GRS MasterRev6.1

GRS
Global Robot Specifications

LMS # 34043
Module 1: Robot Processing

Fundamentals
Revision 6.1
© 2017 General Motors Company.

All Rights Reserved
Objectives
• The student will be able to use robot path
rough cycle time estimation.
• The student will be able to define DCS.
• The student will know the robot rules of
process.
• The student will know the details of path
control signals.
2
Course Overview
• This course will provide participants with the ability to
explain the purpose of the GRS Common Global Robot
Specifications (GRS) including build and integration of
Robots and their applications.
• Remember to refer to the GRS Specifications found on
the GM intranet or www.gmsupplypower.com.
• The GRS standards are comprehensive and will have
the latest information. This training course is used as
an instructional guide and may not contain the absolute
latest information from the specifications. 3
Global Robot Specifications Overview
GRS1 Robot Technical Specification
– Out of the box content
– Ethernet/IP communication for all control signals
– Ethernet for upload/download support
– Ethernet/IP communication for all safety signals
– Ethernet/IP for I/O on end of arm tooling and legacy
interfaces
GRS1
4
GRS2 Robot Rules of Process Specification
– Sets the maximum limits for robot processing
– Rough cycle time rules
GRS2
5
GRS 2 Specification Overview
• This specification is intended to guide robot simulation
operators and process engineers in the standardization
of processing and designing robot applications.
• It provides robot processing requirements that promote
proper robot utilization and extend the life of robots,
robot dress and other associated equipment
• The “Rules of Process” were developed to ensure
common application of the standard interface in the
processing of robots.
GRS2
6
GRS3 Robot Integration
– Path segment tables
– Robot Dress
– Robot Interference Zones
– TCP Definition
– Application Setup and Programming
– Style and Option Code Usage
– Buyoff Checklist
GRS3
7
GRS4 Robot Interfaces
– Robot to cell controller interface
• Shop specific and user defined bits
– Robot to process equipment interface
• Shop specific and user defined bits
GRS4
8
Robot-Cell Controller Physical Interface (GRS-1)
The GRS-1 Robot Specification defines the basic
hardware and software capabilities of the robot.
This includes:
– Robot Arm Requirements
– Robot Controller Requirements
– Teach Pendant Requirements
– Robot Software Requirements
• Instructions
• Utilities
GRS1
9
Robot-Cell Controller Physical Interface (GRS-1)
(cont’d)
Defines communication requirements (Ethernet/IP)
• Dedicated Ethernet/IP channel between robot and cell
controller
– Safe and non-safe signals over the same Ethernet
channel on the cell network
– Some process equipment may be on the cell network
• Ethernet for upload and download
• Additional Ethernet/IP channel(s)
– Robot to/from Process Equipment
– Controls EOAT IO
GRS1
10
GM GRS-2
Pre-tool design simulation is required and governed by the GM
Vehicle Systems GRS-2, Rules of Process Specification. The
simulation will include all facility features and equipment intended
in the Robot cell, including, but not limited to, the following:
• Perimeter guarding
• Cell entrances
• Operating spaces
• Restricted spaces at operator load/unload stations
• Auxiliary equipment located within the cell guarding
• Facility equipment and/or obstructions in the cell
• Tooling and transfer systems
GRS2
11
Robot Restricted Space and Dynamic Limiting
Devices (DLD)
• Through the use of DLDs, the robot’s restricted
space can be automatically changed during a
portion of the robot’s cycle to allow manual
loading/unloading tasks to be performed while the
moving robot is clear of the operator’s work area.
• DLD Device Examples:
– Base Limit Switch
– Light Curtain
– Dual Check Safety (DCS)
GRS3
12
Robot Restricted Space and
Dual Check Safety (DCS)
• Since Global 2, FANUC robots have certified
safety software systems that can be setup to
perform safety functions such as emergency stops,
general stops, teach T1 and T2 modes, as well as
safe monitoring of position and speed.
• Global 4 uses Ethernet/IP Safety I/O
• DCS position monitoring can be used for
redefining the robot’s restricted envelope or
dynamic limitation of the robot envelope (DLD).
13
GRS3
DCS Zone 1 and Zone 2 Layout
(Top View)
• DCS zones can be used
to replace other robot
DLD’s such as light
screens or axis switches.
• In this case DCS Zone 1
is configured as the
shared space, and as
safe OUTSIDE the
position zone.
GRS3
14
DCS Zone 1 and Zone 2 Layout
(Side View)
• With zone 1 configured as a
shared space and as safe
OUTSIDE the position zone:
– The robot must operate outside
the defined space.
– If the robot enters Zone 1 while
the light screen is not reset, the
robot will E-stop.
– If the operator screen is reset
then the PLC will set the zone’s
disabling input active and the
robot will not be stopped.
GRS3
15
DCS (continued)
• The robot DLD light screen and operator inside
light screen can be replaced with DCS Zones.
• Zone 1 replaces the robot light screen
• Zone 2 replaces the operator inside light
screen and restricts the robot at all times for
entering the operator area.
GRS3
16
DCS Operator Zone
GRS3
17
DCS Operator Zones (continued)
GRS3
18
DCS Fence Zones
GRS3
19
Validating DCS
• Place temporary awareness barrier in operator station to
prevent anybody from entering the operator station.
• Teach robot test path:
– Teach path from robot Home position over the tool and through the
operator light screens as far as the robot can reach. No further testing is
required if the robot cannot reach beyond the outer operator light screen.
– Moves taught with primary robot axis (i.e. Joints 1, 2 and 3)
– Moves taught at 100% speed
– Moves taught as CNT100 termination type
– Moves taught as joint motion type
• Ramp up test path to full speed in T1.
• Test by ramping up to full speed in T2.
• Verify that the robot stops before the robot. End effector,
or interrupts the outer operator light screen.
• Adjust the DCS Zone and/or add hard stops if required.
• Controls Engineer signs off Functional Buyoff checklist is
complete.
GRS3
20
Validating DCS (cont’d)
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
6. If the distance is too small then increase the size of the zone
7. Redo steps 1-5 until the test passes
8. The 2nd test point should be used if a User Frame is used on the zone. The 2nd
test point should be as far away as possible from the 1st location to make sure the
DCS plane is not skewed. Repeat steps 1-7 for the second test point.
GRS3
21
Exercise 1.1
1. What is DCS?
2. Can DCS replace a light curtain or a robot axis

switch in an operator/robot station?
GRS4
22
Exercise 1.1
3. What will be the result if the operator light
curtain is reset and the robot enters the defined
shared space?
A. Robot is E-stopped
B. Robot is paused
C. Robot continues
D. Robot finishes segment and waits
23
Exercise 1.1
curtain is not reset and the robot enters the
defined shared space?
B. Robot is paused
C. Robot continues
24
Exercise 1.1
5. Robots equipped with certified safety software
can be setup to perform which function(s) over
Integrated DeviceNet Safe (IDNS) or Ethernet/IP
Safety?
A. Position and Speed
B. Emergency Stops and General Stops
C. Teach T1 and T2 modes
D. All of the above 25
Exercise 1.1
Exercise Solutions
26
Exercise 1.1: Solution
1. What is DCS?
Dual Check Safety
2. Can DCS replace a light curtain or a robot axis
switch in an operator/robot station?
Yes, either one
27
curtain is reset and the robot enters the defined
shared space?
B. Robot is paused
C. Robot continues
28
curtain is not reset and the robot enters the
defined shared space?
B. Robot is paused
C. Robot continues
29
5. Robots equipped with certified safety software
can be setup to perform which function(s) over
Integrated DeviceNet Safe (IDNS) or Ethernet/IP
Safety?
A. Position and Speed
B. Emergency Stops and General Stops
C. Teach T1 and T2 modes
D. All of the above 30
Robot Payload Analysis (Ref: GRS-2)
• During the early design of robot carried tooling,
the payload is analyzed to determine the
correct robot model.
• Payload analysis rules are found in the current
version of GMD-1.
• The “FANUC Payload Checker” Excel file
should be included with all EOAT designs.
GRS2 31
Enter the values for
the mass, center of
gravity, and moments
of inertia for the
EOAT. Do the same
for the EOAT with
parts.
GRS2 32
Has tab that shows a
screen similar to the
FAUNC Payload Entry
Screen with values
generated from the Excel
sheet
GRS2 33
Rough Cycle Time Rules
• Many factors affect cycle time including access
to spots, metal types and stack ups.
• Rough cycle time calculations are used:
– When little is known about the product or the tooling
in the robot’s path.
– Prior to simulation to obtain early estimates of cycle
time.
– Does not replace robot simulation cycle times.
– Most of the time they will only apply to Body Shop 34
GRS2
Respot Robots
– Rough Cycle Time = 2.5 sec in + (# of Weld Spots X
2sec/spot) + 2.5 sec out
GRS2
35
Framing or Geo-set Robots
– Rough Cycle Time = 2.5 sec in + (# of Weld Spots
X 3sec/spot) + 2.5 sec out
– Where, # of Weld Spots = the number of weld
spots planned for that robot
GRS2
36
Example: Respot Robot Analysis
Assume an engineer is analyzing a respot robot
application where it is uncertain if the robot will
have to reorient in order to get the estimated 12
welds. Also, the product data is not well defined.
The cycle time for that robot should be calculated
as follows:
– Rough Cycle Time = 2.5 sec in + (12 Spots X
2sec/spot) + 2.5 sec Out
– Rough Cycle Time = 29 sec for Respot robot
– Rough Cycle Time = 41 sec for Geo-set robot 37
GRS2
MH and Pedestal welding robots
– Rough Cycle Time = 6 to 9 sec pick & clear + (# of
Weld Spots X 2 sec) + 6 to 9 sec drop & clear
– Could apply the rough MH times to Powertrain
applications
GRS2
38
Example: MH Robot
Assume an engineer is analyzing a robot application
where a Fanuc robot will carry a long narrow part like a
Tie Bar. The robot will use 7 sec (in the range of 6 – 9
sec) to pick & clear and drop & clear. The robot has 12
Ped welding spots to do. The cycle time for this robot
should be calculated as follows:
– Rough MH Cycle Time = 7 sec Pick & Clear + (12
Ped Spots X 2 sec) + 7 sec Drop & Clear
– Rough Cycle Time = 38 sec for that robot
– Rough Cycle Time = 14 sec for just MH
39
GRS2
Carried stud welding robots
– Stud Weld Cycle Time = 2.5 sec In + (# of Studs X
[SWT + .5 per move]) + 2.5 sec Out
• Where: (# of Studs) = Number of stud welds for that robot
• And: (SWT) = Stud Weld Time for that type of weld.
• And: .5 sec per move between studs for studs within a few
inches on the same plane.
– Consult a Vehicle Systems Robot engineer for
additional information regarding rough cycle times of
carried stud welders or other robot weld
applications.
GRS2
40
Example: Carried Stud Welder
Assume an engineer is analyzing a robot carried
stud weld application where the robot will have
an estimated 8 stud welds of type M6x25mm,
which welds take 2.2 seconds
– Stud Weld Robot Cycle Time = (2.5 sec in) + (8
Studs X (2.2 + .5) sec) + (2.5sec Out)
– Stud Weld Robot Cycle Time = 26.6 sec
41
GRS2
Carried Dispense Robots
• Processing rule: Utilize this cycle time calculation to determine an
estimate of the length of the dispensing process based on the
available cycle time
Bead Length in mm 200 mm

# of beads X 2.5 sec In 2.5 sec Out
Robot Speed in mm/sec
• 200 mm accounts for 100 mm before and after each continuous
bead do to sticky material and line straightening
• An estimate of the process cycle time based on the given length of
dispensing process
42
GRS2
Other Rough Cycle Time Calculations
• Carried arc welding robots
Rough Cycle Time
Bead Length in mm
2.5 sec In 0.6 sec Arc Start 0.6 sec End Fill Delay
Robot Speed in mm/sec
2.5 sec Out
• Projection nut welding robots

– Rough Cycle Time = 6 to 9 sec pick & clear + (# of Weld Spots X 3
sec/spot) + 6 to 9 sec drop & clear
– Project Nut welders are controlled by the cell controller
43
GRS2
Other Rough Cycle Time Calculations
• Clinch nut welding robots
– Rough Cycle time = 2.5 sec in + (# Weld Spots X 2
sec/spot) + (2.5 sec out)
• Tool changer timing
– Tool Changer = (0.3 sec unlatch) + (0.3 sec latch) +
(6.0 sec concurrent with return to home motion)
• NOTE: As a guideline in early processing, 12 seconds can be used to
estimate the total time to exchange tools
44
GRS2
Exercise 1.2
Exercise Solutions
45
Exercise 1.2: Rough Cycle Time Exercise
• Calculate the rough cycle time for a carried
stud welder that must make 11 stud welds.
– 2.5sec + [(2.2+0.5)*11] + 2.5 = 34.7
• Calculate the rough cycle time for a material

handler/ped welder. Assume the pick/clear
and drop/clear utilize 8 seconds each. There
will be 7 weld spots.
– 8 + (7*2) + 8 = 30
GRS2
46
Robot Rule of Process
Robot reach
Each robot shall be placed in simulation, and called
out in the system layout, such that the actual robot
can be misplaced on the floor by up to 100 mm in any
direction and still be able to reach all of its spots
Home and pounce
The home and pounce positions should be
programmed as close to the work position as possible
without interference with moving material or tooling.
GRS2
47
Robot Rules of Process
Robot clearances and tip wear
Clearances between the gun shanks and
product while welding or in motion shall be
greater than 5 mm before and after tip
wear.
GRS2
48
End-effector mounting
1. It is square to the base of the robot when the robot’s joints are
centered at (zero degrees) synch position, minimizing the need
for angle brackets.
2. While the robot is running its path, joint 5 has a bend in it (near
90 degrees is preferred) to avoid singularities whenever
possible. Avoid key positions where joint 5 must be near zero
degrees. (ex., at spot welds, while dispensing, pick, drop, tip
dressing, etc.)
GRS2
49
End-effector mounting (cont’d)
3. There is as little rotation as possible from the robot’s home
position to the position where the joint angles of the robot are at
zero degrees—also taking items 1 and 2 above into account.
4. The CG is as close as possible to the centerline and surface of
the robot’s faceplate.
5. Joints 4 and 6 should be centered rather than turned one way at
home position and during its motion, if possible. This method of
programming will help when synchronizing the robot.
GRS2
50
Weld spot distribution requirements
• Weld spots are grouped by gun orientation due to robot dress
• Minimize weld gun rotation
• The robot shall weld on no more than two grossly different weld
planes, where the angle difference is greater than 45 degrees
GRS2
51
Tip Dressers
The following tip dress parameters shall be followed for robot carried gun tip
dressers within the cell. Place tip dresser in simulation following these
parameters:
• The weld gun orientation at the tip dress position should be approximately
the same orientation utilized when welding
• The robot shall be clear of the line transferring while moving to the tip
dress location to permit tip dressing while during line transfer.
• The robot should be clear of the other robots’ paths (i.e., no interference
zones in the tip dress path)
• One tip dresser per robot with carried gun(s)
GRS2 52
Robot Control
The sharing of process-related devices,
controlled by a robot, is not permitted
Example: A ped welder controlled by one
robot and being used by another robot.
GRS2
53
Two Process Rule
• A robot shall be limited to two processes based on
the use of two process controllers. (i.e. ped weld
and ped dispense)
– Material handling in conjunction with two processes is
permitted.
– MH is not a process
• A single end-effector shall be limited to two
functions.
– MH is a function
GRS2
54
Spot Weld Gun Combinations
The following table defines the number of guns that can
be used with 1 or 2 SCR’s
DC Welding requires use of 1 SCR and 1 Weld Gun.

