metal Forming
Division
Offline program: OLP; a specific deliverable from simulation
Positive Part Transfer: Positive part transfer allows fixed station tooling to clamp, pin or apply vacuum to a part while an
MH robot has the part clamped, pinned or held with vacuum in its end-effector. Positive part transfer also allows an MH
robot end-effector to clamp, pin or apply vacuum to a part while fixed station tooling has the part clamped, pinned or held
with vacuum. Positive part transfer requires an additional handshake (an additional path segment) with the PLC.

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Restricted Space: Portion of maximum space restricted by limiting devices that establishes the limits that cannot be ex-
ceeded
Robot data sheet: RDS; a specific deliverable from simulation that contains data helpful for initial robot setup
Robot Transfer Unit (RTU): Rail and carriage assembly that gives the robot an extended range (sometimes called 7th axis
rail). These rails can be floor or overhead mounted.
Tool center point: TCP; a point defined on the end-of-arm-tooling to facilitate path programming and touch-up. Also known
a user tool or UTOOL.
User Frame (UFrame): A user definable frame that can be setup in any location in any orientation. User frames are used so
that positions in a program can be recorded relative to the origin of the frame. User frames are most often used as remote
tool center point frames for things like pedestal welders or sealers. The origin of the frame is defined as the tool center
point.
Vehicle Systems: OV Automation / Execution team members.
Weld process data sheets: WPDS; refers to the OV weld process data sheets that define welding requirements for a robot
application
Wiring diagram: WD; refers to the OV wiring diagrams
1.6 Resources
The following links are provided for resources that are referenced throughout this document:
DocInfo
Fanuc FTP Site
2 Order Robots
2.1 Robots
To order robots, the supplier shall submit robot order forms to the Vehicle Systems lead robot engineer using the Robot Or-
der Form located on DocInfo. Once ordered, any changes to the robots shall be communicated to the Vehicle Systems lead
robot engineer by updating the robot order form and clearly identifying the changes.
2.2 Cables
The supplier shall accurately estimate the required robot cable lengths at the time the robots are ordered. The supplier is
responsible to perform any cable exchanges if needed.
3 Robot Programming Safety

3.1 Verify Correct Teach Pendant Cable Length
Verify that the teach pendant reaches all areas of the cell required to safely program the robot when entering through a cell
gate while holding the teach pendant.

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3.2 Verify that Robots Lag Bolts are installed

Visually check to make sure that robot, base plate, and riser machine screws and lag bolts, are installed and appear tight.
Robots must be attached to a base plate or riser before any robot motion occurs, per manufacturer’s guidelines.
3.3 Verify Advanced DCS Deliverables from Simulation

Simulation will provide a separate sheet for each of the following DCS deliverables:
1. Plan view of the robot with a transparent overlay of the restricted envelope, the relative perimeter fence layout,
and the J1-3 Hard stop positions as required.
2. Plan view of robot with its EOAT DCS model visible, its DCS zone elements with callouts, and the relative fence lay-
out
3. Isometric view of Robot with EOAT model and DCS zones boxes shown from the robots perspective.
4. Robot EOAT model Top View, side view and right side ISO view.
5. Robot EOAT model data and ref. model image
On the Advanced DCS picture(s) provided by simulation (see Figure 3.1), verify that the:
1. DCS User Model envelope(s) around the end effector appears to encompass the entire end effector and part in-
cluding J6 bracket
2. End effector is mounted in the proper orientation
3. Weld gun and clamps are shown open, cylinders are shown in most extreme state 4. Cell is laid out properly
5. DCS zones are positioned properly with respect to the operator station and other obstacles
Record the DCS signature and date on the DCS picture(s) and place the copy of the picture(s) into the plastic sleeve on the
robot controller. The DCS current signature can be viewed on the robot [MENU], [UTILITIES] [DCS] [Safety Signature] (hex
value).
Figure 3.1: Advanced DCS picture from Simulation

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3.4 Verify SMC Cylinder Locks

Confirm that the SMC cylinders are in the locking configuration by verifying that the dust cap has a colored dot and the lock-
ing screw is in the position shown in Figure 3.3.
Figure 3.3: SMC Cylinder – Locking Configuration
3.5 Bypass DCS CIP Safety

If the robot is not connected to functional PLC network, perform the network bypass procedure and install the hardware
Estop safety jumper (on G3 robots if applicable). The CIP Safety Bypass procedure and the E-stop safety jumper plug instal-
lation procedure are both located in the Global 2 (or 3) Wizard Execution and Robot Setup Manual. Remove the CIP Safety
Bypass and the jumper plug when the safety network to the PLC is setup and communicating to the robot.
3.6 Verify Presence of Light Screens

Verify that operator and DLD light screens are connected and installed in the correct locations. Robotic programing must
account for these light screen positions.
3.7 Robot Programming SOP’s

Prior to programming the robot, reference the appropriate robot programming Safe Operating Procedure (SOP) on OV Ve-
hicle Systems Supply Power. See the lead OV Vehicles Systems Robotics Engineer if the correct SOP cannot be located.
4 Configuration of Robot
4.1 Verify/Load Latest Software

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Verify, with the OV Vehicle Systems Lead Robot Engineer, that the proper release of robot software, running fixes, and sys-
tem updates are loaded on the robot. Load the correct software version if required.
4.2 Run the Setup Wizard

Setup application, I/O interface, template program, parameter system settings, and EOAT options using the setup wizard.
For reference, see the Global 2 (or 3) Wizard Execution and Robot Setup Manual.
Some applications such as Flow Drill Screw, Arplas, and Self Piercing Rivet cannot be fully setup in the Wizard and may re-
quire additional steps to configure. Contact the OV Vehicle Systems Lead Robot Engineer for further instructions.
4.3 Set Controller Date and Time

Set the robot controller date and time so that programs and other items such as alarms will have the proper date and time
stamp.
4.4 Load Offline Programs

Load offline programs provided by simulation into the robot controller for final programming. Examples include
(S0XPROCX, S0XPICKX, S0XDROPX, S0XPOUNC, TOOLDATA, STYLEXX, DCS_ZONE, etc.).
4.5 Run Offline Program Setup Utilities

Execute utility programs TOOLDATA and DCS_ZONE to input robot parameters for setup. These programs are provided by
the simulation supplier and will setup tool frames, home position, payload data, DCS zone positional areas, etc….
4.6 Configure Ethernet I/P Address & Parameters

Enter the Ethernet I/P addresses for the robot, and process equipment. Global 3 robot software will prompt the user for this
information during the Setup Wizard. Examples of Ethernet I/P address are: (Robot, Spot Weld Controller, Stud Weld Con-
troller, 2nd Water-Saver programmed, etc.).
4.7 Configure Device Net Node Parameters

All robotic Device Net node addresses for the robot, and process equipment shall be entered and or scanned. Examples of
Device Net nodes are: (Robot Safety Board, I/O Input-Output Block, TipDresser Motor Starter, Material Handling Valve Pack,
Vacuum Pump, Pneumatic Welding Regulator, etc.).
4.8 Configure Material Handling Software

Configure the material handling software using the instructions in the Global 2 (or 3) Wizard Execution & Robot Setup Man-
ual, which is posted on DocInfo.
4.9 Verify Operation of EOAT

Verify that the EOAT functions correctly when executing the program MH instructions. Verification of the MH configuration
requires that robot output power is enabled. More information on MH setup can be found in OVRS-4E and the Global 2 (or 3)
Wizard Execution and Robot Setup Manual.
1. Grip Part: Shifts valves to “A” position and checks associated cylinder position feedback.
2. Release Part: Shifts valves to “B” position and checks associated cylinder position feedback.

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3. Part Present: Verifies part presence at selected switches. The ability for continuous checking is configurable by the
user, which is described in the Global 2 (or 3) Wizard Execution & Robot Setup Manual.
4. Check No Part Present: Verifies no part presence at selected switches.
5. Prepare to Pickup: Makes sure that specified valves are ready to pick-up a part. This instruction shall be placed at
the beginning of the pickup routine. Additional calls of this routine may be made in the pickup routine as required.
6. Turn ON Vacuum: Shifts vacuum valves to the vacuum state and checks for associated vacuum made feedback.
The ability for continuous checking is configurable by the user.
7. Turn OFF Vacuum: Shifts vacuum valves to the blowoff state. Parameters allow for time based blowoff.
8. Turn OFF Blow-off: Shifts vacuum valves to the neutral state and checks for loss of associated vacuum feedback.
Parameters allow for time based blowoff.
4.10 Set Payload and Armload Data

Set the robot payload and armload and verify the data is correct. Payload is defined as the mass, center of gravity, and
mass moments of inertia for all equipment attached to the robot faceplate. Armload is defined as the mass for all equip-
ment attached to the upper arm of the robot. Payload information will be supplied by simulation in most cases.
A separate payload shall be defined and utilized in the robot program each time the payload changes. Examples include
the payload with and without a part in the end effector, the payload of one style versus another style, and the payload with
and without a carried tool as in the case of a tool changer.
4.10.1 Manual Load Definition

The payload data from the simulation Offline Program shall be utilized if available. If the Offline Program is not available,
the integrator shall utilize the Payload Checker information from the design source and the armload information from the
Vehicle Systems lead robot engineer. If the Payload Checker information is not available, the integrator shall weigh the end
effector and obtain the CG and Moments of Inertia information for the end of arm tool from the UG model data from the
tooling design source.
4.10.2 Payload Naming Convention

The first available payload data, or Payload1, shall be used for the primary EOAT without carried parts. Primary EOAT is
defined as the EOAT that the robot is holding at the Home position. A single payload definition, Payload 1, may be ade-
quate for typical carried process equipment without material handling or tool changing. Material handling or tool changing
may require additional payload definitions. The second available payload data, or Payload2, shall be used for the primary
EOAT with part or as a second carried tool when tool changing.
Subsequent payloads are named in sequential order as they are encountered in the robot’s process sequence, beginning
with Style 1, until all unique loading scenarios are defined. For tool changing, the robot-without-tool shall be defined as the
last defined payload.
4.11 Verify Robot Mastering

Follow the robot manufacturer’s procedure to verify counts and master the robot if required. If the robot is re-mastered,
record the mastering values on a sheet inside the robot controller cabinet. In some cases due to work cell construction veri-
fying all axis at the same time is not achievable. In this case each axis can be verified in separate steps. Both mastering
(arm) and zero position (carriage) must be verified on Robotic Transfer Units, RTU.

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4.12 Create MASTERPS

After the robot mastering is verified, create a program called “MASTERPS”. When executed, this program allows the robot
mastering to be checked by examining the alignment of the witness marks. The “MASTERPS” program shall contain the
following steps:
1. A safe path that avoids any dress problems or tooling collisions from the home position to the mastering position for all
6 axes if possible, or for the 3 major axes if not possible.
2. An instruction to PAUSE program execution.
3. A safe path that avoids any dress problems or tooling collisions from the major axes mastering position to the mastering
position for the 3 minor axes (if required).
4. An instruction to PAUSE program execution.
5. A safe path back to home.
6. Set Robotic Quick Master Reference. Refer to the Robotics Manufacture Operations Manual.
5 Setup Weld Gun

5.1 Setup Servo Weld Gun
Setup the servo weld gun per the Servogun Setup Manual, which is posted on DocInfo.
5.2 Setup Pneumatic Weld Gun

5.2.1 Pressure Control
Verify that the pressure control for Consult OVRS-4 B2 Resistance Weld Dense Pack Interface Specification for additional
information.
5.2.2 Equalization Control

Verify that the gun equalization is working properly. Some equalization will feature a manual regulator with an option to
flip the equalization direction, others will offer a proportional digital control. Consult OVRS-4 B2 Resistance Weld Dense
Pack Interface for additional information.
6 Accessory Weld Equipment Setup and Functionality

6.1 Setup Water Saver
Setup is conducted from the teach pendant web screen (MENU / BROWSER / Proteus). Reference Global 2 or 3 Wizard Execu-
tion and Robot Setup Manual located on DocInfo.
6.2 Setup Tip Dresser

Setup the tip dresser per the Global Tip Dresser Setup User’s Manual, which is posted on OV Vehicle Systems Supply Power.
6.3 Verify Tip Dress Motor Functionality

1. Verify that the cutter is rotating in the correct direction.
2. Verify with the BIW Welding Engineer that the correct cutter retainer and blade is installed and is operating cor-
rectly.

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3. Verify that the tip dress blade holder is on the same side as the movable shank as shown in the left picture in Figure
6.1.
4. Verify that tip dress direction is in the same orientation as the springs (red arrows) in the right picture of Figure 6.1.
If the head is rotated 90° from the direction shown in the picture then the springs cannot equalize properly when
the gun is closing on the cutters and could impact dress quality.
Figure 6.1: Tip Dress Blade Holder and Spring Orientation
6.4 Verify Tip Dress Blow Off

1. Air blow-off should be operated at line pressure (at least 60 psi or 4 Bar).
2. Test each air blow-off individually for each robot. It is easy to overlook a non-functioning air blow-off in a cell with
several robots if they all dress at the same time.
3. Pay particular attention if the tip dresser is mounted on the robot end effector, since the air hose routing is very
long and occasionally kinked or pinched.
4. During cap changes, always look at every tip dresser to see if the blade is clogged or damaged.
6.5 Verify Dress Verification Gauge (DVG)

Where used, verify operation of the Dress Verification Gauge (DVG). Refer to the appropriate Tip Dresser Setup Users Man-
ual for more information.
6.6 Verify Auto Cap Changer

Where used, verify operation of the Auto Cap Changer. Refer to the appropriate Tip Dresser Setup Users Manual for more
information.

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7 Programmed Paths
This section describes the requirements for teaching/verifying required program paths.
7.1 Verify and Update TCP / RTCP

A tool center point (TCP) is required for each process and material handling end-effector. For multiple function end effec-
tors, a TCP is required for each function. A remote tool center point (RTCP) is required for any process equipment with
which the robot interacts that is not physically mounted to the robot arm. Verify that all TCPs and RTCPs provided in the off
line programs follow the standards defined in this section, and if the TCPs and RTCPs are missing or incorrect, add or correct
them. Refer to the robot manufacturer’s user’s manual for instructions on defining a TCP and RTCP.
7.1.1 Tool Center Point Naming Standards
TCPs included in an OLP shall maintain the TCP names established by the robot download translator. TCPs not originating
from an OLP shall follow the following standard for TCP naming:
1. Robots with a single carried TCP shall be programmed using TCP 1. Robots with more than one carried TCP shall
be programmed with TCP’s numbered in ascending order based on the process sequence for each robot. Ro-
bots that are processed to use different TCP’s (or in a different sequence) based on Style program shall be pro-
grammed using TCP’s in ascending order starting with Style 1 and continuing until all TCP’s are named.
2. Robots with pedestal applications shall use the standard above for naming of carried TCP’s. Stationary TCP’s
shall be numbered in ascending order beginning with the process sequence of Style 1 and continuing until all
stationary TCP’s are named.
7.1.2 Tool Center Point Location and Orientation Verification

The TCP shall be located at the point where work is performed. For spot weld guns, the TCP shall be located where the
gun tips come together. For material handlers with locating pins, the TCP shall be located at the tip of the main locating
pin. For material handlers without locating pins, the TCP shall be located at the corner of a clamp. For dispensing, laser
welding, stud welding, and other processes where the work is performed at a “working distance” from the tip of the tool,
the TCP shall be located that “working distance” from the tip of the tool.
The TCP shall be oriented such that a move in the positive Z direction moves the work piece closer to the tip of the tool.
For tools with a throat such as spot weld guns, the TCP shall additionally be oriented such that a move in the positive X
direction moves the work piece into the throat of the tool, and the positive Y direction comes from the right hand rule.
For tools without a throat the positive X should be aligned with the major axis of the tool and the positive Y axis follows
from the right hand rule.
For carried applications, verify the location of each TCP by setting the robot jog mode to tool coordinates and jogging the
robot so that it rotates around the tool X, Y, and Z axes. The TCP shall not move more than 2mm in any direction throughout
a 45-degree rotation about any axis. Verify the orientation of each TCP by jogging the robot in the positive directions of
the X, Y, and Z axes. The tool center point shall move linearly in the positive direction of each axis as defined in following
sections.

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For pedestal applications, verify the location of each remote TCP by picking a stationary point on the EOAT and jog the ro-
bot so that the point lines up with the pedestal TCP. Then place the robot in remote tool coordinates and rotate the EOAT
around the X, Y, and Z axes. The EOAT shall not move more than 2mm in any direction relative to the pedestal TCP during a
45-degree rotation about any axis. Verify the orientation of each remote TCP (RTCP or UFRAME) by jogging the EOAT in the
X, Y, and Z directions. The EOAT shall move linearly in the positive direction of each axis such that the relative motion of the
part to the pedestal TCP is the same as for the carried application.
Figure 7.1: Carried Weld Gun TCP Example
Figure 7.2: End Effector TCP Example
Figure 7.3: Pedestal TCP Example

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Figure 7.4: MH Multiple TCP Example
Gripper
Pin UTOOL
2
Part
UTOOL
Fixture
1 Angled
Pin UTOOL
1
Pins with different orientation: Parts with same orientation:
Number of utools = 2 Number of utools = 1
Gripper
Pin
UTOOL
Part 2
Fixture
UTOOL Pin
1
UTOOL
Pins with same orientation:
Number of utools = 1 Parts with different orientation:
Number of utools = 2
7.2 Verify TCP / RTCP Motion Instruction in all Paths

Verify that the remote tool center point (RTCP) instruction, or tool center point (TCP) is present in the motion commands. All
programs with motion shall have a line to set the appropriate Utool at the beginning of the path. Reference SpotTool+
Setup and Operations Manual

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7.3 Verify Motion, Speed, and Termination Types

Recommended robot motion types, maximum speeds and termination types are defined in Table 7.1 below. Refer to GEP-1
Section 14 for dispense speeds. Please see the dispense engineer responsible for dispense bead requirements for your spe-
cific application.
Table 7.1 Recommended Motion, Speed and Termination Types
Motion
Description Speed Term Type
Type
Wide open moves Joint (or Linear)
100%(2000mm/sec) CNT100
(carried gun, arc, dispense, or MH without part)
Wide open moves - MH with SMALL part Joint (or Linear)
90%(1800mm/sec) CNT100
(part is less than 610mm, diagonally)
Wide open moves - MH with LARGE part 80%(1600mm/sec) Joint (or Linear)
CNT100
(part is greater than 610mm, diagnally) 60%(1200mm/sec)
Pick & Drop - Rough locators FINE (coming in)
600mm/sec Linear
(coming and going within 200 mm) CNT100 (going out)
Pick & Drop - Pins FINE (coming in)
400mm/sec Linear
(coming and going within 200 mm) CNT50 (going out)
To a servo gun weld spot, GREATER than 300 mm away. 1000mm/sec Linear CNT100
To a servo gun weld spot, LESS than 300 mm away. 800mm/sec Linear CNT100
To discrete work position/air gun spot weld, GREATER than
1000mm/sec Linear FINE
300 mm away.
To discrete work position/air gun spot weld, LESS than 300
800mm/sec Linear FINE
mm away.
Tip in access hole - NO rotation 400mm/sec Linear -
Tip in access hole - WITH rotation 200mm/sec Linear -
To home 100% Joint FINE
To pounce - Joint FINE
Changing configs - Joint 5 - Joint -
Point clear of interference zone, upon exiting - - FINE
Changing UTOOLs - - FINE