GRS2
55
Stud Weld Gun Combinations
The following table defines the number of carried or
pedestal guns that can be used
GRS2
56
Dispense Gun Combinations
The following table defines the number of dispense guns
that can be used with number of controllers
GRS2
57
Material Handling
Rules for Valves, Clamps, Electric Part Holders, Part
Present Switches and Vacuum Pumps
Max allowed Max allowed Max allowed Max allowed
Max Preferred Max allowed
Device (2006 Global (2009 Global 2 (2012 Global 3 (2016 Global 4
(all) (2004 Arch)
Arch) Arch) Arch) Arch)
Valves 3 5 10 10 10 15
Clamps 6 12 18 18 18 24
Electric Part
N/A N/A N/A 8 8 8
Holders
Part present
3 6 9 9 9 16
switches
Vacuum pump
2 4 4 4 4 4
channels
GRS2
58
GRS2
Tool Changers
• The maximum number of tool changer stalls or
positions shall be four per robot. The tool changer
stalls may be arranged on single or separate
stands.
• Trans guns shall be used when spot weld gun
changes are required. Cable guns may not be
used with tool changers
• Use tool changers only when absolutely
necessary or in a tooling back-up situation
GRS2
59
GRS2
GRS2 – Robot Rules of Process Summary
GRS2 sets the maximum limits for robot
processing. These limitations are critical to the
ability to purchase common equipment.
– Maximum of 24 Robots per Cell (Gated Area)
– Maximum of 2 process control panels per robot
– Maximum of 2 end effector functions
GRS2
60
Path Control Signals (GRS-4)
The Path Control signals contain information on what program the
robot should run and control signals while running
Controller to Robot Robot to Controller
Global Robot Specification Global 4 Global 3 Prior Global4 Global 3 Prior
Style Number 0-255 0-127 0-31 Style Number Echo 0-255 0-127 0-31
Option Bits A, B, C, A, B, C, A, B, C Option Bits Echo A, B, C, A, B, C, A, B, C
D, E D, E D, E D, E
Initiate Style Manual Style Request
Decision Code 0-31 0-31 0-15 Decision Code Echo 0-31 0-31 0-15
Clear to Enter Zone 1-12 1-12 1-6 Clear Zone 1-12 1-12 1-6
Path Segment Ok to Continue Path Segment Request to Continue
Path Segment Echo 0-255 0-255 0-63 Path Segment 0-255 0-255 0-63
In Cycle
Task OK
GRS4
61
Style
Style Number 0-255 Style Number Echo 0-255
• Style Numbers (1 to 24) identify different robot paths required by

the “style” of the part being operated on.
– Style Number (1 to 24) for Production Paths
– Style Numbers (25 to 34) for Special / Maintenance Paths
– Style Numbers (35 to 49) for Maintenance Styles
– Style Numbers (50 to 255) User Defined Styles
• The Style Number is read when the Initiate Style bit is turned on
GRS3
62
Style Numbers
GRS3
63
Style Numbers (cont’d)
GRS3
64
Options
Global 3 and 4 Prior Global 3 and 4 Prior
Option Bits A, B, C, D, E A, B, C Option Bits Echo A, B, C, D, E A, B, C
• The option bits (A, B, C, D and E) identify minor

path variations within a given robot style program.
• The robot reads options once when “Initiate Style
Program” bit is ON from the controller and then it
(the robot) echoes the option bits to controller
GRS3
65
Path Segments
Global 3 and 4 Global 3 and 4
Path Segment 0-255 Path Segment 0-255
• The Path Segments numbers (0 to 255) from the robot identify the
location of a robot along its path within a style program
– For example: A robot with Path Segment number equal to 1
represents the robot “Moving to Pounce”
• The Path Segment numbers (0 to 255) from the PLC are used as
an echo of the robot Path Segment Number when the conditions
are met to move into the next segment, otherwise it will be zero
GRS3
66
Path Segments
• Path Segment numbers shall be unique within a
style program
• Path Segment numbers are reused between
style programs
GRS3
67
Path Segments
• Path segments definitions
GRS3
68
Path Segments
Path segments 10-59 and 110-149
Segment # Usage Segment # Usage
10-13 Pick 1 30-33 Drop 1
• Pick/Drop 1-5 are used
14-17
18-21
Pick 2
Pick 3
34-37
38-41
Drop 2
Drop 3
in the Body Shop
22-25
26-29
Pick 4
Pick 5
42-45
46-49
Drop 4
Drop 5
• Pick/Drop 1-10 are
110-113
114-117
Pick 6
Pick 7
130-133
134-137
Drop 6
Drop 7
used for Powertrain
118-121 Pick 8 138-141 Drop 8
122-125 Pick 9 142-145 Drop 9
126-129 Pick 10 146-149 Drop 10
Segment # Usage
50-54 Process 1
55-59 Process 2
GRS3
69
Recovery Path Segments
• Path segments 201-210 are used for recovery from pick 211-220
are used for recovery from drop.
• This is currently only being used for Powertrain Advanced MH
Recovery
Recovery For Recovery For
Segment # Segment #
(Original Segment #) (Original Segment #)
201 Pick 1 (10-13) 211 Drop 1 (30-33)
202 Pick 2 (14-17) 212 Drop 2 (34-37)
203 Pick 3 (18-21) 213 Drop 3 (38-41)
204 Pick 4 (22-25) 214 Drop 4 (42-45)
205 Pick 5 (26-29) 215 Drop 5 (46-49)
206 Pick 6 (110-113) 216 Drop 6 (130-133)
207 Pick 7 (114-117) 217 Drop 7 (134-137)
208 Pick 8 (118-121) 218 Drop 8 (138-141)
209 Pick 9 (122-125) 219 Drop 9 (142-145)
210 Pick 10 (126-129) 220 Drop 10 (146-149)
GRS3
70
Stamping Path Segments
Segment # Usage Segment # Usage
0 Home/Unknown 28 Drop Back to Pick 2
1 Pick 1 Pounce/Enter Zone 1 29 Drop 2 Pounce
2 Pick 1 Pounce 30 Drop Sneak
3 31
4 To Camera Calibration 32 Drop 1 Approach and Drop
5 To Repair 33 Drop 1 Depart and Clear
6 34
7 35
8 Brake Check 36 Enter Zone 1 Return
9 37
10 38
11 Approach Pick 1 39 Return to Pick Pounce
12 At Pick 1 40‐49 Spare
13 Lift Pick 1 50 To Tool Drop
14 Depart Pick 1 51 From Tool Drop
15 Clear Pick 1 52 To Tool Pick
16 Enter Zone 2 53 From Tool Pick
17 Auto Retry Pick 1 54
18 Drop Back to Pick 1 55 Clear Press Access
19 Drop 1 Pounce 56 Move to Show Part
20 57
21 Approach Pick 2 58
22 At Pick 2 59
23 Lift Pick 2 60
24 Depart Pick 2 61
25 Clear Pick 2 62
GRS3 26 63 Return to Home
71
27 Auto Retry Pick 2
“Continue” Signals
A “Request to Continue” (RTC) signal is required
when the robot needs to handshake with the
controller at a specific point in the path. Some of
these points may be:
– At pounce position always requires RTC
– Clear to drop / pick
– No part check / part check
– Decision code point
GRS3
72
Style Differences Between Shops
The structure of the style program differs depending on what shop
(body shop, powertrain, stamping) the robot is in. The differences are
detailed in the next few slides.
Body Shop
1. Style program is called
2. Robot moves to Pounce and RTC
3. Then calls SXXPICK, SXXPROC, or SXXDROP programs as
needed
4. Robot returns to home for next cycle
GRS3
73
Style Differences Between Shops (cont’d)
Powertrain
1. Style program is called
2. Robot moves to Pounce and RTC
3. The SXXDCDPK is called to choose the pick location
4. RTC
5. SXXPROC if needed
6. RTC
7. SXXDCDDP is called to choose drop location
8. RTC
9. Loops back to look for next pick without going home
GRS3
74
Style Differences Between Shops (cont’d)
Stamping - Destacking 10. RTC – wait for drop
1. Style program is called 11. Drop and move up
2. Robot moves to Pounce and RTC 12. RTC – check to go back to pick
3. Robot moves to pick in the style pounce
program 13. Loops back to pick pounce without
4. RTC going home
5. Pick
6. RTC – decide what to do with blank –
continue or return to stack
7. Move up
8. RTC – check for double blank
9. Move Clear
GRS3
75
Weld Program RTC
R e q u e s t to C o n tin u e
“A t P ounce”
S e g 5 0 : W e ld
Seg 1: Pounce
“ R e q u e s t t o C o n t in u e ”
S e g 6 3 : A ll C le a r N o t A lw a y s R e q u ir e d !
S e g 6 2 : T o o l C le a r
“ O p tio n a l”
GRS3
76
Robot Clear of Station
R e q u e s t to C o n tin u e
“A t P ounce”
S e g 5 0 : W e ld
Seg 1: Pounce
C le a r o f S ta tio n N o t C le a r o f S ta tio n
S e g 6 3 : A ll C le a r
“ O p tio n a l”
GRS3
77
Weld Task OK - Successful Process
R e q u e s t to C o n tin u e T ask O K
“A t P ounce” V e r ifie d o ff a t p o u n c e
Seg 1: Pounce C o n tin u e O K
T a s k O K tu r n e d o n
T a s k O K o ff
S e g 5 0 : W e ld
S e g 6 3 : A ll C le a r Task O K on
I n itia te S ty le
T a s k O K , tu r n e d o ff
O p tio n a l
Automatically taken care of as part of the
GRS3
78
ATPOUNCE program
Weld Task OK - Incomplete Process
R eq u est to C o n tin u e T ask O K
“ A t P o u n ce ” V e rifie d o ff a t p o u n c e
S e g 1 : P o u n ce C o n tin u e O K
T a sk O K tu rn ed o n
Task O K on
T a s k O K o ff
S e g 5 0 : W e ld
W eld fau lt
S e g 6 3 : A ll C le ar S kip p e d o n tea c h p en d a n t
T a sk O K , tu rn e d o ff
In itiate S ty le
T a sk O K , tu rn e d o ff
S eg 6 2 : T o o l C lea r
O p tio n a l
GRS3
79
Weld with Clamp Reposition
GRS3
80
Path Decision Control
Decision Code numbers
are used when different Seg 31:Move clear of Drop
paths are required within Request to Continue

“Are Drop 1 Part Switches On?”
the same robot style Decision Code 1 sent to robot
program Seg 30: Drop 1 & Clear Part
Seg 11: robot has part and moving
clear of pickup
Seg 12: robot is clear of pickup
Seg 63:Clear of All Request to Continue
Seg 35:Move clear of Drop “Which Drop is Ready”
Request to Continue Decision Code 2 sent to robot
“Are Drop 2 Part Switches On?” Seg 34: Drop 2 & Clear Part
GRS3
81
• Typical use: Multiple pick / drop locations for the
same style of part
• Requires robot to be at a “Request to Continue”
point
• Decision code is read by the robot when “Continue
Ok” bit is ON from the controller and is then
echoed back to controller
• Unlike decision code, the option bits (A-E) identify
minor path variations within a given robot style
program
GRS3
82
Predefined Decision Codes
– Decision 14, Cap Change Reset at Request Continue
– Decision 15, Return Home From Pounce
– Decision 16, Advanced MH Return Home From Pick
GRS3
83
Stamping Path Decision Control
GRS3
84
Body Shop/Powertrain MH Example
Seg11: At Pick 1 Seg31: At Drop1
RTC RTC
Seg12: Clear Pick 1 Seg32: Clear Drop 1
DC =15 Seg10: To Pick 1 Seg30: To Drop 1

or 16
DC =1 DC =1
Seg63
RTC RTC
Seg1:Pounce
DC =2 DC =2
Seg63: All
Seg14: To Pick 2 Seg34: To Drop 2
Clear –
Powertrain Seg16: Clear Pick 2 Seg36: Clear Drop 2
Seg63: All Clear – Body Shop
RTC
RTC Seg15: At Pick 2 Seg35: At Drop 2
GRS3
85
Stamping Example
GRS3
86
Exercise 1.3: Draw a Robot Path
Layout the robot path with segment numbers in
the diagram in your exercise manual include the
request for continue points and decision codes
for the following operations:
– Weld
– Return home (Decision Code 15)
GRS3
87
Exercise 1.3: Draw a Robot Path
Layout the robot path with segment numbers in the
diagram in your exercise manual include the request for
continue points and decision codes for the following
operations:
– Pick from either of two locations
– Drop to a single location
– Wait for station to clamp
– Weld
– Return home
88
Exercise 1.3
Exercise Solutions
89
Decision 15 RTC
1 Decision 0
50
63
62
GRS3
90
*No Part check

Dec1
10 RTC*11
Dec15 12
RTC RTC Is Drop ready?
1 RTC* 16 30
14 15
RTC Part Check
63 Dec2 31
32
62 RTC Are Clamps
50
Closed?
GRS3
91
Module 1: Review
• What tool can be used during early robot cell
design to approximate running time for various
robots?
– Rough Cycle Time Calculation
• What is DCS?
– Dual Check Safety. DCS position monitoring can be
used for redefining the robot’s restricted envelope or
dynamic limitation of the robot envelope (DLD).
• What is the maximum number of processes
allowed for a single robot?
– 2
92
Module 1: Review
• What are the path control signals used between
the PLC and robot?
– Robot uses Path Segment Request to Continue
– PLC responds with Path Segment Ok to Continue
93
GRS
LMS # 34043
Module 2: Robot Integration

Revision 6.1

All Rights Reserved
Objectives
• The student will understand the phases of integration, the
hardware setup requirements, and the contents of the buyoff
checklist.
• The student will know how to setup the robot payload.
• The student will know the requirements for mastering.
• The student will be able to explain/setup Tool Center Point (TCP)
for multiple robot applications.
• The student will know program naming conventions and move
speed settings.
• The student will know robot interference zone rules.
• The student will define Collision Detection Setup.
2
Robot Integration
The responsible robot programmer shall document
completion of all Pre-Integration (Test Cell), On-Line
Integration (Including Home Line), and Re-Integration
(After Shipping) tasks using the appropriate columns of
the consolidated “GRS 3 Robot Buyoff Checklist”
GRS3
3
Pre-Integration
When the pre-integration (test cell) option is specified at
time of quote, the integrator shall be responsible to
complete all tasks that appear in Pre-Integration (Test
Cell) column of the “GRS 3 Robot Buyoff Checklist”
GRS3
4
On-line System Integration
• The integrator shall be responsible to complete all tasks
that appear in the On-Line Integration (Including Home
Line) column of the “GRS 3 Robot Buyoff Checklist”
• Any items not completed during pre-integration in the
test cell must be complete during on-line integration
GRS3
5
Re-Integration
When plant startup assistance is specified at the time of
quote, the integrator shall be responsible to complete all
tasks that appear in the Re-Integration (After Shipping)
column of the “GRS 3 Robot Buyoff Checklist”
• For home-line integration, the Re-Integration is not
applicable
GRS3
6
Order Robots
• To order robots the integrator should submit the Robot
Order Form from SupplyPower to the GM Vehicle
Systems Engineer
• Accurately estimate cable lengths needed for the robot
GRS3
7
Robot Programming Safety
• Verify Teach Pendant length can safely reach
all areas of the cell
• Verify lag bolts are installed properly
• Verify Dual Check Safety (DCS) info sheets
from simulation
• Check for tool changer switch or jumper
• Verify SMC cylinders are set to the locking
position
GRS3
8
Robot Programming Safety (cont’d)
• Bypass DCS Common Industrial Protocol
(CIP) safety
• Verify presence and function of light curtains
• Reference Safe Operating Procedures (SOP)
GRS3
9
Configuration of Robot
• The latest version of core software should be loaded on the robot
• The integrator shall utilize the Set-up Wizard to achieve the
following deliverables at integration:
– Configure the robot software for proper control of the robot process
equipment
– Comment I/O points in the robot I/O map to match the wiring diagrams
• The integrator shall also configure the following during integration

– Define valves, valve types, sensor inputs, and associated feedback
devices – MH Valves
– Set up any associated delays and timeout value
– Setup all part present sensors for continuous checking as opposed to
GRS3 discrete 10
Configuration of Robot (cont’d)
• Set date/time
• Load offline programs and run the TOOLDATA program
• Verify EOAT operation
GRS3
11
Load Data Setup
• Load Data, encompasses both Payload and Armload.
• Payload is defined as the mass, center of gravity, and
mass moments of inertia for all EOAT and carried parts
manipulated by the robot.
• Armload is defined as the mass and center of gravity of
the dense pack and any other arm-mounted equipment
carried by the robot
GRS3
12
Load Data Setup (cont'd)
• Payload and Armload data shall be utilized in all
programming that contains motion
• A separate Payload shall be defined and utilized in the
robot program for each physical scenario in which there
is a unique payload characteristic *
* Exceptions to the above rule are allowed in cases where the
mass difference between two physical loading scenarios is less
than 5%
GRS3
13
Payload Definition
• Payload data from simulation contained in the Offline
Program (OLP) shall be utilized.
– OLP is the output from simulation that is loadable and on the
robot.
• If OLP is not used, the integrator shall be responsible for
calculating and implementing Payload data for all
programming that contains motion.
– (Note: The integrator shall utilize Roboload Payload information
wherever Roboload has been provided by the mechanical design
source.)
– Armload data for manual entry will be provided by GM Vehicle
Systems
GRS3
14
Payload Naming Convention
• Payload1, or the first available payload data, 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.
• For carried process equipment without material
handling or tool changing, only Payload1 is typically
necessary. For material handling or tool changing,
additional payload definitions are usually required
GRS3
15
Payload Naming Convention (cont'd)
• Payload2, shall be used for the primary EOAT with its
carried part for Style 1. For tool changing, Payload2
shall be used for the second carried tool
• 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 loading
scenario shall be defined as the last payload
GRS3
16
Mastering
• Mastering defines the location of the robot by
synchronizing the mechanical unit’s position with the
robot controller’s stored positional data.
• In order for the robot motion to behave properly the
robot must be properly mastered. Prior to performing
any path teaching or setup (e.g. teaching frames)
the robot’s mastering shall be verified
GRS3
17
Verify Mastering
• The integrator shall be responsible to review and follow
the appropriate manufacturer’s procedure to master the
robot
• The integrator shall also verify that the appropriate
mastering values are recorded on a print out or a
sticker placed inside the robot controller cabinet
• Any problems with mastering that are encountered
during system integration shall be reported to the GM
Vehicle Systems Robots engineer
GRS3
18
Verify Mastering (cont'd)
• Mastering will be reviewed at the time of robot
buyoff
– For FANUC robots, the witness marks specify the
mastered position when aligned
GRS3
19
Zero Position Mastering
• If zero position mastering was possible then
the mastering position will coincide with the
zero position and should be directly entered
to assure that all joints are at precisely zero
• Once the integrator has completed the
manufacturer’s procedure they shall create
a program called “MASTERPS”
• Running this routine and checking the
physical position of the arm by examining
the witness marks can verify the robot
mastering
GRS3
20
Zero Position Mastering (cont'd)
• A safe path (avoiding any dress problems/tooling
collisions) from the home position to the mastering
position.
• An instruction to PAUSE program execution.
• A safe path to home
GRS3 21
Zero Position Mastering Not Possible
• If zero position mastering was NOT possible then the
responsible GM Vehicle Systems engineer shall be
contacted to provide direction
• Mastering of the robot will have to be completed in 2
steps. The first step shall involve aligning axis 1, 2, and 3
to zero, with the wrist axes in such a position as to avoid
any collisions
• The second step shall involve aligning axis 4, 5, and 6 to
zero, with the major axes in such a position as to avoid
any collisions
GRS3
22
Zero Position Mastering Not Possible (cont'd)
• Once the integrator has completed the manufacturer’s
procedure they shall create a program called
“MASTERPS”. Running this routine and checking the
physical position of the arm by examining the witness
marks can verify the robot mastering
GRS3
23
Zero Position Mastering Not Possible (cont'd)
• A safe path (avoiding any tooling collisions) from the
home position to the mastering position for axis 1, 2,
and 3
• An instruction to PAUSE program execution
• A safe path (avoiding any dress problems/tooling
collisions) from the mastering position for axis 1, 2, and
3 to the mastering position for axis 4, 5, and 6
• An instruction to PAUSE program execution
• A safe path to home
GRS3
24
Setup Weld Gun and Accessory Weld
Equipment
• Set up the Servo Gun based on the Servo Gun Setup
Manual
• Setup Water Saver
• Setup Tip Dresser
• Verify Tip Dresser motor and blow off functionality
GRS3
25
Tool Center Point (TCP)
• A tool center point shall be defined for each process
and material handling end-effector to facilitate path
teaching and recovery.
• Each individual process feature of a dual or multiple
function end-effector shall have a unique TCP defined.
• Remote TCPs are required for any robot controlled or
PLC-controlled process equipment with which the robot
interacts that are not physically mounted to the robot
arm.
GRS3
26
Tool Center Point (TCP) (cont'd)
• Tool center point location, orientation, and
naming convention shall follow the standard
defined in GRS3
• TCP verification shall immediately follow TCP
definition or updating, and will be rechecked as
part of the GM Vehicle Systems buyoff checklist
GRS3
27
Teach TCP
• If an offline program is provided, the X-Y-Z of the tool
center point that is provided from simulation shall be
updated prior to path touchup
• If an offline program is not provided, a new TCP shall
be defined according to the standard documented in
this Section, prior to path teaching
• For pedestal applications, a remote TCP coordinate
system for the pedestal portion of the path shall be
defined
GRS3
28
Verify TCP Location - Carried Applications
• Using the teach pendant, set the robot jog
mode to tool coordinates and jog the robot so
that it rotates around the tool X, Y, and Z axes
• The TCP shall not move more than 2 mm in