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7.4 Verify and Comment Path Segments

A path segment is a group output from the robot to the PLC that is used to inform the PLC which part of the robot path is
being executed. Whenever the robot is not at home, it must indicate a valid path segment to the PLC.
7.4.1 Path Segment Numbering

The valid path segment numbers range from 1 to 255, for Global 3 robots, as shown in Table 7.2. Global 1 & 2 robots are lim-
ited to path segments 0-63.
Table 7.2: Path Segments for Global 3
Segment Usage Segment Usage
0 Unknown 46-49 Drop 5 Path Segments
1 Pounce 50-54 Process 1 Path Segments
2 Home to Repair 55-59 Process 2 Path Segments
3 Repair to Home 60 ZDT Self Test
4 Process1 Tip Dress/Purge 61 Spare
5 Process 2 Tip Dress/Purge 62 Tool Clear
6 Cap Change 63 All Clear
7 Tool Change 64-71 Maint. / Quality Verification1
Brake Check,
8 72-99 Maintenance Path Segments
Collab. Sensor Check
9 Fast Fault Recovery 100-108 Spare
10-13 Pick 1 Path Segments 109 Return From Fail Check
14-17 Pick 2 Path Segments 110-149 Spare
18-21 Pick 3 Path Segments 150-154 Process 3 Path Segments
22-25 Pick 4 Path Segments 155-159 Process 4 Path Segments
Combined Cap Change, Tip
26-29 Pick 5 Path Segments 160-164
Dress, DVG (superpath)
30-33 Drop 1 Path Segments 165-199 Spare
34-37 Drop 2 Path Segments 200-209 Advanced MH Recovery
38-41 Drop 3 Path Segments 210-255 Spare
42-45 Drop 4 Path Segments
Notes:
1. For Dispense applications, segments 64-71 are allocated as follows:
64-65 Bypass Path for Process 1/Process 2
66-67 Move to/from Visual Check 1
7.4.2 General Path Segment Rules

The following general path segment rules apply

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1. Path segment instructions shall be preceded by a comment line in the program indicating which area of the path the
robot is entering such as part check, weld path, no part check, repo tool, etc…..
2. The “Request Continue” instruction shall be used at the end of each path segment (immediately before calling the next
path segment) in which the robot requires permission from the PLC to continue. The “Request Continue” instruction
shall be called from a motion statement whenever possible.
3. Global 3 robots have enhanced functionality where the robot will not wait if the next segment is already clear. In order
for this functionality to work properly for pedestal applications, the programmer must call the next process segment
when the application is finished. For a welder the next segment would be called after the last weld is completed. For a
dispenser, the next segment would be called after the dispense path is complete and before the call to “Dispense Com-
plete”. This lets the PLC know that the application has finished successfully and can allow the robot to move into the
next segment without stopping.
4. When more than four path segments are required for a given pickup or dropoff, the next available pickup or dropoff
segment numbers shall be utilized in ascending order until all of the pickup or dropoffs are complete.
5. The use of additional segments with “Wait For Continue” after the Pounce position requires approval by the Vehicle
Systems Lead Robotic Engineer.
6. Any non-standard usage of a segment(s) requires approval by the Vehicle Systems Lead Robotic Engineer and cap-
tured as a deviation for the specific program being impacted.
7.4.3 Path Segment Example

This section shows common path segment examples.
Table 7.3: Carried Single Application with Process

Program Sequence Placement Termination Robot Action
- Process ENABLED and robot Ready for STYLE
Robot Ready at HOME -
Initiate
Set Segment 1 Pounce - Notify PLC that robot is moving to pounce
Move to Pounce Pounce FINE Move to Pounce position
Request Continue Pounce - Wait for PLC to allow proceed from Pounce
Set Segment 50 Proc1 - Notify PLC that robot is performing process
Process path Proc1 - Perform process
Move clear of tooling Proc1 FINE/CNT* Move to position clear of application tool
Set Segment 62 Proc1 - Notify PLC that robot is clear of tool
Move clear of transfer Proc1 FINE/CNT* Move to position clear of transfer
Set Segment 63 Proc1 - Notify PLC that robot is clear of transfer
Move to Home Mov_Home FINE Move to home
Table 7.4: Material Handling with Pedestal Process

Robot Ready at HOME - - Reset I/O and verify home location
Set Segment 1 Pounce - Notify PLC that robot is in segment 1
Move to Pounce Pounce Fine Move to Pounce position

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Request Continue Pounce - Wait for PLC to allow proceed from Pounce
Set Segment 10 Pick - Notify PLC that robot is in segment 10
Move to pick position Pick Fine Move to pick position
Close gripper Pick - Close grippers/clamps, turn on vacuum
Move to PP check Pick Fine Move to PP check location, clear of tool PP switches
Pick Wait PLC to verify that the part present switches are
Request Continue -
clear
Move clear of pick up tool Pick Fine/CNT* Move to clear of the pick up tool
Move clear of pedestal Pick Fine/CNT* Move to clear of pedestal
Set Segment 50 Proc - Notify PLC that robot is in segment 50
Process path Proc - Perform process
Move to End Of Process Proc Fine Move to End Of Process
Proc Set next segment to notify PLC that the process is com-
Set Segment 51 (Global 3
- plete. **New for Global 3 to facilitate “no wait” at
Only)
next Request Continue.
Request Continue Proc - Wait until the drop off tool is ready to accept the part
Set Segment 30 Drop - Notify PLC that robot is in segment 30
Move to drop off Drop Fine Move to the drop off position
Drop Open EOAT grippers/clamps, turn off vacuum/activate
Open gripper -
blow off
Request Early Drop - Set Request Early to advance PLC Handshake
Move to PP check Drop Fine Move to part present check location, tool reads PP
Request Continue Drop - Wait for tooling to verify that the PP switches are made

Move clear of dropoff tool Drop Fine/CNT* Move to clear of the Drop off tool
Move to Home Mov_Home Fine Move to home
7.5 Comment MH Instructions

Add comments on the line before the MH valve instruction(s) to describe the function. The
following are examples of MH valve instruction comments:
Figure 7.5: MH Valve Comment Example
15: !Retract Pins ;
16: Release Part(5) ;
32: !Advance Pins ;
33: Grip Part(4,5,6) ;
7.6 Verify and Comment Weld Spot / Joining Annotations

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All Robot welding or joining instructions shall include the proper weld or fastener number and annotation from the process
data sheet. Robotic programs that do not have a specific joining instruction shall have the process joining annotation as a
comment before the joining instruction. Dispense paths shall have each bead commented to define which area of the part
is being sealed; for example, “door header bead” or “hem flange bead”. Typically the joining or fastener name is provided
in the simulation download program.
7.7 Teach Home to Pounce and Pounce to Home Paths

Teach a home position (Reference), a home to pounce path and a home from pounce path that is clear of all robot, tooling
and transfer interferences. In the cases where there are multiple Home positions and multiple Pounce positions additional
programs and direction will be required. Consult the Vehicle Systems Lead Robotic Engineer for direction.
7.8 Teach Pick and Drop Paths

Teach the pick and drop paths. The following sections will show more detail for pick and drop paths.
7.8.1 Program Pick Paths

Teach the pick path. A pick program is defined as the portion of the robot’s style program that is used to pick up a part. See
Figure 7.6 below.
Figure 7.6: Pick Routine Template Example

1: !******************************** ;
2: !PICKUP PART FROM TOOL X ;
3: !******************************** ;
4: ;
5: !ASSIGN PATH SEGEMENT VALUES ;
6: SET SEGMENT(10) ;
7: !SET SEGMENT(10), Pick1 ;
12: ;
13: !*******IMPORTANT************ ;
14: !for MH tool changers ;
15: !make sure Set MH TOOL(AR) ;
16: !matches tool number ; Faults the robot if the grip-
17: ; pers associated with valve X
18: Set MH Tool(1) ; are not open (does not auto-
19: ; matically open the grippers)
20: !Check for EOAT In Correct ;
21: !State Prepare to Pick(X) ;
22: Prepare to Pick(0) ;
23: ;
24: !MOVE TO TOOL X PICKUP ;
25: UTOOL_NUM=1 ;
26:J P[1] 100% CNT100 ;
27: L P[2:pick1] 400mm/sec FINE ;

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28: ; Use multiple Grip Part

29: Grip Part(0) ; instructions to sequence
30: PAYLOAD[...] ; valve activation.
31: ;
32: !MOVE ABOVE PICK POS ;
33: !TO CHECK NO PART IN TOOL ;
34: L P[3] 400mm/sec FINE ;
35: !CHECK PART IN EOAT ; Check for part presence after
36: Part Present(0) ; moving above the tool
37: ;
38: REQUEST CONTINUE ;
45: ;
46: !MOVE CLEAR OF TOOL X PICKUP ;
47:J P[4] 100% FINE ;
48: ;
55: ;
56: !MOVE TOWARDS DROP ;
57:J P[5] 100% CNT100 ;
58: ;
7.8.1.1 Teach Common Pick Paths (S01PICK1)

S01PICK1 is a common pick program that can be called from multiple styles or from a decision pick sequence or macro. All
parts must be of the same style in the picking fixture.
7.8.1.2 Teach Style Specific Pick Paths (SXXPICKY)

A style specific pick is used for picking up a style specific part from a common picking fixture that can hold different styles of
parts. The XX is the style number placeholder. The Y is the pick sequence number; for example, if style 1 has two pick loca-
tions there would be an S01Pick1 and S01Pick2 program.