any direction during a 45-degree rotation about
any axis
GRS3
29
Verify TCP Location - Pedestal Applications
The location of each remote TCP shall be verified in the following
manner:
• Pick a stationary point on the End of Arm Tooling (EOAT) or process part (if
carried by robot) and jog the robot so that the point lines up with the pedestal
TCP
• Place the robot in remote tool coordinates and rotate the EOAT or carried part
around the X, Y, and Z axes
• The EOAT or carried part shall not move more than 2mm in any direction relative to
the pedestal TCP during a 45-degree rotation about any axis
GRS3
30
Verify TCP Orientation - Carried Applications
With the robot jog mode set to tool coordinates,
jog 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
GRS3
31
Verify TCP Orientation - Pedestal Applications (cont'd)
The orientation of each remote TCP shall be verified in the
following manner:
• Pick a stationary point on the EOAT or process part if carried by
robot and jog the robot so that the point lines up with the pedestal
TCP
• Place the robot in remote tool coordinates and move the EOAT or
carried part in the X, Y, and Z directions
– The EOAT or carried part shall move linearly in the positive direction of each
axis.
– For pedestal spot welding, jogging in the remote tool +X direction swallows
the metal and jogging in the remote tool +Z direction brings the
stationary tip closer to the metal
GRS3
32
TCP Naming Convention
• Robot programs originating from Offline Programming (OLP) shall
maintain the TCP names established by the GM Robot download
translator
• Robot programs not originating from OLP shall follow the following
standard for TCP naming
– 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.
– Robots that are processed to use different TCPs (or in a different sequence)
based on Style program shall be programmed using TCPs in ascending order
starting with Style 1 and continuing until all TCPs are named
GRS3
33
TCP Naming Convention (cont'd)
• Robots with pedestal applications shall use the standard
above for naming of carried TCPs.
• Stationary TCPs (FANUC UFRAME/RTCP) shall be
numbered in ascending order beginning with the
process sequence of Style 1 and continuing until all
stationary TCPs are named
GRS3
34
Material Handling Application
• A TCP shall be created for each part that is handled
• The origin of the TCP coordinate system shall be located at the
EOAT 4-way locating pin
• If the EOAT does not have a locating pin, the drop off TCP shall be
set in the center of the locating hole in the part that corresponds to
the 4 way locating pin in the drop off station
• In this case, the TCP orientation shall be aligned with the pin in the
station and is not always aligned with the surface of the clamp
detail. For the pick up path, the TCP shall be set on the corner of
one of the clamp details
• Note that multiple TCP should be created (i.e. one for the pick up
path and one for the drop off path) to make programming quicker
and easier.
GRS3
35
Material Handling Application (cont'd)
• As a general rule, a TCP should be created for each
location that the robot must rotate about. For example,
a robot that picks up a door inner and marries it to a
door outer, will have two TCP
– One TCP will be used for most of the path and will be set at the
EOAT 4 way pin
– A second TCP will be located along one edge of the part.
During the marriage process, the part will be rotated about this
second TCP to snap the two parts together
GRS3
36
• In cases with no pins on the EOAT or in the
tooling, the TCP shall also be set to the corner
of one of the clamp details
• In cases with no pins or details on the EOAT or
in the station (i.e. suction cups or magnets
only), the TCP shall be set in the center of each
set of suction cups or magnets
GRS3
37
The orientation of the TCP shall be defined
according to the following rules
– The +Z direction is defined as the direction the end-effector will
approach the part
– The X and Y directions are defined square to the part and
according to the right hand rule
GRS3
38
MH TCP Definition for robots With Pin
GRS3
39
MH TCP Definition for robots Without Pin
GRS3
40
Standard TCP Definitions - Weldgun Application
For servo weld guns, the origin of the TCP shall
be centered on a new cap attached to the
stationary weld arm
GRS3
41
Pedestal Spot Weld TCP Definition for Fanuc
GRS3
42
Standard TCP Definitions - Weldgun Application (cont'd)
For rocker-type guns, the origin of the TCP shall be the

point in space where the weld tips meet the metal
– The +X direction shall be out of the throat of the gun in the
plane of the sheet metal
– The +Z direction shall be out of the stationary weld shank and
normal to the plane of the metal that is welded by the gun. The
“movable” tip is generally connected to the cylinder rod and the
“stationary tip” is the other tip
– The +Y direction follows from the right hand rule
GRS3
43
Rocker-Type Guns
• Definition of TCP for rocker-type guns: First,
determine where gun tips will meet on metal
• Next draw a line from the pivot point between
the 2 gun arms through the point of contact of
the tips on metal.
GRS3
44
Rocker-Type Guns (cont'd)
• Draw the +Z vector normal to metal (pointing
away from the stationary tip) and the +X vector
outward from the throat of the gun
• The TCP may be defined in space for guns
where both tips move to meet metal
GRS3
45
Stud Welding
• For stud welding, the origin of the TCP shall be 1.5
times the stud length off the stud gun collet with the +Z
direction out of the collet
• The +X and +Y direction shall be square to the stud

gun following the right hand rule, with a minimum of
rotation from the robot default TCP
GRS3
46
Stud Welding (cont'd)
Carried Stud TCP Definition for ALL robots
GRS3
47
Stud Welding (cont'd)
Pedestal Stud TCP Definition for Fanuc.
GRS3
48
Sealing Application
• For sealing, the origin of the TCP coordinate system
shall be defined 1/4 inch off the nozzle, with the +Z
direction out of the nozzle
• The +X and +Y direction shall be defined square to the
nozzle parallel to the world coordinate system, if
possible, and follow the right hand rule
GRS3
49
Sealing Application (cont'd)
• Carried Sealing TCP Definition for ALL robots
GRS3
50
Sealing Application (cont'd)
• Pedestal Sealing TCP Definition for Fanuc
– Note that +X points toward the pedestal sealer base
GRS3
51
Program Naming Convention
• Common paths that can be called from multiple styles will use the
following naming convention
– S01PICKy
– S01DROPy
– S01PROCy
• y represents the pick/drop location number, or the process number (1-2)
• Style specific paths will use the following naming convention
– SxxPICKy
– SxxDROPy
– SxxPROCy
• xx represents the style number that the path is used for (i.e. STYLE02 pick 1 would
be S02PICK1)
• y represents the pick/drop location number, or the process number (1-2)
GRS3
52
Recommended Move Speeds
GRS3
53
Recommended Move Speeds (Cont’d)
GRS3
54
Programming Paths
• Add path segment numbers and comments as needed
• Add comments before MH instructions
• Verify weld/joint numbers
• Teach home to pounce and pounce to home
• Teach pick, drop, and process paths based on the templates
• Teach fast fault recovery paths
• Teach tool changer paths
• Setup style, option bits, and decision codes
• Teach repair/service paths (tip dress, purge, etc.)
GRS3
55
MOV_POUNCE (Power Train (PT) Only)
• Used to move from pounce to pounce without going home (similar to old
powertrain router)
• Uses two arguments – CALL MOV_POUNCE(Arg1, Arg2)
– Arg 1 – What pounce to go to? – uses PR[1] – PR[10] which are also tied to reference positions 1‐10
– Arg 2 – Is the robot at a known pounce? – Yes = 1, No = 2
• 1 is used when you should be at a pounce – at the top of a pick or drop – verifies that it is at a valid pounce
• 2 is used when moving to a pounce – at the end of a pick or drop
• Will perform a joint move from current location to the selected pounce position
• If the robot cannot go from pounce to pounce then a linking program can be
used that has via points between pounces. This is setup under DATA – F1[TYPE] –
Pounce Data
56
Multiple Pounce Data (PT Only)
• A program can be assigned with the linking moves between two pounces
• It must be enabled for the MOV_POUNCE program to check and run the
program
57
Path Recorder (PT Only)
• Path recorder is used to record the path
moving to a pick or drop.
• It will periodically store the robot joint
positions while the path is running.
• This is used as part of recovery to back
the robot out of the path.
– Rec Path Start – starts recording
– Rec Path Pause – pauses recording
– Rec Path Resume – resumes recording
– Rec Path End – stops recording
– Do Bwd Exit – runs the recorded path backward
• If the pick or drop has happened it will
continue forward through the path
58
Path Recovery (PT Only)
• Path recovery is based off the skip
condition of DI[521:diMHRecoveryReq] =
ON
• The points going to the pick or the drop
should end with SkipJump, LBL[999] –
When DI[521] turns on from the PLC the
robot will stop the current motion and
jump to label 999 to recover
• MOV_RCVY will then set the recovery
path segment (201‐220) and will move
back to pounce
59
Review 2-1
• Once the integrator has completed the manufacturer’s
procedure for mastering they shall create a program
called?
MASTERPS
• Why is a tool center point defined for each process and
material handling end-effector?
To facilitate path teaching and recovery
• For a common path give the name for the first pick
position?
60
S01PICK1
Interference Zones
An interference zone between two robots exists if,
at any time, the path of one robot causes a
potential interference with the path of another
robot. An interference zone shall be used when
any part of the robot (wrist, upper arm, weldgun /
EOAT, motor housing, cables, etc.) could collide
with any part of another robot that crosses its
path
GRS3
61
When to Use Interference Zones
• The purpose of an interference zone is to protect the
robot and robot equipment from colliding with another
robot under any possible condition. The integrator shall
properly implement interference zones to avoid
damaging GM’s equipment
• Interference zones are not to be used between material
handling robots when passing parts from one robot to
another via a rest fixture.
– Collisions shall be avoided using PLC control of path
segments.
GRS3
62
Setting Up Interference Zones
• Each robot has 12 pre-defined interference zones
available (defined by R1 through R12). If robot R5 has
an interference zone with robot R3, then at the position
before entering that zone, robot R5 must call “Enter
Interference Zone 3” and once robot R5 is clear of the
zone it calls “Exit Interference Zone 3”
• In each station, note which robot has the longest
individual cycle time and set up the interference zones
such that this robot never pauses during normal
operation
GRS3
63
Interference Zone Rules
1. The home position shall be clear of all potential
interferences
2. Multiple interference zones between two robots shall
be avoided whenever possible
3. Use the interfering robot number as the zone number
whenever possible
4. If a robot interferes with two robots of the same
number, use the next available zone number for the
interference with the robot that is down stream (based
on part flow)
GRS3
64
Interference Zone Rules (cont'd)
5. The programmer shall include a comment for each
interference zone in the path program which includes
robot number and zone number.
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
GRS3
65
Interference Zone Numbering Example 1
Flow 10R2
Zone 1 Zone 2
Zone 4 Zone 2
Zone 1 Zone 2 Zone 3 Zone 4 Zone 1
Zone 1 Zone 1
5R2 STA. 5 5R1 STA. 10 10R1 STA. 20 20R2
Zone 3 Zone 2 Zone 3
*The zone between 5R1 and Zone 1 Zone 3 *The zone between 10R1 and
5R2 is not normally needed. 10R3 20R1 is not normally needed.
Requires Vehicle Systems Requires Vehicle Systems
approval when used. approval when used.
* Path segment control from the PLC is preferred.
GRS3
66
Flow
Zone 1 Zone 1 Zone 2 Zone 1

STA. 5 5R1 STA. 10 10R1 STA. 20 20R1
GRS3
67
R2 R4 R6 Interference with Robot # Use zone number
R1 1
R2 2
R3 3
Flow
R4 4
R5 5
R6 6
R1 R3 R5
GRS3
68
Procedure for Implementing Interference Zones
The programmer will set the “Enter Interference Zone”
and “Exit Interference Zone” instructions for all robots in
every station
– Program each robot to minimize potential interferences with
other robots
– Run each robot individually, noting areas where interference
zones may be needed
– Determine where each robot enters and leaves the
interference zone and insert the appropriate programming
instructions into the program
GRS3
69
Teaching Interference Zones
GRS3
70
Teaching Interference Zones Entering Zone
To determine the interference zone locations in the path
programs for the drawing above:
1. Move robot R2 to the node immediately before
entering the estimated interference zone
2. Run robot R4 through its entire path if possible. If an
interference still exists, move to a previous node
3. Set the “Enter Interference Zone 4” signal at this
node for robot R2
GRS3
71
Teaching Interference Zones Exiting Zone
1. Move robot R2 to the node immediately after leaving
the estimated interference zone
2. Run robot R4 through its entire path if possible. If an
interference still exists, move to the next node (or
adjust the position of this node) until robot R4 can run
through its entire path cleanly
3. Set the “Exit Interference Zone 4” signal at this node
for robot R2
GRS3
72
Procedure for Testing Interference Zones
• After properly programming the interference zone
instructions, the programmer will verify that PLC logic
for the station has been set up to work with the
interference zones that were used.
• Interference zone interlocks are typically added to the
PLC logic at the request of the robot programmers. This
procedure is required to avoid accidental robot crashes
during integration.
GRS3
73
Test Robot R2
• Let robot R2 move inside its interference zone with
robot R4 and stop the program.
• Run robot R4. Robot R4 should proceed up to the node
where “Enter Interference Zone 2” is called and then
should stop, waiting for the clear to proceed input from
the PLC.
• Continue robot R2's program. Once R2 executes the
“Exit Interference Zone 4” instruction, robot R4 should
receive the PLC input and be capable of continuing its
program to completion.
GRS3
74
Test Robot R4
• Let robot R4 move inside its interference zone with
robot R2 and stop the program.
• Run robot R2. Robot R2 should proceed up to the node
where “Enter Interference Zone 4” is called and then
should stop, waiting for the clear to proceed input from
the PLC.
• Continue robot R4's program. Once R4 executes the
“Exit Interference Zone 2” instruction, robot R2 should
receive the PLC input and be capable of continuing its
program to completion.
GRS3
75
Test Instructions
The integrator shall be responsible for the following
deliverables at integration:
– Verify that software is properly configured by exercising all
process instructions under normal circumstances
– Verify cycle time for all styles
– Check that the proper diagnostic messages are reported by
inducing faults into the system
GRS3
76
Software Housekeeping
• Delete temporary programs
• Remove unused macros from the macro table
• Remove temporary tools and frames
• Remove temporary payload settings
• Enable prompts and alerts – Simulated IO, Machine Lock,
Production Speed
• Backup robots (see Module 4)
• Setup Upload, Download & Compare (UD&C)
GRS3
77
Hardware Housekeeping
• Verify robot is dressed properly – cables do not rub, service loops
on cables, welding equipment isolated from the robot
• Stencil number on robot arm
• Stencil number on controller
• Install dust cover on unused receptacles
GRS3
78
Electrical and Pneumatic Connections
The integrator shall be responsible for performing the
following electrical and pneumatic deliverables at
integration:
– Connect and verify the electrical and pneumatic connections
per the end-effector wiring diagrams
– Correctly set dip switches on any peripheral equipment
– Correctly set adjustable levels on all equipment
– Mark-up all wiring diagrams during build
– Update all drawings such that the documentation matches the
build
GRS3
79
Tagging
The integrator shall be responsible for the following
deliverables at integration:
Tag and label all cords, sensors, grippers and Ethernet/IP nodes
per GCCB-1
GRS3
80
Robot Limiting Hardware and Software
• Set soft limits and hard stops
• Verify soft limit and hard stop settings
• Verify light curtain locations
• Validate DCS per GRS3 Appendix A
GRS3
81
Collision Detection Setup
• The integrator shall be responsible for implementing
collision detection on all General Motors’ robots that are
equipped with the collision detection software option.
• Collision detection must be on at all times during
program execution. Exceptions to this standard shall
require written approval from the GM Vehicle Systems
Robots Engineer
GRS3
82
Collision Detection Setup (cont'd)
• Accurately set Load Data, including Payload and
Armload
• Do not utilize any external reporting that the collision
detection software provides
• Optimize global sensitivity. While running continuously
cycling with carried parts, increase the global sensitivity
by increments of 10% until collision detection faults
occur. Then decrease the global sensitivity by 10%
GRS3
83
Collision Detection Setup (cont'd)
• Optimize local pickup and dropoff sensitivities (material
handling robots only). The programmer shall include
instructions in the path program to change the collision
detection sensitivity several moves before each pickup
and dropoff location
• Optimize pedestal welding sensitivity to avoid nuisance
faults
GRS3
84
Integration Documentation
The integrator shall complete the following from
the “GRS Robot Buyoff Checklist”
1a. New Robot Tasks or 1b. Existing Robot Tasks
2. Controller Data
3. DCS Tasks – DCS Validation in Appendix A of GRS3
GRS3
85
Prepare for Shipping
• Block and band Robot Arm
• Band Robot Controller
• Mount robot and controller to pallet
– Steel OEM pallets should be used when possible
GRS3
86
Module 2
Exercise Solutions
87
a 1
b 3
c 2
d 1
e 2
Flow 10R2 f 3
g 4
Zone 1 Zone 2 h 1
Zone 4 Zone 2 i 3
Zone 1 Zone 2 Zone 3 j 2
Zone Zone k 1
5R2 STA. 5 5R1 1 STA. 10 1 10R1 l 3
Zone 2 Zone 3
Zone 3
The zone between 5R1 and Zone 1 Zone 3
5R2 is not normally needed. 10R3
Requires Vehicle Systems
approval when used.
88
Carried Spot Weld TCP for all C guns
GRS3
89
Material Handling TCP with pin
GRS3
90
Module 2: Review
1. What is the purpose of an interference zone?
The purpose of an interference zone is to protect the entire
robot, dress, arm, EOAT, etc., and the robot equipment from
colliding with another robot under any possible condition.
91
GRS3
Module 2: Review (cont’d)
2. Define TCP tool data set up.
A tool center point will be defined for each process and
material handling end-effector to facilitate path teaching and
recovery. Each individual process feature of a dual or
multiple function end-effector will have a unique TCP defined.
GRS3
92
3. Define the Collision Detection setup procedure.
• Accurately set Load Data, including Payload and Armload.
• Do not utilize any external reporting that the collision detection software
provides; i.e. do not attempt to map any collision detection related outputs
to the PLC that may be supported in the software.
• Optimize global sensitivity. While running continuously cycling with carried
parts, increase the global sensitivity by increments of 10% until collision
detection faults occur. Then decrease the global sensitivity by 10%.
Collision guard sensitivity should be set at the highest possible value
where nuisance trips are not present.
• Optimize local pickup and dropoff sensitivities (material handling robots
only).
• Optimize pedestal-welding sensitivity. As needed, the programmer will
include sensitivity instructions in the path program immediately before and
after pedestal welding in order to avoid any nuisance tripping that occurs
during the welding operation.
GRS3
93
4. What is the purpose of mastering a robot?
Mastering defines the location of the robot by synchronizing
the mechanical unit’s position with the robot controller’s
stored positional data so that the robot can be programmed
to accurate positions.
GRS3
94
GRS
LMS # 34043
Module 3: Robot Interfaces