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7.8.2 Program Drop Paths

Teach the drop path. A drop path is defined as the portion of the robot’s style program that is used to drop off a part. See
Figure 7.7 below.
Figure 7.7 Drop Routine Template
1: !******************************** ;
2: !DROPOFF PART TO TOOL X ;
3: !******************************** ;
4: ;
5: !ASSIGN PATH SEGEMENT VALUES ;
6: ;
8: !SET SEGMENT(30), Drop1 ;
13: ;
14: !******IMPORTANT************ ;
15: !for MH tool changers ;
16: !make sure Set MH TOOL(AR) ;
17: !matches tool number ;
18: ;
19: Set MH Tool(1) ;
20: ;
21: !MOVE TO DROPOFF TOOL X ;
22: UTOOL_NUM=1 ;
23:J P[1] 100% CNT100 ;
24:L P[2:drop] 400mm/sec FINE ;
Use multiple Release Part
25: ; instructions to sequence
26: Release Part(0) ; 27: PAYLOAD[...] ; valve activation.
28: ;
29: !MOVE ABOVE DROP POS ;
30: !TO CHECK PART IS IN TOOL ;
31: L P[3] 400mm/sec FINE;
32: !CHECK NOPART IN EOAT ;
33: Check No Part(0) ;
34: ;
35: REQUEST CONTINUE ;
42: ;
43: !MOVE CLEAR OF TOOL X DROPOFF ;

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44:J P[4] 100% FINE ;

45: ;
52: ;
53: !MOVE TOWARDS HOME ;
54:J P[5] 100% CNT100 ;
55: ;
7.8.3 Teach Common Drop Path (S01DROP1)

S01DROP1 is a common drop program that can be called from multiple styles or from a decision drop sequence macro. All
parts must be of the same style in the drop off fixture.
7.8.4 Teach Style Specific Drop Path (SXXDROPY)
A style specific drop off is used for dropping of a style specific part from a common drop off fixture that can hold different
styles of parts. The XX is the style number placeholder. The Y is the drop sequence number; for example, if style 1 has two
drop-offs there would be an S01Drop1 and S01Drop2 program.
7.9 Program Fast Fault Recovery Paths

Fast Fault Recovery is a fault recovery method that minimizes the need to manually jog the robot when recovering from a
process fault. Depending on the teach pendant selection by the user, the robot will finish its process with the process off
and move to a repair position. When the repair is complete, the robot will move back to the process and continue based on
the selection by the user. The programmer shall touchup any process specific FFR paths if required. FFR path templates are
typically provided when the user runs the setup wizard and are process specific such as FFRPROC1. Carried applications do
not normally require FFR paths because they typically start and end at home.
7.10 Program Tool Changer Pick and Drop Paths

The programmer is responsible to program the tool change pick and drop paths for each head. The appropriate program
templates and macros will be loaded in the robot when the user configures the robot for tool changing in the setup wizard.
7.11 Determine Style and Option Coding

Style paths with unique options are used to organize robot programs. The following sections explain the required style and
option usage.
7.11.1 Style Code Usage

The integrator shall utilize standard styles as defined by OV Vehicle Systems on a per program basis. The standard styles
are provided in the following table.

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Table 7.2: Style Usage

Value Name Global 1&2 Description Global 3 Description
0 N/A not valid not valid
1 STYLE01 Common Common
2 STYLE02 Division #1 Division #1
6 STYLE06 Platform #1 Common Platform #1 Common
7 STYLE07 Platform #1 Division #1 Platform #1 Division #1
Platform #4 Division #4 (G1)
25 STYLE25 Brake Check, OptA = ZDT Self Test
Brake Check (G2)
26 STYLE26 Tool Change Tool Change
27 STYLE27 Cap Change Cap Change
28 STYLE28 Tip Align Auto Cap Changer
29 STYLE29 Process 1 Tip Maintenance Process 1 Tip Maintenance
30 STYLE30 Process 2 Tip Maintenance Process 2 Tip Maintenance
31 STYLE31 Repair Repair
32 STYLE32 not valid Repair 2
35-49 STYLE35-49 not valid Reserved for Maint. Styles
50-255 STYLE50-255 not valid User Defined Styles

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7.11.2 Option Code Usage
The integrator shall utilize standard option codes as defined by OV Vehicle Systems on a per program basis. The available
Option codes for Global 1 & 2 are A-C. Available Option codes for global 3 are A-E. See OVRS-4A on DocInfo for more infor-
mation.
7.11.3 Style Specific Paths
When paths that are only performed in one style are required, use the following naming convention to distinguish
between style specific programs where XX is style number 1-24 or 50-255 (see style usage table above) and Y is the
sequence number (1, 2, 3, etc):
SXX PICKY Style XX, pick partY – start pick numbering at 1 for 1st pick
SXX DROPY Style XX, drop partY – start drop numbering at 1 for 1st drop
SXX PROCY Style XX, processY – start process numbering at 1 for 1st process
SXX POUNC Style XX, pounce
**FFRPROCY FFR programs are process based. Multiple FFR programs can be declared and used.
7.12 Program Process Paths
A process program is defined as the portion of the robot’s style program that is applying content to the product. Examples
of these paths are spot welding, stud welding and dispensing programs called from the main style program.
7.12.1 S01PROC1
SO1PROC1 is a common process program that can be called from multiple styles. All parts must be of the same style and
receive the same type of processing, as they will utilize the exact same path.
7.12.2 SXXPROCX
A style specific process is used when the robot deals with multiple styles of parts that use a common piece of process equip-
ment.
7.13 Verify Decision Codes
A decision code is a group input signal to the robot from the PLC that gives the robot a direction at any request to continue
when a decision needs to be made.

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7.13.1 Decision Code Usage
The integrator shall be responsible to use the standard decision codes in the manner described in Table 7.6. Any deviations
from this shall be reviewed with Vehicle Systems Lead Robotics Engineer prior to making changes.
Table 7.6: Decision Code Template [Global 3]
Value Usage Value Usage
0 No Decision 9 Pick/Drop9
1 Pick/Drop1 10 Pick/Drop10
2 Pick/Drop2 11 Pick/Drop11
3 Pick/Drop3 12 Wake up Dispenser
4 Pick/Drop4 13 Pre Cap Change Dress
5 Pick/Drop5 14 Cap Change
6 Pick/Drop6 15 Return Home From Pounce
7 Pick/Drop7 16 Advanced MH Return Home From Pick
8 Pick/Drop8 17-31 User Defined
7.14 Program Robotic Racking and Unracking Paths
If OLP is provided for rack pickup/dropoff, it will contain only the first position of the “search routine”, a linear move to the
most extreme pickup/dropoff location, and the path from/to the most extreme pickup/dropoff routine.
The integrator shall be responsible for installing the latest available Vehicle Systems Robotics standard robot logic for rack
pickup/dropoff and modifying the logic, as required and with Vehicle Systems approval, to meet process requirements of
the system.
The integrator shall be responsible for verifying the paths at every pickup/dropoff location.
Robotic racking can consist of but is not limited to:
- Logical Robotic Search programing with EOAT mounted sensors

- Logical Robotic Search programming with remote mounted sensors
- Robotic mechanical compliance devices
- Robotic Vision
o Carried Camera
o Remote Mounted Camera

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7.15 Program Dispense Path
Reference the Global Dispense Setup User’s Manual, located in the Global Robotics Standards section of OV Vehicle Systems
Supply Power, for instructions on properly setting up the robot for the dispense application.
The integrator shall adhere to the following robotic programming best practices when programming or touching up dis-
pense paths:
1. Follow the maximum robot speed guidelines in chapter 7.3.

2. Avoid fine termination types when turning the gun on or off or when dispensing material.
3. Avoid entering interference zones or requesting path segments during a dispense bead.
4. Program bead approach and depart motions in the same direction of the bead where possible.
5. Minimize the number of points used to create dispense beads.
6. Keep the nozzle within 15 degrees of normal to metal.
7. Slightly point the nozzle opposite to the direction of travel to pull extruded beads.
8. Maintain a standoff distance of roughly twice the diameter of the bead for extruded beads.
9. Maintain a standoff distance of no more than 50mm for streaming beads.
10. Minimize TCP speed variation while dispensing the bead to maintain a consistent bead size.
11. Use seal schedules per the Global Dispense Setup User’s Manual.
7.16 Program Dispense Verification “Show Me” Path
Some pedestal dispense applications require bead verification with a vision camera. In the event that the camera is by-
passed or faulted, the robot must be able to show the part to an operator at the fence. The integrator shall program a dis-
pense verification “show me” path to move the robot from the end of process to a manual inspection point visible from out-
side fence and back to the end of process if required. The template programs are loaded by the system when the robot is
configured as a pedestal dispense application.
7.17 Program Repair/Service Paths
The integrator shall program any required repair/service paths without robot, tooling or transfer interferences wherever
possible. Examples of these paths include: Pounce, Repair, Tip Dress, FFR, Calibration/Mastering, Purge, Cap Change, Auto-
matic Cap Changer, nozzle change, dispense tip change, any ZDT paths, etc…..
Where interferences between service paths and production paths of other robots cannot be avoided, interference zones
shall be used. These zones may be programmed to include the entire service path(s) and production path(s) that interfere
between the two robots.

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Automatic cap changers are sometimes used to remove and reinstall weld gun caps in areas where frequent cap changes
are necessary. The removal of the cap is achieved by using robot motion to strip the cap off the shank. To protect for the
robot motion needed to remove the cap, a minimum clearance of 60 degrees is required.
Carried Servo gun Repair position requires water intrusion considerations during Cap Change. The orientation of the servo
gun in the repair position should attempt to minimize water collection on the rod end of the servo motor. Refer to Figure 7.8
below.
Figure 7.8: Servo gun Repair position examples.
8 Interference Zones
An interference zone must be used between two robots if any portion of the path of one robot interferes with any portion of
the path of another robot. Timing is not an acceptable alternative for collision prevention. Collisions are prevented
through PLC control via specified inputs, outputs and routines. For thru-put enhancements multiple interference zones can
be present between robot(s).
The standard PLC logic assumes that the Pounce, Repair, Tip Dress, FFR, Purge, and Cap Change paths are free of inter-
ferences. If any of these paths can’t be programmed to avoid interferences, they must be reviewed with the responsi-
ble Vehicle Systems Lead Robotics Engineer and Controls Engineer. The following recommendations should be follo-
wed whenever possible:
1. Teach robot paths and modify robot secondary dress as required to eliminate the need for interference zones.
2. Multiple interference zones between two robots should be avoided.
3. Setup the interference zones such that the robot with the longest cycle time has minimal pauses during normal
operation.
4. Interference zones shall only be used between robots in the same station. If this is unavoidable, they must be
reviewed with the responsible Vehicle Systems Lead Robotics Engineer and Controls Engineer.

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8.1 Verify Interference Zones Numbering and Comments

8.1.1 Interference Zone Numbering Convention
1. Use the interfering robot number as the interference zone number whenever possible.
2. If a robot interferes with two robots of with the same robot number, use the next available interference zone num-
ber for the interference with the robot that is downstream based on part flow.
3. If a station has more than 12 robots/zones, the zone numbers should be agreed upon between the robot program-
mer and the PLC programmer.
4. If a robot has multiple interferences with the same robot, use the next available number(s) for the additional inter-
ference zones.
5. Where interference zones between service paths and production paths of other robots are required, interference
zones 11 and 12 between multiple robots may be used. Use zone 11 for the production path(s) of interfering robots.
Use zone 12 for the service path(s) of interfering robots. In all cases ensure that interference zone numbers are
agreed upon between the robot programmer and the PLC programmer.
6. Exiting an interference zone shall use FINE termination on the motion instruction. Consult the lead Vehicle Systems
Robotics Engineer for deviations.
8.1.2 Comment Interference Zones

All Robot programs using interference zones must have a program comment indicating the robot number and zone number
that the robot is interfering with. Comments must be used for both zone entry and exit and in the event of multiple zones
between (2) or more robots additional comments should indicate what the additional zone declarations are.
Figure 8.1: Example for Interference Zone Comments

COMMENT “********************************”
COMMENT “STYLE XX PROCESS 1”
COMMENT “********************************” ;
SET SEGMENT(50) MOVE J P1 100% CONT100 ;
COMMENT “Enter I-Zone with F120-R4 in Z1”
ENTER INTERFERENCE ZONE(4) ;
MOVE L P2 100mm/s CONT100
8.2 Verify Interference Zones with PLC

After properly programming the interference zone instructions the robot programmer shall verify, with the Controls Engi-
neer, that the PLC logic for the station has been setup to work with the interference zones that were used. Once confirmed,
the following procedure is used to validate that the interference zones are functioning properly.
To test robot 1:
1. Jog robot 1 to the first position after the “Enter Interference Zone (2)” instruction.
2. Run robot 2 and verify that it stops at the line of code that says “Enter Interference Zone 1”.
3. Continue jogging robot 1 until it executes the “Leave Interference Zone (2)” instruction. At this point, robot 2
should continue its path.
Continue in this manner to test all interference zones for each robot.

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9 Verify Cycle Time
All robots shall run at or below designed cycle time. The robot programmer is responsible to validate that the robot meets
the required cycle time.
9.1 Verify All Styles 100% with Metal

Verify that all style programs are running at 100% speed with parts.
9.2 Verify and Record Cycle Time

Verify and record the designed and actual cycle times on the buyoff checklist.
10 Software Housekeeping
Delete Temporary Programs
All temporary programs used in the integration phase must be deleted, so as not to fill the teach pendant with useless and
confusing data.
10.1 Remove Unused Macros

Remove any unused macros from the macro table.
10.2 Remove Temporary UTOOLS and UFRAMES

Unused UTOOLS or UFRAMES should be zeroed out and naming should be removed.
10.3 Remove Temporary Payload Information

Any unused payload should be zeroed out and naming should be removed.
10.4 Enable Required Prompts and Alerts

Enable all prompts and alerts such as Simulated IO, Machine Lock, Production Run Speed, and Production Resume Speed.
10.5 Backup Robots

When integration robot programming is complete and bought off, perform an image and MD backup of each robot. Pro-
vide backups to the Vehicle Systems Lead Robot Engineer.

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10.6 Setup UD&C
Configure the robot to interface with the plant Upload, Download & Compare (UD&C) system once the robot installed and
powered on at the production facility. Follow the instructions in the UD&C Configuration document posted on DocInfo. Nav-
igate to Global Robot Specifications and then under Quick Links.
11 Hardware Housekeeping
11.1 Verify Robot Dress
11.1.1 Robot Dress Requirements

The integrator shall be responsible to adhere to requirements in the Leoni LSH-Advanced Dress Pack Guide document,
which is located on OV Vehicle Systems Supply Power, for all robots using the Leoni dress packages. The integrator shall
contact the Vehicle Systems Lead Robot Engineer for approval if any deviations are needed.
11.1.2 Robot Dress Rules

The integrator shall also be responsible to adhere to the general dress guidelines in this section. The integrator shall re-
dress any robots that do not meet dress requirements in this specification at the discretion of the Vehicle Systems Lead Ro-
bot Engineer. The integrator shall also be responsible to correct the dress for any robot that does not pass the final ac-
ceptance check performed by the robot/dress supplier at the final installation location.
1. Welding applications shall be electrically isolated from the robot – including faceplate, transformers and junction
boxes
a. For combination carried weld guns with material handling (regardless of insulated face plate), verify electri-
cal isolation is correctly installed between weld gun and end effector.
2. The integrator is responsible to paint-mark all adjustable dress components once tuned in so the dress can be
quickly readjusted in the case of a crash.
3. EOAT 4-pin micro connection cords shall have a service loop next to termination on the proximity switch end
4. Hoses and cords shall be neatly secured to EOAT. Hoses and cords shall follow the EOAT frame wherever possible
and there shall not be any loose sections that could be snagged and damaged.
5. The integrator is responsible to supply any required bulkheads for air or water for the EOAT
6. Robot welding transformers shall be hardwired and shall have a strain relief connector provided at the transformer.
Conductors (including the equipment ground conductor) shall be terminated inside of the primary junction box of
the weld transformer.
11.2 Stencil Robot Arm and Controller
All robots shall have stenciling data placed on the robot arm, and controller, and end of arm tooling using the conventions
listed below.

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11.2.1 Robot ID
The robot stencil ID shall comply with GEP-1 Section 5.2.5 Robot Numbering. If space for the stenciling is a concern, the un-
derscores may be removed from the robot name.
11.2.2 Stencil ID Placement – Robot Arm
All robots shall have the robot ID stenciled on the arm in at least three places and shall be visible when looking at the robot
from any side (see Figure 11.1). Note that this requires stenciling on the robot arm and/or counterweight in addition to the
counterbalance cylinders. Letter height for the robot arm shall be as large as possible, but not smaller than 75mm.
Figure 11.1: Stencils on the Robot Arm
11.2.3 Stencil ID Placement - Robot Controller
All robot controllers shall have the ID placed on the front of the cabinet door and in a location where robotic peripheral de-
vices attached to robot controller (i.e. teach pendant) will not obstruct the view of the ID. Letter height is 2 inch max and
1.5 inch minimum. See Figure 11.2 for a stencil example of the longest possible robot name on a Global 3 Fanuc Asize cabi-
net. See Figure 11.3 for a stencil example for the larger Fanuc B-Size cabinet.

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Figure 11.2: Robot Controller Stenciling (Fanuc A-Size Cabinet)
Figure 11.3: Robot Controller Stenciling (Fanuc B-Size Cabinet)

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11.3 Install Dust Covers

All unused electrical receptacles on a robot and robot controlled equipment (robot, robot controller, weld controller, water
saver, dispense controller, end effector input block, end effecter valve pack, etc.…) shall have a dust cover installed to pre-
vent contamination and possible short circuits.
12 Robot Limiting Hardware and Software

12.1 Set Axis Soft Limits
Enable and set robotic axis limits for axes 1-3. The software axis limit shall be set to fault the robotic system prior to reach-
ing a mechanical limit. The limit set function found in MENUS, UTILITIES, [F1], TYPE, reads all of the programmed positions
on the robot automatically and determines the maximum and minimum taught joint angles used in all programs. It then
takes this information and sets the specified joint limits automatically, while taking into account a limit buffer of at least 5
degrees. The limit set function also reports the appropriate angles for the mechanical hard stop placement. Remove tem-
porary programs before running the limit set function. Then make sure you can go to zero degree mastering, as a reality
check. By default, software axis limits will be set only for axes 1, 2, and 3. Do not set soft limits for axes 4-6.
12.2 Install Robot Hard Stops

Robot hard stops are the preferred method used to limit the robot envelope and define the restricted space. Place the axis
1 and 3 hard stops a minimum of 2 degrees from the soft limit. Robot arms that are not capable of flip-over do not require
hard stops on axis 3 unless required by the specific application to restrict the envelope. If the robot does not require a J3
stop and the robot comes with one provided, the integrator shall mount it in the full-open position.
12.2.1 Verify Hard Stops are Placed Correctly

In some cases the hard stops are the primary method to limit the robot envelope. Jog the robot toward the hard stop and
verify that the robot cannot move into the guarded area.
12.3 Validate Operator Light Screen Placement

The operator light screen is serving two purposes. First, it stops the robot if the operator walks into the station while the ro-
bot is working in the tool. The light screen placement allows enough time for the robot to stop before a person can reach it.
Second, the light screen will also stop the robot in the unlikely event that it attempts to move toward the area where the
operator stands outside the light screen. This validation procedure will check that the operator light screen is placed the
correct distance from the robot programmed path.
12.3.1 Operator Light Screen Placement Validation Procedure

The placement of the operator light screen is based on the robot stopping distance and the safe distance formula. Table
12.1 below is shown in the Perimeter and Operator Station Setup Guidelines document and is used to place the light screen:
Table 12.1: Operator Light Screen Placement

Safe Distance Formula
Robot Model
Inches mm
ArcMate, M10, M20 24 600
R1000 24 600
R2000 125L, 165F, 210F 24 600

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R2000 185L, 200R, 210R, 220U, 250F, LR Mate 36 900

M900 260L, 280, 280L, 350, 360 36 900
M900 400L 48 1200
M900 700 53 1350
M2000 72 1800
Follow the steps below to validate that the operator light screen is placed correctly:
1. Place the robot into low speed teach (T1 mode).