Revision 6.1

All Rights Reserved
Objectives
• The student will explain the different robot to PLC
interfaces and the appropriate I/O signals.
• The student will explain the following robot to
equipment Interfaces and define I/O signals:
– Resistance weld water saver and tip dress interface
– Resistance weld controller interface.
– Integrated servo gun controller interface.
– Dispense tool controller interface.
– Stud weld interface.
– Flow drill screw and self piercing rivets
2
– Material handling interface.
Cell Controller
• The system level signals between the robot and the cell
controller are limited to eight inputs and eight outputs
• The vendor and Vehicle Systems will determine which
eight inputs and outputs are to be used from the
available signals
GRS4
3
Robot Inputs
Initiate Style Program: This signal goes high to indicate to the robot that the
style bits are valid and can be read.
Style Bits (1,2,4,8,16,32,64,128): The style bits form a binary number that
indicates the style of part. The eight signals are combined to indicating up
to 255 styles possible styles.
Option Bits (A, B, C, D, E): The option bits are discrete signals that allow up
to five individual options to be applied to the style selected.
Decision Code Bits (1,2,4,8,16): The decision code bits form a binary
number indicating up to 31 specific operations within the style that are to
be performed.
GRS4
4
Robot Inputs
Interference Zone (1,2,3,4,5,6,7,8,9,10,11,12) Clear To Enter: The
interference zone clear to enter are discrete signals that go high to indicate
a specific interference zone is clear to enter.
Path Segment Request Bits (1,2,4,8,16,32, 64,128): The path segment bits
are a binary combination of 8 bits that are used as handshakes with the
portion of the robot path being executed.
Path Segment Request to Continue: The path segment continue signal goes
high to indicate the robot is clear to proceed into the next path segment.
GRS4
5
Robot Inputs
Tryout Mode Request: The tryout mode signal goes high to indicate the robot
should run in the tryout mode.
Fast Stop Request: Used to pause the robot after an operation has occurred.
Used for applications like flow drills screw and self-piercing rivets
Equipment Remote Reset: A signal indicating a cell level reset is requested
for approved equipment faults such as water saver faults.
GRS4
6
Robot Inputs
Process 1/Process 2 On Request: Indicates to the robot that the process
should be performed. When the signal is low, the robot will place the
process equipment in “off” mode.
Process 1/Process 2 Bypass Request: Request that the process be
bypassed. This ignores the process and allows MH to continue.
Shop Specific Bits (128 available): The Shop Specific bits are used
differently depending on what area is chosen (Body Shop, Powertrain,
Stamping, Paint Shop). For example:
Stamping uses bits for stack searching
Powertrain uses bits for interference checking
Paint uses bits for raising the hood and deck lid
GRS4
7
Robot Outputs
Home 1 – Home 10: Tied to reference positions that turn on a digital output
when the robot is within the specified range of joint values for all joints.
In Cycle: The “In Cycle” signal indicates that the robot is operating and the
style program is being performed. This signal is set as an
acknowledgment that a valid style has been received. This signal will be
set until the style program is complete, aborted or returned from pounce.
Manual Style Request: The “Manual Style Request” signal causes the cell
controller to read the manual style bits, manual option bits and manual
decision codes to determine which style is being requested from the robot.
GRS4
8
Robot Outputs (cont’d)
Manual Style Bits (1,2,4,8,16,32,64,128): The ‘Manual Style Bits’ form a
binary number that allows up to 255 styles to be requested in the isolate
mode. In the interlock mode the robot uses these bits to echo the style
selected to the cell controller. The robot is programmed to set the manual
style bits from within execution of the style program.
Manual Option Bits (A, B, C, D, E): The manual option bits are discrete
signals that select a specific option under the selected style in the isolate
mode. In the interlock mode the robot uses these bits to echo the option to
the cell controller.
GRS4
9
Manual Decision Code Bits (1,2,4,8,16): The ‘Manual Decision Code Bits’
form a binary number that selects a specific operation within the style.
Robot In Interlock: The ‘Robot in Interlock’ signal indicates that the robot is
in Interlock mode.
Robot In Isolate: The ‘Robot in Isolate’ signal indicates that the robot is in
Isolate mode.
Tryout Mode: The Tryout Mode’ signal indicates that the robot is in Tryout
(Dry Cycle) mode.
GRS4
10
Robot Outputs (cont'd)
Robot Clear Of Interference Zone (1,2,3,4,5,6,7,8,9,10,11,12): These
discrete signals are used individually to indicate the robot is clear of the
interference zone the bit represents.
Path Segment Bits (1,2,4,8,16,32, 64,128): The path segment bits are a
binary combination of 8 bits that indicate which portion of the robot path is
being executed.
Path Segment Request To Continue: This signal is a request to the cell
controller for permission to continue onto the next path segment.
GRS4
11
Robot Outputs (cont'd)
Manual Intervention: This signal indicates that robot needs attention at the
teach pendant
Fast Fault Recovery Active: This signal indicates that the Fast Fault
Recovery mode is active and that the robot may be moving to a service
location.
Fast Stop Acknowledge: This signal is used in response to a Fast Stop
Request to tell the cell controller that the signal has been received
Simulated I/O: Indicates that at least one input or output has been simulated
on the teach pendant
Tool Changer Safe Switch Missing: Indicates that the tool changer unlatch
safety switch is disconnected
GRS4
12
Process 1/Process 2 Enabled: Indicates that the robot has placed the
process equipment into the “on” mode.
Process 1/Process 2 Bypassed: Indicates that the process has been
bypassed.
Process 1/Process 2 Fault: Indicates that a major error has occurred within
the process.
Process 1/Process 2 Alert: This signal indicates that a minor error has
occurred within the process.
Process 1/Process 2 Alert 2: This signal indicates that maintenance is
required on the process equipment.
GRS4
13
Process 1/Process 2 Out Of Tolerance: This signal indicates that the
process has detected an out of tolerance condition. This signal is used in
dispense applications to indicate that the process flow measurement is
bypassed.
Process 1/Process 2 Task OK: The “Task OK” signal indicates that the
processing of the part is OK. This signal will be set low upon a style initiate
as an anti tie-down measure. It will be set when the 'continue from pounce'
signal is received. This signal will be set low when the process is disabled
or has encountered a questionable state (e.g. a skipped weld, continue
dry).
GRS4
14
Process 1/Process 2 One Joint Made: This signal indicates that a
successful joint has been made (spot weld, rivet, or screw)
Process 1/Process 2 Equipment Messages (56 available): Depending on
the chosen process there are 56 bits allocated for messages from the
process equipment. For example, spot welding has messages for tip
change required and tip maintenance(tip dress) required. Dispense has a
message for purge request. A self piercing rivet application has a
message for rivets low. Flow drill screw uses a message for screws low
GRS4
15
Shop Specific Bits (128 available): The Shop Specific bits are used
differently depending on what area is chosen (Body Shop, Powertrain,
Stamping, Paint Shop). For Example:
Stamping uses bits for racking
Powertrain uses bits for interference checking status
Paint uses bits for pressure and temperature output
GRS4
16
Cell Controller / Robot Inputs
Robot Input Description Signal Name
In01 System Level Signals—Robot Specific* *IMSTP
In02 System Level Signals—Robot Specific* *Hold
In03 System Level Signals—Robot Specific* *SFSPD
In04 System Level Signals—Robot Specific* Cycle Stop
In05 System Level Signals—Robot Specific* Fault reset
In06 System Level Signals—Robot Specific* Start
In07 System Level Signals—Robot Specific* Home
In08 System Level Signals—Robot Specific* Enable
In09 (Reserved) (Reserved)
In10 Tryout Mode Request TryoutModeReq
GRS4
17
Cell Controller / Robot Inputs (cont’d)
In20 Option Bit A OptionBitA
In21 Option Bit B OptionBitB
In22 Option Bit C OptionBitC
GRS4
18
In23 Option Bit D OptionBitD
In24 Option Bit E OptionBitE
In25 Style (Bit 1) StyleBit1
In33 Fast Stop Request FastStopRequest
GRS4
19
In35 Initiate Style Program (Cycle Start) InitiateStyle
In36 Equipment Remote Reset EqptRemoteRes
In37 Interference Zone 1 Clear to Enter ClearToEntrZone1
GRS4
20
In49 Decision code (Bit 1) DecisionCodeBit1
In54 (Reserved) Decision code (Bit 32) (Reserved) DecisionCodeBit32
In55 (Reserved) Decision code (Bit 64) (Reserved) DecisionCodeBit64
GRS4
21
In56 Path Segment Continue OK PathSegContOK
In57 Path Segment (Bit 1) PathSegmentBit1
GRS4
22
Robot Input Description Signal name
In65 Process 1 On Request Process1OnReq
In66 Process 1 Bypass Request Proc1BypassReq
In67 – In128 Process 1 (Reserved) Proc1 (Reserved)

In129 Process 2 On Request Process2OnReq
In130 Process 2 Bypass Request Proc2BypassReq
In131 – In192 Process 2 (Reserved) Proc2 (Reserved)
GRS4
23
In257 – In416 Shop Specific Inputs diShopSpec
In417 – In432 Robot Option Bits
In433 – In448 Multi Home (Reserved)
In449 – In496 Advanced MH
In498 – In512 Vision Bits
In513 – In520 Tool Number (Reserved)
In521 – In528 Common MH Bits
In529 – In640 Reserved (Reserved)
In641 – In672 User Defined
In673 – In800 Reserved (Reserved)
GRS4
24
Cell Controller / Robot Group Inputs
GIN# Signals Description Signal Name
1 In25 to In32 Style Style
2 In49 to In53 Decision Code DecisionCode
3 In57 to In64 Path Segment Select PathSegmentSelec
26 In657 to In672 User Defined UserDefined
GIN# Signals Description Signal Name

8 In385 to In392 Decision Code 2 DecisionCode2
9 In393 to In400 Decision Code 3 DecisionCode3
GRS4
25
Cell Controller / Robot Outputs
Robot output Description Signal name Housekeeping
State
Out01 System Level Signals—Robot Specific -
Cmd enable
System ready
Prg running
Prg paused
Motion held
Fault
BatteryLowAlert
TP enabled
Out09 (Reserved) (Reserved) -
Out10 Tryout Mode TryoutMode -
Out11 In Cycle InCycle Low
GRS4
26
Cell Controller / Robot Outputs (cont’d)
Robot output Description Signal name Housekeeping State
Out12 -
Robot In Interlock InInterlock
Out13 -
Robot In Isolate InIsolate
Out14 Low
Manual Style Request ManualStyleReq
Out15 -
(Reserved) (Reserved)
Out16 -
Out17 Low
Manual Intervention ManInterventReq
Out18 Low
Fast Fault Recovery Active FFRActive
Out19 -
Out20 Manual Option Bit A ManualOptionBitA Low
Out21 Manual Option Bit B ManualOptionBitB Low
Out22 Manual Option Bit C ManualOptionBitC Low
GRS4
27
Out23 Manual Option Bit D ManualOptionBitD Low
Out24 Manual Option Bit E ManualOptionBitE Low
Out25 Manual Style (Bit 1) ManualStyleBit1 Low
Out33 Fast Stop Acknowledge FastStopAck Low
GRS4
28
Out34 Simulated I/O SimulatedIO Low
Out35 (Reserved) (Reserved) -
Out36 Tool Changer Safe Switch Missing Alert TCSafeSwMissing Low
Out37 Robot Clear of Interference Zone 1 ClearOfZone1 High
GRS4
29
Out49 Manual Decision code (Bit 1) ManDecCodeBit1 Low
Out54 (Reserved) Low
Manual Decision code (Bit 32) (Reserved)ManDecCodeBit32
Out55 (Reserved) Low
Manual Decision code (Bit 64) (Reserved)ManDecCodeBit64
GRS4
30
Out56 Path Segment Request to Continue PathSegReqToCont Low
Out57 Path Segment (Bit 1) PathSegmentBit1 Low
Out60 Path Segment (Bit 8) PathSegmentBit8 -Low
GRS4
31
Robot Output Description Signal name
Out65 Process 1 Enabled Process1On
Out66 Process 1 Bypassed Process1Bypassed
Out67 Process 1 Fault Process1Fault
Out68 Process 1 Alert Process1Alert
Out69 Process 1 Alert2 Process1Alert2
Out70 Process 1 Out of Tolerance Process1OutOfTol
Out71 Process 1 Task OK Proc1TaskOK
Out72 Process 1 One Joint Made Proc1OneJntMade
Out73 – Out128 Process1 Equipment Messages doProc1EqMsg
GRS4
32
Out129 Process 2 Enabled Process2On
Out130 Process 2 Bypassed Process2Bypassed
Out131 Process 2 Fault Process2Fault
Out132 Process 2 Alert Process2Alert
Out133 Process 2 Alert2 Process2Alert2
Out134 Process 2 Out of Tolerance Process2OutOfTol
Out135 Process 2 Task OK Proc2TaskOK
Out136 Process 2 One Joint Made Proc2OneJntMade
Out137 – Out192 Process2 Equipment Messages doProc2EqMsg
GRS4
33
Out257 – Out384 Shop Specific doShopSpec
Out385 – Out416 (Reserved) (Reserved)
Out417 – Out432 Robot Option Bits
Out433 – Out448 Home 1 -10 doHome
Out449 – Out496 Advanced MH
Out497 – Out512 Vision Bits
Out513 – Out520 Tool Number
Out521 – Out528 Common MH Bits
Out529 – Out640 EOAT Status
Out641 – Out672 User Definable
Out673 - Out800 DCS Safety Signatures
GRS4
34
Cell Controller / Robot Group Outputs
GOUT# Signals Description Signal Name
1 Out25 to Out32 Manual Style Select ManualStyle
2 Out49 to Out53 Manual Decision Code ManDecCode
3 Out57 to Out64 Path Segment PathSegment
26 Out657 to Out672 User Defined UserDefined
GOUT# Signals Description Signal Name