2. Select the robot program path that works in the tool.
3. Run the program path and stop the robot at the point that is closest to the light screen. Make sure that the path is
run in the worst case condition. If the part sticks out toward the light screen then this procedure must be run with a
part.
4. With the robot stopped at the closest location to the light screen, measure from the closest point on the robot/part
to the light screen.
5. Make sure the light screen is placed a minimum distance from the robot based on the arm type you are using in Ta-
ble 12.1 above.
6. If the distance is too small, move the light screen to the correct distance and rerun this procedure.
7. Redo steps 1-6 of this procedure for all robots and path programs that work in the tool.
12.4 Optimize Collision Guard Sensitivity

Collision guard shall be enabled at all times during robot program execution. Setup the collision guard software as de-
scribed in the following steps:
1. Verify that Load Data, including Payload and Armload, is accurate.
2. While running at 100% speed with carried parts, increase the global sensitivity from the default value of 100% by
increments of 10% until collision guard faults occur.
3. Then decrease the global sensitivity by 10%.
4. If there are specific moves which cause collision alarms, while the rest of the path runs without a problem, the user
shall attempt to reprogram the move(s) to smooth the path and eliminate the alarms.
5. If the moves cannot be smoothed by reprogramming, global sensitivity can be decreased in certain areas of the
path by using a COL GUARD ADJUST command as shown in Figure 12.1.
Figure 12.1: Collision Guard Sensitivity Adjustment

40: !SET COLLISION DETECT ;
41: R[25]=125 ;
42: COL GUARD ADJUST R[7] ;
43: ;

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6. Increase collision guard sensitivity prior to any pick or drop location. Decrease collision guard sensitivity back to
the prior value immediately after the drop.
7. If needed, reduce collision guard sensitivity as described above immediately before and after welding to avoid any
nuisance tripping that occurs during the welding operation.
13 Robot Documentation
The integrator shall provide electronic and hardcopy documentation, described in the following sections, to the VS Robotics
Engineer upon request.
13.1 Electronic Documentation

The following documentation shall be provided upon request to the VS Robotics representative:
1. Robot controller image as well as MD backup

2. Electronic copy of RDS spreadsheet in Powerpoint format, detailing the robot's tool data, frame/base data, home
position and payload values. Any changes should be clearly documented in this file.
3. Electronic copy of all Fanuc Payload Checker or other applicable vendor specific (VS Robotics approved) payload
data.
4. DCS Deliverables from simulation
5. List of any customizations or deviations from the standards that were required for the specific task:
• additional macros/subprograms
• additional path segments/decision codes
• hardware/wiring changes
• program naming convention
13.2 Hardcopy Documentation

The integrator shall ensure that all original robot documentation that came with the robot, such as master data, is still in the
controller at the time of shipment. The integrator shall provide a hard copy of the Robot Data Sheet (RDS), DCS delivera-
bles, and any approved deviations. This documentation shall be provided in a plastic sleeve attached to the robot control-
ler.
14 Prepare Robot and Controller for Shipping

This section provides integrators with guidelines for the proper handling, blocking, strapping, moving, and shipping all ro-
botic items. This section supplements, but does not replace, the robot manufacturer’s handling and transportation require-
ments.
The EOAT shall remain attached to the robot during shipment. The EOAT may be detached, however, if doing so decreases
taxes, tariffs or duties. When shipped attached, the EOAT shall be positioned such that it hangs down from the wrist of the
robot during transportation.

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Robots shall be removed from risers or base plates and secured to the original shipping pallet on which they were received.
The robots shall NOT be lifted with the risers attached.
When the robot is placed in shipping position, the center of gravity shall be over the base of the robot, and all lift points and
fork pockets shall be accessible.
All attached cables, hoses, and wires shall be wrapped to the robot arm in a manner that will prevent loosening and wear
during shipment.
The plastic document sleeve shall be removed and placed inside each robot controller for shipment.
14.1 Block Robot Arm

Blocks shall be used to secure the robot arms for transportation. Lower the upper arm until it faults out as it loads up
the block which may be placed between the lower and upper arm or between the pallet and the EOAT (see Figure 14.1).
Blocks should also be used, whenever possible, between the EOAT and the robot (see Figure 14.2).
Figure 14.1: Robot Blocking Between the Lower and Upper Arm of the Robot
Figure 14.2: Robot Blocking Between the EOAT and the Robot

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14.2 Band Robot Arm and Controller

Blocking shall always be accompanied by banding. The robot arm and EOAT must be banded such that neither is capable of
motion relative to the shipping pallet during transportation.
14.2.1 Band Robot Arm

Where shipping pallets are required, robots shall be reattached in the same manner, on the same pallets, and using the
same mounting hardware, as the robots were received. Any restrictions described in the robot manufacturer’s manuals
must be followed. If metal banding is likely to rub on any of the robot cables, hoses or dress components, plastic bands can
be used or some protection added to avoid damage to dress. Banding holds the upper arm of the robot in place during
shipping. Between blocking and banding any bouncing force should be absorbed without loading the J3 motor.
14.2.2 Band Controller

The controller should be banded to a wood pallet with the door closed. Teach pendants can either be placed inside before
banding the door closed, or zip tied to the top of the controller. If placed inside the controller cabinet it is helpful to leave a
note taped to the outside like this: “teach pendant inside.”
14.2.3 Detached EOAT Shipping

In cases where robots must be shipped separately from the EOAT, it is necessary to detach the EOAT using the following
procedure:
1. Photograph the robot and EOAT prior to detaching the EOAT so as to simplify the re-attachment of the EOAT.
2. If possible, remove the EOAT without disconnecting the robot dress and ship the EOAT strapped to the robot pallet
and wrapped in plastic. Include all mounting hardware in boxes and strap these boxes to each pallet containing
the equipment that hardware belongs to.
3. Label each EOAT with the corresponding robot ID. All connections disassembled are labeled and protected from
shipping damage.
4. Before removing an EOAT, use a paint pen or other marking methods to indicate a reference point where the tool
was mounted.

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14.3 Palletize Robot Arm and Controller

14.3.1 Robot Arm
The steel OEM pallets shall be used when possible. Mount robots back on the original pallets just as they arrived, with modi-
fications to the robot orientation as required to accommodate the end effector.
Steel shipping bars are less stable but are preferred over wood pallets. If shipping bars are used, the robot should be ori-
ented such that the center of mass falls between the bars. Lower fork pockets shall not be used to secure a robot arm to the
truck.
14.3.2 Controller
The controller may be palletized together with the arm on the OEM pallet. OEM pallets support the weight of the controller
without using their wheels. If this method is used, the controller is banded to the pallet.
Controllers are usually palletized separately on wood pallets. Controllers must be palletized such that the wheels are not
loaded during transportation. This can be done by adding wood blocks to the pallet to support the weight of the controller.
The controller shall be banded to the pallet to prevent it from tipping or opening.
14.4 Prepare Robot Transport Unit for Shipping

The integrator shall prepare the Robot Transport Unit (RTU) for shipment using the following guidelines:
1. Robots are to be removed from the carriages for shipping

2. All moving items are to be fixed stationary for transport to prevent damage during shipping
3. Carriages shall be moved to the center of the rail section and strapped in place per Figure 14.3
4. Protect all steel machined surfaces with a lubricant with rust inhibiting properties
5. Lubricate and protect all uncoated metal surfaces such as carriage mounting surface, linear bearings, and gear
racks
6. The cable track shall be unbolted from the fixed end and rolled up into the base
7. Single RTU’s will be shipped with the carriage in the center of the base
8. Multiple section RTU’s will be separated at the intersections and shipped separately
9. See Figure 14.3 for proper lifting of the RTU sections
Figure 14.3: Lifting Example

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OVRS-3 Appendix A
DCS Validation Procedures
January 2018
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Appendix A: 1. General
Appendix A: 1.1 Purpose
This document contains detailed procedures to validate DCS in an automation cell. These procedures will verify
the following:
1) Verify the DCS end effector model is properly sized to cover the end effector and part
2) DCS SafeIO Connect is setup and functioning properly
3) An operator is properly protected by DCS while working in the robot/operator shared workspace
4) Location of the DCS zone preventing the robot from moving beyond the operator light screen
5) Location of the DCS zone protecting the cell perimeter
6) Location of the DCS zone protecting a person performing tasks in an adjacent cell
7) Location of a joint position check
8) Speed limit zone location and function
Appendix A: 1.2 Definitions

DCS: DCS stands for Dual Check Safety, which is a certified safety software system, using dual inputs and dual
CPUs, that can be set up to perform safety functions over integrated DeviceNet Safe or Ethernet/IP Safe. One of
the functions DCS enables is safety position zones that limit the robot envelope. In this document, DCS is used
to mean the safety position zones feature of DCS.
DLD Zone: The DCS zone created to prevent the robot hitting the operator while he or she is working in the ro-
bot/operator shared workspace. This PLC-controlled zone replaces the robot light screen or base limit switch
that were previously used as the Dynamic Limiting Device (DLD).
End Effector: Any tooling attached to the robot faceplate (Gripper, Weld Gun, etc…). End of arm tooling (EOAT)
Operator Guarded Space: The area in which the operator stands and is detected by presence sensing devices
(see Figure 1.1).
Operator Station Restricted Zone: The DCS zone created to prevent the robot from moving beyond the opera-
tor guarded space. This robot-controlled zone (Power-off stop) replaces the old 10” light screens that were just
inside the operator light screen.
Operator Workspace: The area comprising the Operator Guarded Space and the Tool Floor Space.
PLC-controlled Zone – A type of DCS zone that is set up as a “Not-Stop” type. A status bit is sent to the PLC to
indicate whether the robot is in or out of the zone. The PLC will then issue a General Stop to the robot if re-
quired.
Robot-controlled Zone – A type of DCS zone that is set up as “Power-off Stop” type. The robot will E-stop itself
anytime it moves into the zone. These zone types are only used for areas the robot is never supposed to go.
Robot/Operator Shared Workspace: The overlapping area in which the operator perform work. The robot shall
be disabled when it is in the shared workspace at the same time as an operator.
Total Floor Space: The area established by the outer perimeter of the station tooling. This will typically be
within the robot/operator shared workspace.

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Figure 1.1: Sample Operator Station Layout
Appendix A: 2. DCS End Effector Model

The DCS end effector model validation procedure verifies that the DCS end effector model is properly sized to
entirely surround the end effector and part. This procedure requires the use of pictures provided by simulation
of the end effector DCS model. These DCS pictures can be found on the Simulation Robot Data Sheet (RDS).
Appendix A: 2.1 Validate DCS End Effector Model
1. Review the DCS pictures to verify that the DCS User Model envelope(s) around the end effector encom-
pass the entire end effector and part. See Figure 2.1 below for an example of the DCS EOAT picture
that should be provided.
2. Jog the robot holding the part to the same joint positions represented in the DCS pictures.
3. Verify the user model setup parameters from the DCS Simulation Deliverables match what is setup in
the robot controller.
4. Using the robot teach pendant (Global 3 robot) or RoboGuide (Global 2 or older robots), visually verify
that the number, size and location of the DCS envelopes around the end effector are the same as shown
on the DCS pictures.
5. If any of the above verification items fail, correct any identified problems before proceeding.

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Figure 2.1: End Effector DCS Model
Appendix A: 3. Validate SafeIO Connect Mapping

The DCS SafeIO Connect area has interconnects that are needed for the robot safety system to function
properly. The map in Figure 3.1 includes mapping for up to 7 zone status bits. Add the number of bits for the
number of shared (plccontrolled) zones that are needed.
Figure 3.1: DCS SafeIO Connect Mapping (G3, SpotTool+ V8.20P/04)

Corresponds to “IDNS” safety driver in GCCS-2
This area is the

default Safe IO
Connect map.
This area has the

optional mapping for
DCS shared (PLC -
controlled) zone status
bits
Note: For Global 2 the circled line is CSO[9]=SSI[4]

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Figure 3.2: DCS SafeIO Connect Mapping (G3, SpotTool+ V8.20P/42)

Corresponds to “IDNS_V2” safety driver in GCSS-2
CSO [ 1] = SSI [ 6]
CSO [ 2] = ! SSI [ 10]
CSO [ 3] = SSI [ 7]
CSO [ 4] = SSI [ 8]
This area has the CSO [ 5] = SSI [ 9]
same for V8.20 CSO [ 6] = SSI [ 5]
P04 and P42 CSO [ 7] = ! SSI [ 11]
CSO [ 8] = CCL [ 1]
CSO [ 9] = SSI [ 1]
SSI [
SSO [ 1] = CSI [ 1] OR
11]
SSO [ 2] = ! SSI [ 11]
SSI [
SSO [ 3] = CSI [ 2] OR
11]
CCR [ 1] = CSI [ 3]
SSI [
P42 only = CSI [ 4] OR
SSO[ 4] 11]
CSO [ 13] = CPC [ 1]
This area has the CSO [ 14] = CPC [ 2]
option mapping for CSO [ 15] = CPC [ 3]
DCS shared CSO [ 16] = CPC [ 4]
(PLC controlled) CSO [ 10] = CPC [ 5]
zone status bits CSO [ 11] = CPC [ 6]
CSO [ 12] = CPC [ 7]
Figure 3.3: DCS SafeIO Connect Mapping (G4)

Corresponds to “IENS” safety driver in GCCS-2
SSO [ 1] = CSI [ 1]
SSO [ 2] = ! SSI [ 11]
SSO [ 3] = CSI [ 2]
SSO [ 4] = CSI [ 8]
CCR [ 1] = CSI [ 9]
CCR [ 2] = CSI [ 10]
CCR [ 3] = CSI [ 11]
CCR [ 4] = CSI [ 12]
CSO [ 1] = SSI [ 6]
CSO [ 2] = ! CSI [ 10]
CSO [ 3] = SSI [ 7]
CSO [ 4] = SSI [ 8]
CSO [ 5] = SSI [ 9]
CSO [ 6] = SSI [ 5]
CSO [ 7] = ! SSI [ 11]
CSO [ 8] = SSI [ 1]

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CSO [ 9] = CCL [ 1]
CSO [ 10] = CCL [ 2]
CSO [ 11] = CCL [ 3]
CSO [ 12] = CCL [ 4]
CSO [ 17] = CPC [ 1]
…… … ……
CSO [ 48] = CPC [ 32]
CSO [ 49] = JPC [ 1]
CSO [ 50] = JPC [ 2]
CSO [ 51] = JPC [ 3]
CSO [ 52] = JPC [ 4]
CSO [ 57] = CSC [ 1]
CSO [ 58] = CSC [ 2]
CSO [ 59] = JSC [ 1]
Appendix A: 4. Validate Operator Station Guarding

Operator station guarding has four different components:
1. Operator Reach Protection

2. Robot DLD Placement
3. DCS zone that prevents the robot from breaching the operator light screen
4. Operator Light Screen Placement (refer to OVRS-3 section 12.3.1)
The validation procedure makes sure that the DLD circuit is working correctly, the robot will stop before reach-
ing the robot/operator shared workspace, the operator light screen is placed properly, and the DCS zone that
protects the operator light screen is in the correct location.
Appendix A: 4.1 Operator Reach Protection

Protect operator standing in Operator Guarded Space from reaching into cell and encountering a hazard.
The DLD zone is placed the minimum required distance from the Operator Guarded Space to prevent an injury
from an operator reaching out towards a hazard.
Appendix A: 4.1.1 Operator Reach Protection Test Procedure

Follow the steps below to validate DLD placement:
1) Select the DCS_Test program and skip to the moves to test the desired zone. The DCS_Test program
is a deliverable from simulation that approaches each DCS zone with a perpendicular move. The
DCS_Test program is intended to aid the programmer/validator in moving the robot to the various
DCS zones. It is the responsibility of the validator to test enough points to adequately verify the lo-
cation of the DLD.
2) If there is no DCS_Test program provided from simulation, jog the robot or create a short program
into the zone. 3) Jog the robot into the zone with the operator light screen broken and the operator
guard bypass box switch in Auto.
4) The robot will stop with an Estop from the PLC.

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5) Measure the distance from the closest point of the EOAT to the operator guarded space. Measure hori-
zontally from the top of the physical barrier (low fence, belly bar, etc.) that restricts the operator from
entering the cell.
6) Verify that the distance meets the minimum requirement in the Perimeter and Operator Guard Guide-
lines document. This is normally 1500mm for 1m barrier.
7) If the distance is too small then increase the size of the zone or modify operator guarded space.
8) Redo steps 1-5 until the test passes.
9) A minimum of two test points should be used to verify the location of each plane of the DLD that the
robot can reach. Repeat steps 1-8 for each plane of the DCS zone that the robot can reach.
Appendix A: 4.2 Validate Robot DLD Placement

Operator DLD’s are typically accomplished with light screens or DCS zones. This procedure assumes a DCS zone
is used as the DLD. This validation procedure verifies that the DLD meets the requirements stated in the Perime-
ter and Operator Guard Guidelines document and will stop the robot before reaching the robot/operator
shared workspace. See Figure 4.2, which is an excerpt from the Operator and Perimeter Guard Guidelines docu-
ment. The DLD DCS Zone is represented by the green dotted line in each example.
Figure 4.2: Operator Station DLD Examples – DLD DCS Zone
Appendix A: 4.2.1 Operator Station DLD Dynamic Test Procedure

Each robot path (style) that enters the operator station must be tested individually. If the robot is a material
handling robot, the gripper must be in the same state as it would be when entering the zone in normal produc-
tion. If there are multiple operator stations, each station must be tested separately. The following steps shall be
followed to verify the DLD DCS zone:
1) Make sure the robot is in Auto 100% and Operator Guard Maintenance SSW is in Auto.
2) Verify that there is no personnel in the robot/operator shared workspace.
3) Momentarily break the operator light screen but do not reset the light screen.
4) Run the robot path into the operator station by initiating in manual from the HMI or by running the pro-
grammed path in T2 mode. Note: if the robot does not initiate into the DLD in Manual from the HMI, the
PLC logic should be corrected before continuing this test.
5) Verify that the robot stops before entering the robot/operator shared workspace. When the robot
stops, make sure that the operator would still be able to perform their normal operation while clear of
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6) If the robot penetrated into the robot/operator shared workspace, move the DLD farther away and re-
peat this test until the robot stops before entering the robot/operator shared workspace.
7) Repeat steps 1-6 for:
a. Each robot style path that moves into DLD.
b. Each additional robot that enters the tool. (Each robot would have its own DCS Zone for
the DLD). c. Each DLD in the station.
Appendix A: 4.3 Validate Operator Station Restricted Area DCS Zone

The operator station restricted area is the area beyond the operator light screen where the robot is never al-
lowed to go. This validation procedure verifies that the DCS zone is placed properly from the outer edge of the
operator guarded space, preventing the robot from reaching outside. The restricted area is represented by the
red shaded area in Figure 4.3 below.
Figure 4.3: Operator Station - DCS Restricted Area Zone
Appendix A: 4.3.1 Operator Restricted Area Validation Procedure

Follow these steps to verify that the operator restricted DCS zone location meets the requirements in the Perim-
eter and Operator Guard Guidelines document:
1) If the robot cannot extend the end effector with part beyond the operator guarded space due to hard
stops or robot reach limitations, this test is not required.
2) For robots that can extend the end effector with part beyond the operator guarded space, run the
DCS_Test path from simulation or jog the robot toward the operator light screen until it stops with a DCS
fault.
3) Verify that the distance between the furthest area of the EOAT or part meets the requirements in the Perim-
eter and Operator Guard Guidelines document. This distance is a minimum of 300mm.
4) If the robot is not far enough from the operator light screen, move the DCS zone or light screen.
5) Repeat steps 2-4 until the minimum distance requirement is satisfied.
6) A minimum of two test points should be used to verify the location of each plane of the DLD that the robot
can reach. Repeat steps 1-5 for each plane of the DCS zone that the robot can reach.
7) Verify all restricted zones are configured as type “Power-off Stop” in DCS.