8 Out385 to Out392 Manual Decision Code 2 ManDecCode2
9 Out393 to Out400 Manual Decision Code 3 ManDecCode3
GRS4
35
Module 3 Review – Robot Inputs/Outputs
This signal goes high to indicate the robot should run in the tryout
mode?
Tryout Mode Request
This signal is a request to the cell controller for permission to
continue onto the next path segment?
Path Segment Request To Continue
Who determines what system level signals between the robot and the
cell controller are used?
The vendor and Vehicle Systems
36
Modes
There are three types of modes the robot can use. They
are :
– Process Enable/Disable
– Tryout
– Interlock/Isolate
GRS4
37
Process Enabled/Disabled
This mode includes the ‘Process On
Request’ inputs from the cell controller
– In Interlock mode, the robot will use the
status of these signals to place the
process equipment in the appropriate
mode
– In “Interlock” mode with “Process Off”, a
“Major Fault” from the process equipment
will not prevent execution of the robot
style program
GRS4
38
Tryout
This mode indicates that no part is to be processed and
that the robot will not check the status of part present
input(s)
– In Interlock mode, the cell controller selects the tryout mode
using the ‘Tryout Mode Request’ bit
GRS4
39
Interlock/Isolate
Interlock and Isolate are valid modes only when the robot
is in Automatic
– In Interlock mode the robot will respond to initiate signals from
the cell controller.
– In Isolate mode the cell controller will only initiate a robot as a
result of a request from the robot. Process modes for peripheral
equipment may be selected from the teach pendant
GRS4
40
Mainline Shell Program
When the robot is at the home position and in automatic it
will perform the following functions:
– Execute the Home Check to verify it is at a home position
– Execute the Housekeeping functions which resets the robot
outputs
– Execute the Special Functions
– Execute the Run Style program that monitors the signals from
the controller
– Return to the top of the list
GRS4 41
Home Check Program
The home check routine will verify the robot is at a home
position. It will:
1. Compare the current position of the robot with the taught home
positions and calculate the difference in position and orientation.
2. If the difference in position and orientation are within the
definable limits, the robot will set the ‘Home 1-10’ bit to the
controller.
3. If distance or orientation difference is greater than the
definable limits, the robot will prompt the user to jog to the home
position.
GRS4
42
Housekeeping
• The robot will set the outputs to the cell controller to the
“Housekeeping State”.
• A separate routine will be provided for any additional
user selected I/O initialization
GRS4
43
Special Functions
• Special functions allow the user to execute specific
routines or commands from the shell loop.
• It is possible to insert any user-defined routine or
programming instruction into the special functions
portion of the shell loop
GRS4
44
Run Style
• In automatic and interlock modes the robot will monitor
the initiate signal from the cell controller.
• If an invalid style is selected by the cell controller the
robot will indicate a fault.
• A fault reset will take the robot back to the Mainline
Shell.
GRS4
45
Robot Mode
A means will be provided to select between Interlock and
Isolate line modes when the robot is in Automatic.
– Upon transition to Automatic, the robot will default to Interlock
mode.
– Upon transition to T1 or T2, the robot will default to Isolate
mode.
GRS4
46
Style Table
The robot will map the cell controller initiated style number
to any valid robot style program
47
GRS4
Style Program Structure
Program style structure will be implemented in a modular format
A template will be provided containing the standard logic
There will be provisions for a common pounce to be shared between all styles
If a style program is selected in teach mode and the robot is placed back in automatic,
upon completion of the style program, the robot will return to the MAINLINE shell
GRS4
48
Repair (Style 31) Sequence
The Repair Sequence routine is executed to move the robot to the repair position
1. Echo Style 31 (move to repair) to the cell controller
2. SetSegment [2]
3. <User to program the path from home to repair here>
4. Wait for continue (cell controller or user input to the robot)
5. SetSegment [3]
6. <User to program the path from repair to home here>
GRS4
49
Cap Change (Style 27) Sequence
This routine will resets the steppers and water savers
1. Echo Style 27 to cell controller
2. Set Segment [6]
3. Check for water saver tripped or bypassed. If neither is detected, generate a fault and prompt the user for acknowledgement prior to continuing.
4. <Automatically reset steppers>
5. <Automatically reset water savers>
6. <Automatically request tip dress style from cell controller if “tip dress on cap change” has been configured and use “New Cap TD Schedule”>
7. <Automatically reset cap change request bits>
8. <Automatically initiate tip wear measurement for servo guns>
GRS4
50
Pedestal Cap Change at the End of a Path Segment
The robot will respond to a cap change command at any

time the robot is waiting for a “Path Segment Continue”
Decision code 14 has been allocated for this purpose. This

routine resets steppers and resets water savers.
If the “Tipdress on Cap Change” signal is set it also sets the

request for tipdress for all spot welding equipment
GRS4
51
Pedestal Cap Change at the End of a Path
Segment (cont’d)
1. <save current path segment>
2. Set Segment [6]
3. Check for water saver tripped or bypassed. If neither is detected, generate a fault
and prompt the user for acknowledgement prior to continuing.
4. <Automatically reset steppers>
5. <Automatically reset water savers>
6. <Automatically request tip dress style from cell controller if “tip dress on cap change”
has been configured and use “New Cap TD Schedule”>
7. <Automatically reset the cap change request bits>
8. <Automatically initiate tip wear measurement for the servo guns>
9. SetSegment [saved segment]
10. RequestContinue
52
GRS4
Purge Sequence
• Style 29 is used for Dispense Process 1 purge
sequence
• Style 30 is used for Dispense Process 2 purge
sequence
1. Set Segment [4(Process 1) or 5 (Process 2)]
2. <user to program a path from home to purge position here>
3. Purge
4. <user to program a path from purge position to home here>
GRS4 53
Tip Cleaning Sequence Style 29, Process 1
This routine is programmed by the user to implement the tip dressing
routine for the spot welding robots
1. Set Segment 4
2. StartTDMotor
3. <User to program path from home to tip dress position here or advance dump for
pedestal(s)>
4. TipDress [gun#X]
5. <User to program path from tip dress to home here or retract dump for pedestal(s)>
6. StopTDMotor
GRS4 54
Tip Cleaning Sequence Style 30, Process 2
This routine is programmed by the user to implement the tip dressing
routine for the spot welding robots
1. Set Segment 5
2. StartTDMotor
3. <User to program path from home to tip dress position here or advance dump for
pedestal(s)>
4. TipDress [gun#X]
5. <User to program path from tip dress to home here or retract dump for pedestal(s)>
6. StopTDMotor
GRS4 55
Enter Interference Zone
This is the request to enter the interference zone and the
cell controller signal clear to enter the interference zone
1. Reset ClearOfZone#
2. Post the message “Waiting for Interference Zone <Zone #> Clear to Enter”
on the teach pendant
3. Wait for Zone#Clear to be set by the cell controller
4. Post the message “Robot in Interference Zone <Zone #>” on the teach
pendant
GRS4 56
Exit Interference Zone
This is the request to exit the interference zone and zone
clear signal to be sent by the controller
1. Set ClearOfZone#
2. Post the message ”Robot Clear of Interference Zone <Zone #>” on the
teach pendant.
GRS4 57
Set Path Segment
A means will be provided to guarantee this instruction is
executed within a programmable distance of the
proceeding programmed position regardless of
programmed termination type
1. Set PathSeg equal to Segment #
2. Reset PathSegReqToCont
3. Post the message: ”Entering Path Segment <Segment #>” on the teach
pendant
GRS4 58
Request Continue
• A means will be provided to execute this instruction
within a programmable time of reaching the proceeding
programmed position such that path program
hesitation can be eliminated
• If the Continue OK indication is not received, path
motion will stop at the programmed position regardless
of the programmed termination type
GRS4 59
Request Continue (cont’d)
1. Reset the PathSegReqToCont
2. Wait for the PathSegContOK to be reset
3. Set PathSegReqToCont
4. Post the message ”Waiting for Continue” on the teach pendant
5. Wait for the PathSegContOK to be set by the cell controller
6. Capture the Decision Code and echo to cell controller using the ManDecisionCode
7. Post the message “Decision Code <DecisionCode> Received” on the teach pendant
8. If the Decision Code is 14 (cap change) then execute the pedestal cap change and return to the top of the program.
9. If the Decision Code is 15, (return home from pounce) and the robot is in path segment 1, return home.
10. If the Decision Code not valid stop and display fault message.
GRS4 60
Early Request to Continue
• The REQ_ERLY program allows the
robot to request to continue earlier
in the path without having to wait
for the Path Segment Continue OK
• In the program R[159] is used as a
flag to indicate that the request
was made
GRS4
61
Early Request to Continue (cont’d)
• In the REQ_CONT program the
robot will skip the request portion
of the code if R[159]=1
• This can help save cycle time by
starting the handshake and check
earlier
GRS4
62
Fault and Alert Handling
Upon the detection of a major fault (either by the process
equipment or by the robot application package), the robot
will:
1. Set the ‘Process # Fault’ signal to the PLC
2. When in ‘Interlock’ mode with ‘Process On Request’ input from the cell
interface on, halt robot motion and process
3. Display and indicate the major fault(s) and recovery options on the teach
pendant
4. Log the faults
GRS4 63
Fault and Alert Handling (cont’d)
• Faults and alerts will be handled on a first-come first-served basis.
• A fault will occur when the expected handshaking between the
robot controller and peripheral equipment is disrupted.
• For material handling faults, the user will be presented with the
option of disabling the checking of the input signal that caused the
fault for a maximum of 20 job cycles.
GRS4 64
Fault and Alert Handling (cont’d)
• Remote recovery will be available for process faults or when
waiting for the correct state of a proximity sensor / cylindicator
input (such as part present, clamp or gun retract).
– The remote recovery option will retry the action or retest the fault condition
upon receiving a robot system input from the cell controller.
– Remote recovery will not be available for some functions, which could result in
equipment damage, such as stud weld faults or water saver faults. These
cases are explicitly stated in the process sections of GRS-4.
GRS4 65
Fast Fault Recovery
An FFR option will be presented for process faults that occur during style
execution. When the FFR option is selected the robot will move through the
programmed path in no-process mode to a user defined position.
Once the fault has been corrected the robot will re-run the taught path and
complete the process. During the FFR, the robot will set the ‘FFRActive’
output on the cell interface.
GRS4 66
Fast Fault Recovery
No-Process Modes
Application FFR Application Mode Comments
Spot Welding No-stroke & No-Weld Activate Retract normally,

as per program instructions
Dispensing Dry
Stud Welding No-stroke & No-Weld
Arc Welding No-weld & No-weave
GRS4 67
Recovery Sequence
It will be possible for the user to implement FFR for an entire process or for
individual segments of a process path
FFR will be supported for either dual carried or dual pedestal processes
independently
For a combination of material handling with a carried process, FFR will be

supported whether material handling occurs before or after the process
GRS4 68
FFR Structure Program - Single Carried Weld
GO[1:Manual Style]=8 ;
ECHO OPTION ;
CALL STPR_CHK ;
CALL SPOUNCE ;
MAINT_PROG[1]=MOV_REPR;
CALL S08PROC1 ;
RUN CAPWEAR ;
MOVE TO HOME ;
WAIT(F1:CapWearComp);
GRS4 69
FFR Structure Program -
Material Handler with Pedestal Weld Process
GO[1:Manual Style]=8 ;
CALL TD_PD_CK ;
ECHO OPTION ;
IF DO[43:FFRActive]=ON, JMP LBL[99] ;
!FFR HANDLER ;
REQUEST CONTINUE ;
IF DO[43:FFRActive]=ON, JMP LBL[R[160]] ;
CALL S06DROP1 ;
CALL STPR_CHK ;
MOVE TO HOME ;
CALL SPOUNCE ;
CALL S06PICK1 ;
LBL[99:PROG END] ;
LBL[10:PROCESS 1] ;
R[160:FFR Process LBL]=10 ;
MAINT_PROG[1]=S06_FFR1;
CALL TDDMPCHK(1) ;
CALL S08PROC1 ;
GRS4 70
FFR Structure Program –
Multi-Part Carried Weld Gun
GO[1:Manual Style]=8 ; REQUEST CONTINUE ;
ECHO OPTION ; LBL[20:PART 2] ;
!FFR HANDLER ; IF (!DO[43:FFRActive]),DO[41:TaskOK]=ON ;
IF DO[43:FFRActive]=ON, JMP LBL[R[160]] ; R[160:FFR Process LBL]=20 ;
CALL SPOUNCE ; MAINT_PROG[1]=MOV_REPR ;
CALL STPR_CHK ; IF DO[43:FFRActive]=ON,CALL
LBL[10:PART 1] ; S08HOMTOPRT2 ;
R[160:FFR Process LBL]=10 ; CALL S08PART2 ;
MAINT_PROG[1]=MOV_REPR ; IF DO[43:FFRActive]=ON, CALL
CALL S08PART1 ; S08PRT2TOHOM ;
IF DO[43:FFRActive]=ON, CALL IF DO[43:FFRActive]=ON, JMP LBL[99] ;
S08PRT1TOHOM ; REQUEST CONTINUE ;
IF DO[43:FFRActive]=ON, JMP LBL[99] ;
GRS4 71
FFR Structure Program –
Multi-Part Carried Weld Gun
LBL[30:PART 3] ;
IF (!DO[43:FFRActive]),DO[41:TaskOK]=ON ;
R[160:FFR Process LBL]=30 ;
MAINT_PROG[1]=MOV_REPR ;
IF DO[43:FFRActive]=ON,CALL
S08HOMTOPRT3 ;
CALL S08PART3 ;
RUN CAPWEAR ;
MOVE TO HOME ;
LBL[99:PROG END] ;
GRS4 72
Student Exercise 3.1
Robot Cell Interface
Complete the exercise in your book.
73
Exercise 3.1
Exercise Solutions
74
Exercise 3.1: Robot Cell Interface: Solutions
Description Signal Name Robot Input
1. Complete Style (bit 1) StyleBit1 In25
the table. Style (bit 2) StyleBit2 In26
Style (bit 8) StyleBit8 In28
Tryout Mode Request TryoutModeReq In10
Initiate Style Program InitiateStyle In35
Path Segment Continue OK PathSegContOk In56
Interference Zone 1 Clear to ClearToEntrZone1 In37

Enter
Decision Code (Bit 1) DecisionCodeBit1 In49
Process 1 On Request Process1OnReq In65
75
(cont’d)
Description Signal Name Robot Output
2. Complete
Manual Style (Bit 1) ManualStyleBit1 Out25
the table.
Simulated I/O SimulatedIO Out34
Tryout Mode TryoutMode Out10
In Cycle InCycle Out11
Path Segment (Bit1) PathSementBit1 Out57
Robot Clear of Interference ClearOfZone1 Out37

Zone 1
Robot in Isolate InIsolate Out13
76
(cont’d)
2. (Continued) Process 1 One Joint Made Proc1OneJntMade Out72
Fast Fault Recovery Active FFRActive Out18
Process 1 Fault Process1Fault Out67
77
(cont’d)
3. Write the steps used to request to enter interference
zone 1.
1. Reset ClearOfZone1
2. Post the message “Waiting for Interference Zone 1 Clear to
Enter” on the teach pendant
3. Wait for ClearToEntrZone1 to be set by the cell controller
4. Post the message “Robot in Interference Zone 1” on the
teach pendant
78
(cont’d)
4. Write the steps used to exit interference zone 1.
1. Set ClearOfZone1
2. Post the message ”Robot Clear of Interference Zone 1” on
the teach pendant.
79
(cont’d)
5. What signal is required at the robot to leave the
pounce position?
The controller sends the “Decision Code Bits” (if required) and
sets the “Path Segment Continue OK” bit.
80
(cont’d)
6. What signal indicates to the robot that the style select
and option bits are valid?
Initiate Style
81
(cont’d)
7. When the robot returns home position what should
the clear of interference zone bits be set to?
On
82
(cont’d)
8. What are the steps the robot should complete upon
returning to the home position?
– Execute the Home Check to verify it is at the home position
– Execute the Housekeeping functions which resets the robot
outputs
– Execute the Special Functions
– Execute the Run Style program that monitors the signals
from the controller
– Return to the top of the list
83
(cont’d)
9. When the robot is switched to Automatic, what mode
should it default to?
Interlock Mode
84
(cont’d)
10. What style is used for:
Repair –
Style 31
Cap Change –
Style 27
Purge Dispense 1 –
Style 29
Purge Dispense 2 –
Style 30
Tip Maintenance –
Style 29 Proc.1, Style 30 Proc. 2 85
Module 3: Review - Robot cell Interface
Identify 5 of the robot to PLC interface signals.
1. Tryout Mode
2. Interlock/Isolate
3. Process Enable/Disable
4. System Level Signals, is limited to 8in/8out
5. Interference Zones
GRS4 86
Robot Software Requirements
Resistance Weld Controllers
87
Overall Mapping Assignment
Slot #
Address: 120.xxx.yyy.zzz Type DESCRIPTION
1 ADP PLC
2 SCN Weld Controller 1
3 SCN Weld Controller 2
4 SCN Dispense Controller
5 SCN Dispense Controller
6 SCN Stud Welder
7
8
9 SCN Self Piercing Rivet 1
10 SCN Self Piercing Rivet 2
11 SCN FDS Weber 1
12
13
14
15
16
17
18
GRS4-B1 19 88
Overall Mapping Assignment
Address 192.168.1.(Slot #) Type DESCRIPTION 45 SCN Spot Weld Carried Integrated Gun 1/ PW Gun1
20 SCN Tip Dresser Gun 1/Servo Dresser 46 SCN Spot Weld Carried/Pedestal Integrated Gun 1
21 SCN Spot Weld Pedestal Gun 1 47 SCN Spot Weld Carried Gun 1
22 SCN Spot Weld Pedestal Gun 2 48 SCN Watersaver1
23 SCN Spot Weld Pedestal Gun 3 49 SCN Spot Weld Carried Gun 2
24 SCN Spot Weld Pedestal Gun 4 50 SCN Watersaver2
25 51 SCN Spot Weld Carried Integrated Gun 2/ PW Gun2
26 52 SCN Spot Weld Pedestal Integrated Gun 2
27 53 SCN Vision
28 SCN Carried Cap Changer 54 SCN Tool Changer End Of Arm (Robot End)
29 SCN Material Handling Vacuum Pump 1 55
30 SCN Material Handling Vacuum Pump 2 56 SCN Tool Changer Nest 1
31 SCN Material Handling Valve Manifold 1 57 SCN Tool Changer Nest 2
32 SCN Material Handling Valve Manifold 2 58 SCN Tool Changer Nest 3
33 SCN Material Handling Valve Manifold 3 (new for G4) 59 SCN Tool Changer Nest 4
34 SCN Material Handling Input Block 1 60 SCN Analog Input Block
35 SCN Material Handling Input Block 2 61 SCN Balluff Analog Input Block
36 SCN Material Handling Input Block 3 62
37 SCN Material Handling Input Block 4 (new for G4) 63
38 SCN Tip Dresser Gun 2
41 SCN Integrated vision I/O Block 1
42 SCN Integrated vision I/O Block 2
43 SCN
44 SCN
GRS4-B1 89
Resistance Weld Controller Interface
• These signals are the communication between the
robot/ PLC and the resistance weld controller
• The vendor and the GM Vehicle Systems Engineers
will determine which inputs and outputs are to be used
from the available signals
GRS4-B1 90
Robot / PLC Inputs (Weld Controller Outputs)
The following signals are outputs from the weld controller to the robot or PLC
1. No Alert: The “No Alert” signal is set to indicate that there are no alerts present. If an
alert occurs the welder control will continue to operate.
The No Alert is reset by the ‘Fault Reset’ signal or when the condition that
prompted the alert clears.
2. No Fault: The “No Fault” signal is set to indicate that there are no faults present.
If the cause of the fault has not been removed after the ‘Fault Reset’ input has been
received, the weld controller will reset the fault after the release of the ‘Fault Reset’
signal.
If a fault(s) is present, the welder control will not cycle until all fault(s) are cleared.
GRS4-B1 91
(cont’d)
3. Weld Mode On: The “Weld Mode On’
signal is set to indicate the weld controller • The robot will compare the ‘Weld Mode On’
is in the weld mode and it will pass
current. The robot will check this signal
signal to its output (weld mode) to confirm that
prior to an initiate weld and will not review the weld controller is in the correct mode.
the signal during that weld.
4. Process Complete: The “Process

Complete” signal is set to indicate the
• This signal remains high until the ‘Initiate
requested schedule was completed and
no faults were generated. This signal also Weld‘ signal goes low.
needs to functions in the ‘no weld’ mode.
GRS4-B1 92
(cont’d)
5. Schedule In Progress: This signal is set to indicate a weld schedule is being executed. The signal drops
low after a ‘Process Complete’ signal or a fault is detected.
•This signal is a response to an initiate signal. While ‘Schedule In Progress’ is high and a schedule is being executed the weld mode
from the robot will be ignored by the weld controller.
6. All Steppers Reset: This signal indicates that the steppers have been reset. The robot will echo the reset
signal for Stepper Weld Controller to the cell controller using the ‘Process X Alert 2’ output.
7. Approaching Cap Change: This signal is an alert from the weld controller indicating that one or more of
the steppers are approaching a cap change or that the maximum number of tip dresses has been
achieved.
GRS4-B1 93
(cont’d)
8. Tip Dress Request: This signal is set to indicate the weld controller is requesting a tip
dress. The weld controller sets this signal after a successful weld, in conjunction with
‘Process Complete’ signal. It is set when the stepper has entered the preset step number
defined for requesting a tip dress. This request will not inhibit further welding cycles. This
signal is reset upon the next initiate.
9. Cap Change Request: This signal indicates a request from the weld controller to perform
a cap change on all guns. The weld controller will set a ‘Cap Change Request’ after a
successful weld. This request will not inhibit further welding cycles (within a preset limit) or
indicate a fault to the robot controller.
GRS4-B1 94
(cont’d)
10. Contactor Open: The “Contactor Open” signal indicates that the isolation contactor in
the weld controller is in the open state. It is not necessary to monitor the ‘contactor open’
signal at the robot. In the weld controller this signal is a pass-through from the isolation
contactor - auxiliary contact block.
11. Not Control Stopped: This signal indicates the weld controller is not in a control-stopped
state. The ‘Not Control Stopped’ signal is determined by the status of the hardware affected
by the 24V Control Stop input to the weld controller.
• The robot will communicate this signal for SWC 1 and SWC 2 to the cell controller using a
Process Equipment Message (for Process 1 – DO[105:doP1EqNotCtrlStopped]).
GRS4-B1 95
Robot / PLC Outputs (Weld Controller Inputs)
1. Binary Select Bits (1,2,4,8,16,32,64,128, 256, 512, 1024, 2048, 4096, 8192, 16384, 32768, 65536, 131072,
262144, 524288): The “Binary Select Bits” form a binary number between 1 and 1,048,575 used to select the weld
schedule. These bits will be set before or at the same time the “initiate weld” or “request pressure” input is received.
2. Initiate Weld: This signal is used to initiate the weld schedule after the binary bits have been set.
3. Weld Mode: This signal indicates the weld controller is requesting weld mode. The weld mode sent from the robot
will be read by the weld controller upon an initiate (and not reviewed until ‘Process Complete’).
•If ‘Weld Mode’ is low and a weld is initiated, the weld controller will execute a normal weld sequence (with the exception of
passing current) and with the isolation contactor open. If the robot detects a mismatch between this signal and the ‘Weld Mode’
input, a process fault will be set.
GRS4-B1 96
(cont’d)
4. Fault Reset: This signal resets the weld controller faults. If the cause of the fault has not been
removed, then the weld controller will reassert the fault after the release of the ‘fault reset’ signal.
5. Enable Contactor Saver: The “Enable Contactor Saver” signal is set to indicate to the weld
controller to hold the contactor closed for the time configured in the weld controller.
•This signal does not have to be set to initiate a weld. If ‘Enable Contactor Saver’ is low at the end of a schedule, the
contactor is opened.
•The weld control will not have any faults or alerts associated with this item. If this signal goes low after a successful weld
but prior to the isolation contactor saver timer timing out, the weld controller will open the contactor immediately.
GRS4-B1 97
(cont’d)
6. Caps Changed: This signal to the weld controller indicates that

all the steppers should be reset. The output remains on until the ‘All
Steppers Reset’ signal is received from the weld controller.
• Note: The tips dressed indication will be made through the use of schedules to the
weld controller. Schedules 61 and 62 are used for signaling that the respective tip
has been dressed. Use schedule 61 for gun 1 and schedule 62 for gun 2.
GRS4-B1 98
Hardwire Outputs
(Weld Controller Inputs)
1. Control Stop: When the “Control Stop” signal is set the welder control is allowed to operate.
When it resets the control will immediately stop all welds and open the isolation contactor. When a
control stop is received, the welder control will perform a safe and orderly shutdown, stopping all
welding current within one line cycle.
2. Transformer Overtemp: This signal is set to indicate that the transformer is operating within its
temperature range. When it is reset it will prevent the initiation of the weld schedules and
annunciate a fault. If it turns off during a weld schedule, the weld schedule will be completed and
then the fault will be set, prohibiting further welding.
• Note: this input is typically wired to the weld controller only in the case of manual welding.
GRS4-B1 99
Robot Inputs: SW 1
EIP Scanner ‐ Slot 2 EIP Scanner ‐ Slot 2
DI[#] Description Signal Name DI[#] Description Signal Name
1025 SW1 No Alert diSW1NoAlert 1042 SW1 Stepper Is Reset For GUN4 diSW1StepResetG4
1026 SW1 No Fault diSW1NoFault 1043 (Reserved) (Reserved)
1027 SW1 Weld Mode On diSW1WeldModeOn 1044 (Reserved) (Reserved)
1028 SW1 Process Complete diSW1ProcCmplt 1045 SW1 Tip Dress Request Gun 1 diSW1TDRequestG1
1029 SW1 Schedule In Progress diSW1InProgrss 1046 SW1 Tip Dress Request Gun 2 diSW1TDRequestG2
1030 (Reserved) (Reserved) 1047 SW1 Tip Dress Request Gun 3 diSW1TDRequestG3
1031 SW1 Contactor Open diSW1ContctrOpn 1048 SW1 Tip Dress Request Gun 4 diSW1TDRequestG4
1032 SW1 No Control Stop diSW1NoCtrlStop 1049 (Reserved) (Reserved)
1033 SW1 Approaching Cap Change Gun 1 diSW1ApprCpChgG1 1050 (Reserved) (Reserved)
1037 (Reserved) (Reserved) 1054 (Reserved) (Reserved)
1039 SW1 Stepper Is Reset For GUN1 diSW1StepResetG1 1056 (Reserved) (Reserved)
1040 SW1 Stepper Is Reset For GUN2 diSW1StepResetG2 1057 SW1 Cap Change Request for Gun1 diSW1CChngeReqG1
GRS4-B1 100
Robot Inputs: SW 1 (cont’d)
1059 SW1 Cap Change Request for Gun3 diSW1CChngeReqG3 1076 SW1 End of Part Reply diSW1EndPrtReply
1060 SW1 Cap Change Request for Gun4 diSW1CChngeReqG4 1077 SW1 Adaptive Capable diSW1AdaptiveCap
1063 SW1 Pressure Bit 1 diSW1Pressure1 1080 (Reserved) (Reserved)
1067 SW1 Read Pressure diSW1ReadPrssre 1084 (Reserved) (Reserved)
1072 (Reserved) (Reserved)
1073 SW1 Weld Process Stop diSW1ProcessStop
1074 SW1 Adaptive Reguation Off diSW1AdaptRegOff
1075 SW1 Adaptive Monitoring Off diSW1AdaptMtrOff
101
GRS4-B1
Robot Inputs: SW 2
1153 SW2 No Alert diSW2NoAlert 1170 SW2 Stepper Is Reset For GUN4 diSW2StepResetG4
1154 SW2 No Fault diSW2NoFault 1171 (Reserved) (Reserved)
1155 SW2 Weld Mode On diSW2WeldModeOn 1172 (Reserved) (Reserved)
1156 SW2 Process Complete diSW2ProcCmplt 1173 SW2 Tip Dress Request Gun 1 diSW2TDRequestG1
1157 SW2 Schedule In Progress diSW2InProgrss 1174 SW2 Tip Dress Request Gun 2 diSW2TDRequestG2
1158 (Reserved) (Reserved) 1175 SW2 Tip Dress Request Gun 3 diSW2TDRequestG3
1159 SW2 Contactor Open diSW2ContctrOpn 1176 SW2 Tip Dress Request Gun 4 diSW2TDRequestG4
1160 SW2 No Control Stop diSW2NoCtrlStop 1177 (Reserved) (Reserved)
1162 SW2 Approaching Cap Change Gun 2 diSW2ApprCpChgG2 1179 SW2 Gun1 Is Tip Dress Reset diSW2G1TDReset
1165 (Reserved) (Reserved) 1182 SW2 Gun4 Is Tip Dress Reset diSW2G4TDReset
1167 SW2 Stepper Is Reset For GUN1 diSW2StepResetG1 1184 (Reserved) (Reserved)
102
GRS4-B1
Robot Inputs: SW 2 (cont’d)
1187 SW2 Cap Change Request for Gun3 diSW2CChngeReqG3 1204 SW2 End of Part Reply diSW2EndPrtReply
1188 SW2 Cap Change Request for Gun4 diSW2CChngeReqG4 1205 SW2 Adaptive Capable diSW2AdptCapable
1195 SW2 Read Pressure diSW2ReadPrssre 1212 (Reserved) (Reserved)
1201 SW2WeldProcessStop diSW2ProcessStop
1202 SW2 Adaptive Reguation Off diSW2AdaptRegOff
1203 SW2 Adaptive Monitoring Off diSW2AdaptMtrOff
103
GRS4-B1
Robot Outputs: SW 1
DO[#] Description Signal Name DO[#] Description Signal Name
1025 SW1 Weld Mode doSW1WeldMode 1042 SW1 Binary Select 512 goSW1BinS512
1026 SW1 Fault Reset doSW1FaultReset 1043 SW1 Binary Select 1028 goSW1BinS1024
1027 SW1 Enable Contactor Saver doSW1EnContact 1044 SW1 Binary Select 2048 goSW1BinS2048
1028 (Reserved) (Reserved) 1045 SW1 Binary Select 4096 goSW1BinS4096
1030 SW1 Request Pressure doSW1ReqPrssre 1047 SW1 Binary Select 16384 goSW1BinS16384
1031 SW1 Initiate Weld doSW1InitWeld 1048 SW1 Binary Select 32768 goSW1BinS32768
1033 SW1 Binary Select 1 goSW1BinS1 1050 SW1 Binary Select 131072 goSW1BnS131072
1036 SW1 Binary Select 8 goSW1BinS8 1053 SW1 Weld BodyID 1 goSW1WeldID1
104
GRS4-B1
Robot Outputs: SW 1 (cont’d)
1059 SW1 Weld BodyID 64 goSW1WeldID64 1076 (Reserved) (Reserved)
1061 SW1 Stepper Reset Gun 1 doSW1StprRstGn1 1078 (Reserved) (Reserved)
1073 SW1 Part Finished doSW1PrtFinished
1074 SW1 Gun Resistance Check doSW1GnResistChk
1075 SW1 Reweld‐Turn Off Adaptive doSW1Reweld
105
GRS4-B1
Robot Outputs: SW 2
1153 SW2 Weld Mode doSW2WeldMode 1170 SW2 Binary Select 512 goSW2BinS512
1154 SW2 Fault Reset doSW2FaultReset 1171 SW2 Binary Select 1028 goSW2BinS1024
1155 SW2 Enable Contactor Saver doSW2EnContact 1172 SW2 Binary Select 2048 goSW2BinS2048
1158 SW2 Request Pressure doSW2ReqPrssre 1175 SW2 Binary Select 16384 goSW2BinS16384
1159 SW2 Initiate Weld doSW2InitWeld 1176 SW2 Binary Select 32768 goSW2BinS32768
106
GRS4-B1
Robot Outputs: SW 2 (cont’d)
1201 SW2 Part Finished doSW2PrtFinished
1202 SW2 Gun Resistance Check doSW2GnResistChk
1203 SW2 Reweld-Turn Off Adaptive doSW2Reweld
107
GRS4-B1
The following software requirements and specifications
have been developed for GM.
• Change between Process modes
• Weld Controller Checking
GRS4-B1 108
Process Modes
1. The ability to change the process mode between Process On (Weld) and Process Off (NoWeld) modes.
2. In Teach or Isolate mode of operation the Process On/Off mode will be selectable from the teach pendant.
3. In Interlock mode the status of the ‘Process X On Request’ input on the cell interface determines the process
mode. The ‘Process X On Request’ bit will be set to 1 for Process On (Weld) mode. The ‘Process X On Request’ bit
will be set to 0 for Process Off (No Weld) mode.
4. The ‘Weld Mode On’ bit will be set according to the ‘Process X On Request’ bit and sent to the weld controller.
5. In No Weld Mode, a means will be provided to select between Stroke and No Stroke modes.
GRS4-B1 109
Process Modes (cont’d)
When the robot is in No Stroke mode it will:
• Open to the backup distance stroke (if specified)
• Resuming path execution.
No Stroke will be utilized in Interlock mode during Fast Fault Recovery.
GRS4-B1 110
Process Equipment Check
1. The robot will check the status of the weld controller prior to
the start of any non-utility style program.
• It will verify weld controller is not faulted
2. If a fault is detected the controller will display an appropriate

message for the fault signal and allow for the following options.
• Retry
• Disable and continue
GRS4-B1 111
Programming Instructions
The following programming instructions need to conform to
specifications set forth by GM:
Spot Weld Instructions Cap Loss Detection
Gun Parameters Flow Monitoring
Welding Cycle Parameters Manual Functions
Pre-, In-, and Post- Weld Functions

Reset Stepper
One Joint Made
GRS4-B1 112
Spot Weld
• The spot weld instruction moves the robot to a
specific position and applies a spot weld.
• Parameters associated with motion for this instruction
will have the ability to be edited according to GM
GRS-1
• The termination type for this command will be
“CNTxxx” for ServoGuns
GRS4-B1 113
Gun # and Schedule Parameters
• The user will be able to specify one schedule per gun
for up to two guns.
• The following parameters can be set for each weld
location
– Weld Identification - Each spot will have a minimum of eight ASCII characters
that are used to identify the weld.
– Starting Distance – Distance the gun should be opened going to the weld
– Pressure – Pressure schedule number to use from the pressure table
– Weld Schedule – Schedule number to send to the weld controller
– Thickness – Used for thickness verification
– Ending Distance – Distance the gun should open after the weld
GRS4-B1 114
Spot Welding Cycle
1. The robot will be able to control up to two SCR’s and four weld guns. The program will be able to
simultaneously weld with two guns on separate SCR’s in a single spot welding instruction.
2. When two welds are required sequentially at a given path location, the program will be able to
execute the spot welding cycle in a single spot instruction or in two separate spot instructions.
• The amount of time it takes to complete these two welds will be no more than 50ms greater
than the larger single spot welding cycle (providing no faults occur).
3. The gun will close as the robot approaches the weld location. After the weld is complete the
robot will wait for the servo gun to open the proper distance before continuing.
GRS4-B1 115
Pre-Weld Functions
The gun will start to close as the robot is moving toward the position. The following will also be
checked while moving to the weld location:
1.Water saver
2. Transformer
3. Enable contactor
4. Close gun. The following steps are included in closing the gun: :
• Close gun
• Set weld schedule
GRS4-B1 116
In-Weld Functions
During the weld the robot will perform the following steps:
1. Initiate the weld
2. Verify the weld schedule is in progress
3. Reset the weld schedule
4. Verify the process completed
5. Check the weld alert
GRS4-B1 117
Post-Weld Functions
The robot will perform the following steps after the weld is completed:
1. Check stepper status – Signal the cell controller if required.
2. Check the tip dress – Signal the cell controller if required.
3. Reset the ‘Initiate Weld’ bit
4. Reset the ‘Process Fault’ bit
5. Open the gun.
GRS4-B1 118
One Joint Made
The signal ‘OneJointMade’ is to be set after the first 'successful' weld, rivet, or screw is
made in a style.
This signal is only to be set if the weld controller is in weld mode and the ‘Process Complete’
signal is received from the weld controller and no faults occur during the weld.
The signal is reset during the 'Housekeeping Routine'.
GRS4-B1 119
Cap Loss Detection and Flow Monitoring
The ‘Cap Loss Detection’ bit will be checked prior to every

weld, with the exception of when the water saver is
bypassed.
The ‘Flow Ok to Weld’ bit is to be checked prior to every

weld.
GRS4-B1 120
Manual Functions
Manual functions will be available to allow the user the
appropriate control of the configured peripheral
equipment for the purposes of programming and
troubleshooting.
GRS4-B1 121
Manual Spot Weld
• The manual spot weld feature allows the operator to
initiate a particular spot weld schedule on the selected
gun
• The user selections will be retained for repeated
execution of this feature
GRS4-B1 122
Reset Stepper
This feature will reset a stepper for the selected SCR(s)
by executing the appropriate weld sequence (61 for Gun
1, 62 for Gun 2) without closing the gun.
GRS4-B1 123
Fault Handling and Recovery-Auto Retry
The robot will be able to automatically open the gun and retry a
faulted weld up to three times
The default retries will be 0 and the maximum number of retries

will be 3
The robot will communicate each retry to the PLC via the ‘Process
X Alert’ signal and post a message to the teach pendant
GRS4-B1 124
Fault Handling and Recovery - Weld Fault
The following recovery options will be available when a fault or weld complete timeout
occurs during the spot weld sequence:
1. Retry – Selecting Retry will initiate a new weld cycle.