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Appendix A: 5. Validate DCS Zones Protecting Cell Perimeter

Robots that are operating near the cell perimeter guarding require hard stops or DCS zones to limit the enve-
lope and prevent the robot from running through the fence. These are areas where the robot is never allowed to
go. The DCS zones are set up as restricted zones (“Power-Off Stop” type). The validation procedure verifies
that the zones are placed the correct distance from the perimeter guarding.
Appendix A: 5.1 Cell Perimeter DCS Zone Validation Procedure
Follow the steps below to validate the cell perimeter zones:
1) Select the DCS_Test program and skip to the moves to test the desired zone.
2) If there is no DCS_Test program provided from simulation, create a short program into the speed zone
or jog the robot into the zone.
3) The robot will stop with a DCS fault.
4) Measure the distance from the closest point of the EOAT to the fence.
5) Verify that the distance to the fence meets the minimum requirement in the Perimeter and Operator
Guard Guidelines document (Table 2). This distance is typically 300/600/900mm depending on robot
model. 6) If the distance is too small then increase the size of the zone.
8) A minimum of two test points should be used to verify the location of each plane of the perimeter zone
that the robot can reach. Repeat steps 1-7 for each additional test point.
9) Verify all restricted zones are configured as type “Power-off Stop” in DCS.
Appendix A: 6. Validate Guarding Between Cells

The guarding between stations inside of a cell is typically fencing or a combination of fence and an inter-cell
light screen. A DCS zone is used to prevent a robot from contacting the fence or breaching the inter-cell light
screen. The validation procedure verifies that the DCS zone is placed correctly and the robot will stop before
moving through the inter-cell light screen. See Figure 6.1 for an example of a cell with an inter-cell boundary.
Figure 6.1: Inter-Cell Guarding

OV ME Strategy
Appendix A: 6.1 Inter-Cell Light Screen Zone Location Validation Procedure

Use the following procedure to validate the inter-cell DCS zone has been placed correctly based on the require-
ments in the Perimeter and Operator Guard Guidelines:
1) Make sure the robot is in Auto and at 100% or in T2 mode (if testing in teach).
2) Make sure the robot EOAT is in the same state as it would be running normal production (ie..Gripper
closed or open or with a part, etc….).
3) Open the gate in the cell on the other side of the light screen (Do not select robot teach at the gate
box).
4) Verify that there is no personnel in robot cell or adjacent cell.
5) Run the robot path toward the inter-cell light screen by initiating in manual from the HMI or by running
the programmed path in T2 mode.
6) The robot will stop with an E-Stop when it reaches the DCS zone.
7) Make sure the robot stops before moving into the light screen.
8) If the robot did not stop before entering the light screen, move the DCS zone farther away.
9) Repeat steps 1-8 until the robot stops before entering the light screen.
10) Repeat this procedure for all paths that move through the inter-cell light screen.
Appendix A: 7. Validate DCS Speed Zones

DCS speed zones are sometimes used to limit the robot speed in an effort to reduce the robot stopping dis-
tance. This is typically done in non-production areas such as set in/ set out or pull offs where the fencing is too
close to use the typical safety distances. The validation procedure will verify that the speed zone will properly
limit the robot speed.
Appendix A: 7.1 DCS Speed Zone Validation Procedure
Use the following procedure to validate
speed zones: 1) Select the DCS_Test
program.
2) If there is no DCS_Test program provided from simulation, create a short program into the
speed zone 3) Place the robot in T2 mode
4) Verify that the speeds for the points moving into the zone to exceed the speed
zone limit 5) Run the robot into the zone using the DCS_Test program or the pro-
gram from step 2.
6) Verify that the robot stops with a DCS fault while moving to a position inside the zone at a speed that
exceeds the speed zone limit.
7) Verify all speed zones are configured as type “Power-off Stop” in DCS.
Appendix A: 7.2 DCS Speed Zone Location Validation Procedure

Follow the steps below to validate the depth of a DCS speed zone:
1) Put the robot into T1 mode.

2) Monitor the zone status in the teach pendant under the Cartesian Position Check screen.
3) Jog the robot into the DCS speed zone.
4) When the zone status changes to unsafe, stop the robot.
5) Measure the distance from the closest point of the EOAT to the fence.
6) Verify that the distance to the fence meets the minimum requirement in the Perimeter and Operator
Guard Guidelines document.
7) If the distance is too small then increase the size of the zone.

OV ME Strategy
9) A minimum of two test points should be used to verify the location of each plane of the zone that the
robot can reach. Repeat steps 1-7 for each additional test point.
Appendix A: 8. Validate Joint Position Checks

Joint Position Check (JPC) is a DCS feature used to limit an individual axis of the robot. These are sometimes
used when a simple Cartesian Position Check (CPC) zone cannot be used. The validation procedure will make
sure that the JPC is placed correctly.
Appendix A: 8.1 Joint Position Check Validation Procedure
Use the following procedure to validate the JPC
location: 1) Select T1 mode.
2) Put the robot into joint mode.
3) Jog the robot axis that is being limited toward the restricted area.
4) The robot will stop with a DCS fault.
5) Verify that the robot stops at the required location.
6) If the position is not correct, increase or decrease the joint limit value as required. 7) Redo steps 1-5 un-
til the test passes.
8) Verify all restricted zones, including JPC’s, are configured as type “Power-off Stop” in DCS.


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February 2018 OVRS-3 4 of 52

2 ORDER ROBOTS .................................................................................................................................... 10

3 ROBOT PROGRAMMING SAFETY ....................................................................................................... 10

4 CONFIGURATION OF ROBOT ............................................................................................................. 12

5 SETUP WELD GUN ................................................................................................................................. 15

February 2018 OVRS-3 5 of 52

6 ACCESSORY WELD EQUIPMENT SETUP AND FUNCTIONALITY.................................................... 15

7 PROGRAMMED PATHS ......................................................................................................................... 17

8 INTERFERENCE ZONES ........................................................................................................................32

February 2018 OVRS-3 6 of 52

9 VERIFY CYCLE TIME .............................................................................................................................34

10 SOFTWARE HOUSEKEEPING ...........................................................................................................34

12 ROBOT LIMITING HARDWARE AND SOFTWARE ..........................................................................38

13 ROBOT DOCUMENTATION ..............................................................................................................40

14 PREPARE ROBOT AND CONTROLLER FOR SHIPPING..................................................................40

February 2018 OVRS-3 7 of 52

Appendix A: 1. General .................................................................................................................. 1

February 2018 OVRS-3 8 of 52

1.4 Normative References

Offline program: OLP; a specific deliverable from simulation

February 2018 OVRS-3 9 of 52

Vehicle Systems: OV Automation / Execution team members.

Wiring diagram: WD; refers to the OV wiring diagrams

3 Robot Programming Safety

February 2018 OVRS-3 10 of 52

3.2 Verify that Robots Lag Bolts are installed

3.3 Verify Advanced DCS Deliverables from Simulation

February 2018 OVRS-3 11 of 52

3.4 Verify SMC Cylinder Locks

Figure 3.3: SMC Cylinder – Locking Configuration

3.5 Bypass DCS CIP Safety

3.6 Verify Presence of Light Screens

3.7 Robot Programming SOP’s

February 2018 OVRS-3 12 of 52

4.2 Run the Setup Wizard

4.3 Set Controller Date and Time

4.4 Load Offline Programs

4.5 Run Offline Program Setup Utilities

4.6 Configure Ethernet I/P Address & Parameters

4.7 Configure Device Net Node Parameters

4.8 Configure Material Handling Software

4.9 Verify Operation of EOAT

February 2018 OVRS-3 13 of 52

4.10 Set Payload and Armload Data

4.10.1 Manual Load Definition

4.10.2 Payload Naming Convention

4.11 Verify Robot Mastering

February 2018 OVRS-3 14 of 52

4.12 Create MASTERPS

5 Setup Weld Gun

5.2 Setup Pneumatic Weld Gun

5.2.2 Equalization Control

6 Accessory Weld Equipment Setup and Functionality

6.2 Setup Tip Dresser

6.3 Verify Tip Dress Motor Functionality

February 2018 OVRS-3 15 of 52

Figure 6.1: Tip Dress Blade Holder and Spring Orientation

6.4 Verify Tip Dress Blow Off

6.5 Verify Dress Verification Gauge (DVG)

6.6 Verify Auto Cap Changer

February 2018 OVRS-3 16 of 52

7.1 Verify and Update TCP / RTCP