2. Skip – Selecting Skip will drop ‘Task OK’, and move to the next weld location.
3. FFR – Refer to the FFR section below.
4. Abort – Selecting Abort will cancel any user program execution, robot motion,
or process execution.
Remote recovery capability will be supported for this type of fault. The response to a
robot specific remote input on the cell controller interface will be to retry the current weld
GRS4-B1 125
Fast Fault Recovery
The recovery sequence will begin when Fast Fault Recovery (FFR) is
active and the robot has finished moving through the programmed path
in ‘No-Process’ mode.
Carried applications will be handled differently than pedestal applications

during the FFR.
GRS4-B1 126
Carried Application
If the application is carried only:
1. The robot starts at the home position.
2. Execute the style program Repair. When the robot is in the repair position the process mode will
default to “ON” to allow full functionality to execute and test the results of repair operations.
3. The robot will be in a state where a ‘Remote Reset’ and ‘Cycle Start’ from the cell controller will
cause the robot to execute the path from repair to home.
GRS4-B1 127
Carried Application (cont'd)
4. The user will be able to turn process mode “OFF” and have the following process
options when the repair style has been completed:
• Continue Last – Begin the re-weld process with the faulted weld
• Continue Next – Drop the ‘Task OK’ bit and begin the re-weld process with the first spot after the faulted weld.
• Abort – Cancel any user program execution, robot motion, or process execution.
5. The robot will restart the application process path and finish the process according
to the user-selected option.
GRS4-B1 128
Pedestal Application
If the application is pedestal:
1. Execute a user-defined path that moves the robot from the final position in the process path to a repair position for
service.
2. Turn process mode “ON”
3. Present the following options to operator:
•Continue Last – Begin the re-weld process with the faulted weld.
•Continue Next – Drop the ‘Task OK’ bit and begin the re-weld process with the first spot after the faulted weld.
•Abort – Cancel any user program execution, robot motion, or process execution.
4. Turn process mode “OFF” and execute the user-defined path that moves the robot from the repair position to the
starting position of the process path and execute the process path according to the user-selected option.
GRS4-B1 129
FFR with Dual Pedestal Process
GRS4-B1 130
Exercise 3.2: Resistance Weld Controller
Resistance Weld
– Complete the Exercise in your book.
131
Exercise 3.2
Exercise Solutions
132
Exercise 3.2: Resistance Weld Controller:
Solutions
1. Complete the Table
Description Signal Name Robot Input
SW1 No Alert diSW1NoAlert 1025
SW1Stepper is Reset for GUN 1 diSW1StepResetG1 1039
SW1 Cap Change Request for Gun 2 diSW1CChngeReqG2 1058
SW1 No Fault diSW1NoFault 1026
SW1 Weld Mode On diSW1WeldModeOn 1027
SW1 Process Complete diSW1ProcCmplt 1028
SW1 Schedule in Progress diSW1InProgrss 1029
SW1 Tip Dress Request Gun 1 diSW1TDRequestG1 1045
SW1 Contactor Open diSW1ContctrOpn 1031

GRS4-B1 133
Solutions (cont’d)
2. Complete the Table
SW2 Weld Mode doSW2WeldMode 1153
SW2 Fault Reset doSW2FaultReset 1154
SW2 Binary Select 4096 goSW2BinS4096 1173
SW2 Initiate Weld doSW2InitWeld 1159
SW2 Binary Select 1 goSW2BinS1 1161
SW2 Enable Contactor Saver doSW2EnContact 1155
SW2 Stepper Reset Gun 1 doSW2StprRstGn1 1189
GRS4-B1 134
3. Write a subroutine to move the robot with a carried
weld gun to the Repair Position. Wait for a repair
complete signal from the operator to return to home.
Don’t forget to add the segment path values.
1. Echo Style 31 (move to repair) to the cell controller
2. SetSegment [2]
3. <User to program the path from home to repair here>
4. Wait for continue (cell controller or user input to the robot)
5. SetSegment [3]
6. <User to program the path from repair to home here>
GRS4-B1 135
4. Write the steps that are in the Request to Continue
macro
– Reset PathSegReqToCont
– Wait for the PathSegContOK to be reset
– Set PathSegReqToCont
– Post Message “Waiting for Continue”
– Wait for PathSegContOK
– Capture Decision Code and echo to cell controller using ManDecisionCode
– Post Message “Decision Code Received”
– Reset PathSegReqToCont
GRS4-B1 136
5. What robot input signal indicates the weld was
completed without errors?
Process Complete
GRS4-B1 137
6. Which robot controller outputs are used to set the
weld schedule?
– Binary Select Bits
– Initiate Weld
GRS4-B1 138
7. What will be the state of the ‘No Fault’ bit from the
controller after a fault reset from the robot is received
but the fault still exists?
No Fault will be low
GRS4-B1 139
8. What are the 4 steps that should be performed before
the weld position?
– Check Water saver
– Check Transformer
– Enable contactor
– Close gun.
GRS4-B1 140
9. What are the 5 steps that should be performed after
the weld is completed?
– Check stepper status – Determine if the cell controller is
requesting a cap change.
– Check the tip dress – Determine if the cell controller is
requesting a tip dress.
– Reset the ‘Initiate Weld’ bit
– Reset the ‘Process Fault’ bit
– Open the gun.
GRS4-B1 141
10. What is the purpose of the One Joint Made signal?
This signal indicates the robot has successfully completed a weld
spot in weld mode.
GRS4-B1 142
Module 3: Review – Robot to Resistance Weld
Controller
Identify 4 of the robot to resistance weld
controller interface signals.
1. Process Complete
2. Weld Mode On
3. All Steppers Reset
4. Tip dress request
GRS4-B1 143
Resistance Weld Water Saver

and Tip Dress Interface
144
Water Saver Outputs / Robot Inputs
1. Water Saver Aux Power OK: This signal indicates that auxiliary power for output(s) is available.
2. Flow OK To Weld: This signal indicates that the water saver is reset and has adequate flow.
3. Minimal Flow: This signal indicates that the water saver is reset and there is minimal flow at the tips.
4. Water Saver Tripped: This signal indicates that the weld water saver has detected a cap loss.
5. Water Valve Closed: This signal indicates that the weld water valve is in the “off” position.
6. Water Saver Bypassed: This signal indicates that the weld water saver is in the bypass state.
GRS4-B2 145
Water Saver Inputs / Robot Outputs
1. Reset Water Saver: This signal resets the water saver.
2. Water Off: This signal shuts the water off at the water saver.
3. Bypass Water Saver: This signal puts the water saver in bypass.
GRS4-B2 146
Robot Inputs and Outputs: Water Saver 1 and 2
DI[#] Description Signal Name DO[#] Description Signal Name
1441 Spot Weld Gun 1 W/S Flow OK to Weld diG1WS_OktoWeld 1441 Reset water saver G1 (flow on) doRstG1WaterSvr
1442 Spot Weld Gun 1 W/S Valve Closed diG1WS_ValveClsd 1442 Water off G1 (flow off) doG1Wateroff
1443 Spot Weld Gun 1 W/S Bypass on diG1WS_Bypassed 1443 Bypass Water saver G1 (flow on) doG1WSBypass
1444 Spot Weld Gun 1 W/S Minimal flow diG1WS_MinFlow 1444 (Reserved) (Reserved)
1445 Spot Weld Gun 1 W/S Tripped/Cap Loss diG1WS_CapLoss 1445 (Reserved) (Reserved)
1447 (Reserved) (Reserved) 1447 (Reserved ) (Reserved)
1448 Spot Weld Gun 1 Water Saver Aux. Power OK diG1WS_PowerOK 1448 (Reserved) (Reserved)

DI[#] Description Signal Name DO[#] Description Signal Name
1449 Spot Weld Gun 2 W/S Flow OK to Weld diG2WS_OktoWeld 1449 Reset water saver G2 (flow on) doRstG2WaterSvr
1450 Spot Weld Gun 2 W/S Valve Closed diG2WS_ValveClsd 1450 Water off G2 (flow off) doG2Wateroff
1451 Spot Weld Gun 2 W/S Bypass on diG2WS_Bypassed 1451 Bypass Water saver G2 (flow on) doG2WSBypass
1452 Spot Weld Gun 2 W/S Minimal flow diG2WS_MinFlow 1452 (Reserved) (Reserved)
1453 Spot Weld Gun 2 W/S Tripped/Cap Loss diG2WS_CapLoss 1453 (Reserved) (Reserved)
1455 (Reserved) (Reserved) 1455 (Reserved ) (Reserved)
1456 Spot Weld Gun 2 Water Saver Aux. Power OK diG2WS_PowerOK 1456 (Reserved) (Reserved)
GRS4-B2 147
Tip Dresser Outputs– Robot Inputs
Each robot will control its own tip dressers(s). Robots cannot share the same tip
dresser(s)
1. Motor Running: This signal indicates that the tip dress motor is
running.
2. Motor Current: Group of16 bits that represent the motor current.
3. Phase Lost: This signal indicates that the tip dress motor starter has
detected a fault on the power feed to the motor.
4. Trip: This signal indicates that the overload has tripped.
5. Overload: An overload condition on the motor starter.
6. Phase Imbalance: This signal indicates that there is a current
imbalance between the three phase motor power.
GRS4-B2 148
Tip Dresser Signal Definitions - Robot Outputs
1. Tip Dress Motor Start: This signal initiates the tip dress motor starter and starts the motor.
An auxiliary contact off of the motor starter is used to energize the blow off valve.
2. Tip Dress Trip Reset: This signal resets the overload/ trip fault in the motor starter.
3. Blow Off On: Turns on the blow off to keep the cutter clean.
GRS4-B2 149
Robot Inputs: Tip Dresser 1
EIP Scanner ‐ Slot 20 EIP Scanner ‐ Slot 20 EIP Scanner ‐ Slot 20
DI[#] Description Signal Name DI[#] Description Signal Name DI[#] Description Signal Name
1473 Trip diTD1Tripped 1489 Short Circuit diTD1ShortCrt 1505 Motor Current Bit 1 diTD1Current
1474 (Reserved) (Reserved) 1490 Overload diTD1Overload 1506 Motor Current Bit 2 diTD1Current
1475 Motor Running diTD1RunningFWD 1491 Phase Loss diTD1PhaseLost 1507 Motor Current Bit 3 diTD1Current
1476 (Reserved) (Reserved) 1492 (Reserved) (Reserved) 1508 Motor Current Bit 4 diTD1Current
1477 Ready diTD1Ready 1493 (Reserved) (Reserved) 1509 Motor Current Bit 5 diTD1Current
1478 (Reserved) (Reserved) 1494 Control Power Lost diTD1CntPwrLoss 1510 Motor Current Bit 6 diTD1Current
1479 (Reserved) (Reserved) 1495 Fault diTD1Fault 1511 Motor Current Bit 7 diTD1Current
1481 (Reserved) (Reserved) 1497 Phase Imbalance diTD1PhaseImb 1513 Motor Current Bit 9 diTD1Current
1485 Keypad On diTD1KeyPadOn 1501 (Reserved) (Reserved) 1517 Motor Current Bit 13 diTD1Current
1486 Disconnect On diTD1DiscOn 1502 Hardware Fault diTD1HWFault 1518 Motor Current Bit 14 diTD1Current
GRS4-B2 150
Robot Inputs: Servo Tip Dresser
Servo Tip Dresser Servo Tip Dresser for Pedestal

1473 (Reserved) (Reserved) 1681 Spot Weld Gun1Aux. Power OK diG1PowerOK
1474 (Reserved) (Reserved) 1682 Spot Weld Gun 1 Retract Closed diG1RetClosed
1475 (Reserved) (Reserved) 1683 Spot Weld Gun1 Backup Retract diG1RetOpened
1476 (Reserved) (Reserved) 1684 Spot Weld Gun1 Transformer Over Temp diG1TransOT
1477 (Reserved) (Reserved) 1685 Tip Dress dump AdvancedG1 diG1TDDumpAdv
1478 (Reserved) (Reserved) 1686 Tip Dress dump retractedG1 diG1TDDumpRet
1479 (Reserved) (Reserved) 1687 Weld Gun Pressure AchievedG1 diG1PresAchieved
1480 (Reserved) (Reserved) 1688 Tip Dress Dump Pin diG1TDDumpPin
GRS4-B2 151
Robot Outputs: Tip Dresser 1-4
1473 Motor On doTD1MotorOn 1521 Motor On doTD2MotorOn
1475 Fault Reset doTD1FaultReset 1523 Fault Reset doTD2FaultReset
1479 Blow Off On doTD1BlowOffOn 1527 Blow Off On doTD2BlowOffOn

1569 Motor On doTD3MotorOn 1617 Motor On doTD4MotorOn
1571 Fault Reset doTD3FaultReset 1619 Fault Reset doTD4FaultReset
1575 Blow Off On doTD3BlowOffOn 1623 Blow Off On doTD4BlowOffOn
GRS4-B2 1576 (Reserved) (Reserved) 1624 (Reserved) (Reserved) 152

Robot Outputs: Servo Tip Dresser
Servo Tip Dresser

EIP Scanner ‐ Slot 20
DO[#] Description Signal Name
1473 doTdBlowoffG1 doTdBlowoffG1
GRS4-B2 153
Module 3: Review – Water Saver Interface
Identify 5 of the water saver outputs – robot
inputs
1. Water Saver Aux Power
2. Flow OK To Weld
3. Minimum Flow
4. Water Saver Tripped
5. Water Valve Closed
6. Water Saver Bypassed
GRS4-B2 154
Servo Guns
155
Integrated Servo Gun
The integrated servo gun manual (GRS4-B3)

contains the GM standard for the robot seventh-axis
It covers the standard interface between robots and

all OEM equipment
GRS4-B3 156
Drive System Requirements
Compatibility
1. The seventh-axis robot control system will interface with all GM

approved servo weld gun suppliers per MD-1 and WG-001.
2. The seventh-axis drive will be compatible with:
a. Tol-O-Matic HT and SW series servo systems
b. Aro water-cooled servos
c. Robot manufacturer servos (e.g. Fanuc, ABB, Kuka)
3. Seventh-axis system will interface to the robot Auto Stop, General
Stop, E-Stop, and enabling device in the same manner as primary
axes.
GRS4-B3 157
Tip Forces
1. The servo gun system will be able to handle all gun forces required by
the WS-1 and WG-01 specifications.
2. The gun tip force will not deviate more than 2% of the programmed gun
force (for direct acting gun, i.e. the actuator is solely responsible for tip
force).
3. The drive system will be able to handle forces ranging from 890 – 8450
Newtons (200lb –1900lb).
GRS4-B3 158
Configurations
1. Configurations for carried and pedestal pneumatic weld guns will

be supported for servo guns.
2. Single point (pogo) servo guns will be supported.
3. Hard automatic (nobot) servo guns will be supported. The nobot
will have the capability to control at least 6 guns individually or
simultaneously in any combination.
GRS4-B3 159
Seventh-Axis Control Software Requirements
Gun Setup
1. Robot servo gun software will provide a setup utility for the creation of new servo
gun definitions.
2. The minimum gun parameters for a new servo gun definition are:
a. Gun opening distance
b. Gun closing distance
c. Servomotor rotation to gun tip displacement ratio
d. Maximum gun force
3. The typical gun mastering position is with gun tips closed but other conditions can
be supported.
4. Robot will maintain gun mastering position and parameters during a robot
controller power failure.
GRS4-B3 160
Tip Force and Velocity

1. The servo gun software will provide a gun calibration utility for proper
gun force calibration. The gun calibration must increase tip force
accuracy to within 2% deviation or less.
2. Servo gun system will dynamically maintain and monitor gun force
during weld execution.
3. The robot will coordinate the seventh-axis electrode velocity to meet the
metal at the programmed position without decreasing the maximum
robot speed.
4. The seventh-axis servo must match the maximum robot speed.
GRS4-B3 161
Programmable Gun Opening Distance
1. The servo drive system and actuator will handle the full gun open and closed positions.
2. The gun opening will be able to be programmable at any point within the robot program.
3. The gun open and close positions will be within 1 cm of the maximum mechanical actuator
unit over-travel position. This distance will prevent the opening or closing of the gun to the
mechanical limit of the gun actuator.
4. Pre-programmed gun openings should be listed in a table for later use during robot
programming.
5. Pre-programmed gun openings are to be manually entered by the robot programmer.
6. Gun openings must be individually labeled in the gun-opening table.
GRS4-B3 162
Software Gun Centering
1. Gun centering is defined as the automatic process in which both

gun arms (stationary and movable) travel with coordinated
motion to the programmed metal surface (taught position).
2. The travel distance of the stationary arm (distance from metal to
stationary cap) can be unique and programmed for each weld
pressure in the pressure table.
3. The robot software must provide the option to enable or disable
automatic software gun centering.
GRS4-B3 163
Software Gun Equalization

1. Gun equalization is defined as the automatic process in which the stationary gun
arm will search for the actual metal position within the programmed metal surface.
2. The robot will close the gun at the location where stationary gun finds the actual
metal position and initiate the weld sequence.
3. Software gun equalization will be available as an option. With the option, the
Servo Gun Control System will be configurable to enable or disable software
equalization.
GRS4-B3 164
Gun Deflection Compensation

• Robot servo gun software will have the ability to compensate for elasticity that is present in the
stationary gun arm of the servo weld gun moving “into the metal” while closing the gun.
• The deflection distance will be either a measured value for each weld force, or an interpolated
value based on a curve that is established during a calibration procedure.
GRS4-B3 165
Tip Wear Compensation
1. Robot servo gun software must offset the “Fixed Weld Tip Position” relative to the
gun TCP to allow for cap wear or cap change.
2. The system should provide more than one method of measuring cap wear in order
to optimize accuracy.
3. The software will provide a programming instruction to initiate the measurement of
worn caps and offset the gun TCP accordingly.
4. The software will provide a programming instruction to initiate the measurement of
new caps and offset the gun TCP accordingly.
GRS4-B3 166
Tip Wear Compensation (cont’d)
5. A servo gun status screen will be provided to display current cap wear amounts
on both gun arms.
6. Cap wear and cap change offset ratios will be manually adjustable. The user will
be able to change cap wear ratios from 50/ 50 Top / Bottom Cap to a user defined
ratio.
7. The software will provide automatic calculation of actual wear by comparison to a
reference surface.
8. The software will provide a means to initiate the “cap wear” instruction based on a
user programmable cumulative number of welds. This will occur while the robot is
at the home position and running Mainline Shell (refer to GRS-4A).
GRS4-B3 167
Tip Wear Compensation (cont'd)
9. The software will provide a user programmable value for maximum cap wear
that generates an error when exceeded. The error detection will be
configurable to:
a. Alarm – Set a warning that there are out of tolerance values.
b. Fault – Stop the process because of out of tolerance values.
c. None – Do nothing for out of tolerance.
GRS4-B3 168
Measurement of Part Thickness

1. The servo gun will be able to detect part thickness +/- 0.1mm.
2. Thickness detection will be programmable for each weld.
3. Thickness detection will also be provided as a program instruction or a
user initiated function. (e.g. THICKNESS [1.5] for a 1.5mm thickness
detection).
4. Thickness error detection will be configurable to:
a. Alarm – Set a warning that there are out of tolerance values.
b. Fault – Stop the process because of out of tolerance values.
c. None – Do nothing for out of tolerance.
GRS4-B3 169
Measurement of Part Thickness (cont’d)

5. An error will be generated for a reading that is less than or
greater than programmed dimension.
6. Out of tolerance values will be user programmable.
GRS4-B3 170
Soft Touch
1. Servo gun must automatically decelerate the electrode speed to

be no greater than 10% at a 2mm-creep distance.
2. The servo gun software, using the metal thickness as a reference
value, must automatically generate a creep distance of 2mm.
3. Soft Touch creep distance for each gun arm will be manually
adjustable and programmable for each weld.
GRS4-B3 171
Jogging and Programming
1. The gun electrode will be jogged from the robot teach pendant.
2. The servo gun software will prevent the gun from jogging outside the gun
opening or closing limits.
3. The software will prevent the gun from exceeding the maximum gun force
when being closed. The software will monitor servo torque to avoid gun
damage due to excessive gun pressure outside designed gun limits.
4. The gun will maintain selected teach speed T1 or T2 per GRS-1.
5. The spot weld positions will be taught with the stationary tip touching the
metal at the weld location. The software will automatically compensate for
the taught position via creep distance during path execution.
GRS4-B3 172
Process Software Requirements
The servo gun system will be compatible with the
requirements of GRS-4 Section B1 (Resistance Weld
Controller Interface) and GRS-4 Section B2 (Resistance
Weld Dense Pack Interface) with the additions/exceptions
described in this section.
GRS4-B3 173
Spot Weld Cycle
1. Tip force will be programmable for each weld.
2. The gun tip force settings will be listed in a pressure table at the robot. The GRS-4 B1 weld pressure
interface does not apply to servo gun applications.
3. It will be possible to manually label the gun forces with a description.
4. The system will initiate the weld cycle when the pressure and metal thickness are both achieved.
5. If there is a fault during the weld sequence the robot will generate an error. During the error recovery
process, the gun will re-open and then reinitiate the weld sequence.
GRS4-B3 174
Process Modes
Tryout Mode
1. A means will be provided to select tryout mode when welding

is performed without metal.
2. In Teach or Isolate the tryout mode will be selectable from the
teach pendant.
3. In Interlock the status of the ‘Tryout Mode Request’ input on
the cell interface will select the tryout mode.
4. The tryout mode status will be communicated to the cell
controller using the ‘Tryout Mode’ output.
5. In Tryout Mode the system will ignore the metal thickness
condition but still keep the programmed gun force and initiate
the weld sequence when gun force is achieved.
GRS4-B3 175
Process Modes
Weld / No Weld
• Weld and No Weld modes, as defined in GRS-4 Section B, will apply to
servo gun operation.
• In No Weld the robot will maintain all servo gun functions including
software equalization or gun centering and programmed gun force.
GRS4-B3 176
Process Modes
Stroke / No Stroke
1. Stroke and No Stroke modes, as defined in GRS-4 Section

B1, will apply to servo gun operation.
2. In No Stroke the robot will temporary disable the software
equalization or the gun centering and execute the
programmed path.
3. In No Stroke, the stationary gun arm will move to the taught
point (stationary cap touching the metal surface).
GRS4-B3 177
Process Modes
Tip Dressing
1. A program instruction will be provided to close the servo gun at the tip
dress cutter using software equalization or gun centering and the selected
tip dress pressure.
2. Both gun tips must close at the tip dress cutter without executing a weld
sequence or sending a non-weld schedule.
3. The gun close instruction can be used as a discrete robot operation or
included in a robot move instruction.
GRS4-B3 178
Module 3: Review – Servo Guns
Identify 4 of the robot to integrated servo gun
controller requirements.
1. The integrated servo gun contains the GM standard for
the robot seventh-axis. It covers the standard interface
between robots and all OEM equipment.
2. The servo gun system will be able to handle all gun forces
required by the WS-1 and WG-01 Specifications.
3. The gun tip force will not deviate more than 2% of the
programmed gun force (for direct acting gun, i.e. the
actuator is solely responsible for tip force).
4. The drive system will be able to handle forces ranging
GRS4-B3 from 890 – 8450 Newton’s (200lb –1900lb).
179
Dispense Interface
180
Robot Inputs - Dispense Controller Outputs
1. Dispenser Ready: This signal indicates that the dispenser is functioning properly with no faults
and ready for a dispense cycle. This signal requires the dispenser to be in the automatic mode and
at the proper temperature (if applicable). The “Dispenser Ready’ signal will be reset during a
remote start, when a fault occurs, or when the system is depressurized.
•When the system is not ready the ‘Dispense Ready’ signal will be reset. The not ready condition will be sent to the cell
controller using the ‘Process X Tip Maintenance Request’ signal.
2. No Fault: This signal is reset when a fault has occurred within the dispensing equipment.
GRS4-C 181
(cont’d)
3. No Alert: This signal is reset when an alert has occurred within the dispense equipment.
The dispenser tracks alerts and they may result in a major fault after a specified number of
occurrences.
• When an alert is detected the robot will set the ‘Process X Alert 1’ output on the cell interface. An alert will not
override processing of the ‘Volume OK’ signal or prevent by itself the setting ‘Task OK’ high.
4. Dispense In Process: This signal indicates that the dispense system has received a valid
style and is in the dispensing process. Resetting this signal while the ‘Dispense Complete’
robot output is set causes the robot to read the ‘Volume OK’, ‘No Fault’ and ‘No Alert’
signals from the dispenser.
GRS4-C 182
(cont’d)
5. Area Volume OK: This signal indicates that the volume dispensed for the given area was completed within the defined limits
6. Total Volume OK: This signal indicates that the volume dispensed for the given style was completed within the defined limits
of the dispense controller. ‘Total Volume OK’ is reset when the robot turns off the ‘Style Strobe’ output. The ‘OFF’ state of this
signal will be checked by the robot prior to setting ‘Style Strobe’ at the beginning of a dispense sequence.
7. Remote Start / Purge In Process: This signal indicates that a remote start has been initiated by the dispense controller. The
‘Remote Start’ remains set until the dispense equipment has achieved ‘Dispense Ready’ status. The remote start process
includes performing a metered or non-metered purge according to parameters defined within the dispense controller.
GRS4-C 183
(cont’d)
8. Drum Empty: This signal indicates that one or both material supply drums are
empty. The ‘Drum Empty’ signal will be interconnected to the appropriate
‘Process X Alert 2’ robot output on the cell interface.
9. Purge Request: This signal is a request to purge the system due to dispense
inactivity. A user definable time set in the dispense controller determines when a
purge is necessary. ‘Purge Request’ status will be communicated to the cell
controller using the ‘Process X Tip Maintenance Request’ signal.
GRS4-C 184
Robot Outputs - Dispense Controller Inputs
1. Style ID Bits (1,2,4,8,16,32,64,128): This group of signals form an eight-bit binary number output that is used to
relay the style information to the dispenser. The style ID bits will be set before the ‘Style Strobe’ is set and drop low
after the ‘Dispense In Process’ is received. A volume target with tolerance limits will be associated with each style
in the dispenser. A fault will be sent to the robot if the volume is not within the specified limits.
2. Style Strobe: A signal indicating that the style bits are set, per body style, and ready for the dispenser to read
them. This bit will remain high until after volume and fault information are read at the end of the dispense cycle. The
robot will reset this signal when a dispense sequence is interrupted.
3. Gun X On (1,2,3,4,): The ‘Gun X On’ signals are discreet signals to the dispenser to turn on guns one through
four. Any combination of the guns may be on at any given time.
GRS4-C 185
(cont’d)
4. Total Dispense Complete: This signal is set when the dispense cycle is completed. This
signal will initiate the dispense controller to perform the volume calculations for the current
job. Based on the volume dispensed, the ‘Volume OK’ signal and/or the ‘Alert’ signal may
be set.
• A fault could be reported based upon the volume dispensed. The ‘Dispense Complete’ signal will be reset after
the ‘Volume OK’ signal is set or a fault signal is detected.
5. Area Volume Complete: This signal is set to check the volume of a certain area that was
just completed
GRS4-C 186
(cont’d)
6. Dispense Material Flow Command (1,2,4,8,16,32,64,128,256,512,1024,2048) - Analog:

This 12 bit binary output represents an analog signal between 0 to 10 V. The analog signal
controls the dispense flow rate.
• This is a binary representation of an analog signal that is proportional to the TCP speed of the robot.
7. Bead Shaping Command (1,2,4,8,16,32,64,128,256,512,1024,2048) - Analog: This 12 bit

binary output represents an analog signal between 0 to 10 V. This signal controls the bead
shaping of the dispensed material. It is possible to control the bead-shaping signal by direct
entry (straight voltage) or as a TCP speed proportional signal.
GRS4-C 187
(cont’d)
8. Remote Start: This signal restarts the dispense system from any “not-ready”
state.
9. Purge: This signal initiates a purge according to parameters in the dispense

controller.
10. Shutdown Command: This command will shutdown the dispense controller
and put it in an idle state. It can be awakened using the remote start command
GRS4-C 188
(cont’d)
11. Fault Reset: The fault reset starts the fault recovery procedure and
attempts to reset a fault condition. If the cause of the fault has not been
removed, then the fault will be resent after the release of the ‘Fault Reset’
signal. The dispense controller also uses this signal to cancel an abandoned
style sequence and reinitialize itself for the next cycle. The dispense controller
checks that this signal is low prior to setting ‘Dispense in Process’ at the
beginning of a dispense sequence. If the fault reset is in the incorrect state
(set), the dispenser will report the fault.
GRS4-C 189
Dispense Controller 1 Outputs / Robot Inputs
1025 Dispense1 Ready diSL1Ready 1041 (Reserved) (Reserved) 1057 Process1 Data Total Volume Bit 1 diSL1TotalVolB1
1026 Dispense1 NO Fault diSL1NOFault 1042 (Reserved) (Reserved) 1058 Process1 Data Total Volume Bit 2 diSL1TotalVolB2
1027 Dispense1 NO Alert diSL1NOAlert 1043 (Reserved) (Reserved) 1059 Process1 Data Total Volume Bit 3 diSL1TotalVolB3
1028 Dispense1 In Process diSL1InProcess 1044 Dispense1 Shutdown Status diSL1ShutDwnStat 1060 Process1 Data Total Volume Bit 4 diSL1TotalVolB4
1029 Dispense1 TOTAL Volume OK diSL1VolumeOK 1045 (Reserved) for 2k Mi1er Change Req diSL1_2KMi1erChgR 1061 Process1 Data Total Volume Bit 5 diSL1TotalVolB5
1030 Dispense1 Area Volume OK diSL1AreaVolOK 1046 (Reserved) for 2k 2k in Mi1er diSL1_2KinMi1er 1062 Process1 Data Total Volume Bit 6 diSL1TotalVolB6
1031 Dispense1 Purge Request diSL1PurgeReq 1047 (Reserved) for 2k diSL1_2K 1063 Process1 Data Total Volume Bit 7 diSL1TotalVolB7
Dispense1 Remote Start In
1032 Progress diSL1RmtStartInp 1048 (Reserved) for 2k diSL1_2K 1064 Process1 Data Total Volume Bit 8 diSL1TotalVolB8
1033 Dispense1 Barrel 1 Low diSL1Barel1Low 1049 Dispense1 Meter is Full diSL1MeterFull 1065 Process1 Data Total Volume Bit 9 diSL1TotalVolB9
1034 Dispense1 Barrel 1 Empty diSL1Barel1Empty 1050 Dispense1 Fill Requested diSL1FillRequest 1066 Process1 Data Total Volume Bit 10 diSL1TotalVolB10
Dispense1 Meter in Re-Fill Station
1035 Dispense1 Barrel 2 Low diSL1Barel2Low 1051 Ready diSL1MtrRSRdy 1067 Process1 Data Total Volume Bit 11 diSL1TotalVolB11
1036 Dispense1 Barrel 2 Empty diSL1Barel2Empty 1052 Dispense1 Meter at Robot Dock Ready diSL1MtrDockRdy 1068 Process1 Data Total Volume Bit 12 diSL1TotalVolB12
1037 Dispense1 Barrel 2K 1 Low diSL1Barl2K1Low 1053 Dispense1 Fill Valve Refill Station diSL1Fill_Inter 1069 Process1 Data Total Volume Bit 13 diSL1TotalVolB13
1038 Dispense1 Barrel 2K 1 Empty diSL1Barl2K1Empt 1054 Dispense1 Meter in Circulate diSL1Circulate 1070 Process1 Data Total Volume Bit 14 diSL1TotalVolB14
1039 Dispense1 Barrel 2K 2 Low diSL1Barl2K2Low 1055 Dispense1 Temp Zone XX Disabled diSL1TmpZnDsbled 1071 Process1 Data Total Volume Bit 15 diSL1TotalVolB15
1040 Dispense1 Barrel 2K 2 Empty diSL1Barl2K2Empt 1056 Dispense1 Process Data Acknowledge XData_Ack 1072 Process1 Data Total Volume Bit 16 diSL1TotalVolB16
GRS4-C 190
(cont’d)
1073 Process1 Data Area Volume Bit 1 diSL1AreaVolB1 1089 Process1 Data System Pressure Bit 1 diSL1PressureB1 1105 Process1 Data Temp Set Point Bit 1 diSL1TempSetB1
Process1 Data Actual Temp Set Point Bit
1081 Process1 Data Area Volume Bit 9 diSL1AreaVolB9 1097 Process1 Data System Pressure Bit 9 diSL1PressureB9 1113 1 diSL1ActTempB1
GRS4-C 191
(cont’d)
1121 Dispense1 Fault Data Bit 1 diSL1FaultBit1 1137 (Reserved) (SL1 Reserved)
GRS4-C 192
1153 Dispense2 Ready diSL2Ready 1169 (Reserved) (Reserved) 1185 Process2 Data Total Volume Bit 1 diSL2TotalVolB1
1154 Dispense2 NO Fault diSL2NOFault 1170 (Reserved) (Reserved) 1186 Process2 Data Total Volume Bit 2 diSL2TotalVolB2
1155 Dispense2 NO Alert diSL2NOAlert 1171 (Reserved) (Reserved) 1187 Process2 Data Total Volume Bit 3 diSL2TotalVolB3
1156 Dispense2 In Process diSL2InProcess 1172 Dispense2 Shutdown Status diSL2ShutDwnStat 1188 Process2 Data Total Volume Bit 4 diSL2TotalVolB4
1157 Dispense2 TOTAL Volume OK diSL2VolumeOK 1173 (Reserved) for 2k Mi1er Change Req diSL2_2KMi1erChgR 1189 Process2 Data Total Volume Bit 5 diSL2TotalVolB5
1158 Dispense2 Area Volume OK diSL2AreaVolOK 1174 (Reserved) for 2k 2k in Mi1er diSL2_2KinMi1er 1190 Process2 Data Total Volume Bit 6 diSL2TotalVolB6
1159 Dispense2 Purge Request diSL2PurgeReq 1175 (Reserved) for 2k diSL2_2K 1191 Process2 Data Total Volume Bit 7 diSL2TotalVolB7
Dispense2 Remote Start In
1160 Progress diSL2RmtStartInp 1176 (Reserved) for 2k diSL2_2K 1192 Process2 Data Total Volume Bit 8 diSL2TotalVolB8
1161 Dispense2 Barrel 1 Low diSL2Barel1Low 1177 Dispense2 Meter is Full diSL2MeterFull 1193 Process2 Data Total Volume Bit 9 diSL2TotalVolB9
1162 Dispense2 Barrel 1 Empty diSL2Barel1Empty 1178 Dispense2 Fill Requested diSL2FillRequest 1194 Process2 Data Total Volume Bit 10 diSL2TotalVolB10
Dispense2 Meter in Re-Fill Station
1163 Dispense2 Barrel 2 Low diSL2Barel2Low 1179 Ready diSL2MtrRSRdy 1195 Process2 Data Total Volume Bit 11 diSL2TotalVolB11
1164 Dispense2 Barrel 2 Empty diSL2Barel2Empty 1180 Dispense2 Meter at Robot Dock Ready diSL2MtrDockRdy 1196 Process2 Data Total Volume Bit 12 diSL2TotalVolB12
1165 Dispense2 Barrel 2K 1 Low diSL2Barl2K1Low 1181 Dispense2 Fill Valve Refill Station diSL2Fill_Inter 1197 Process2 Data Total Volume Bit 13 diSL2TotalVolB13
1166 Dispense2 Barrel 2K 1 Empty diSL2Barl2K1Empt 1182 Dispense2 Meter in Circulate diSL2Circulate 1198 Process2 Data Total Volume Bit 14 diSL2TotalVolB14
1167 Dispense2 Barrel 2K 2 Low diSL2Barl2K2Low 1183 Dispense2 Temp Zone XX Disabled diSL2TmpZnDsbled 1199 Process2 Data Total Volume Bit 15 diSL2TotalVolB15
1168 Dispense2 Barrel 2K 2 Empty diSL2Barl2K2Empt 1184 Dispense2 Process Data Acknowledge XData_Ack 1200 Process2 Data Total Volume Bit 16 diSL2TotalVolB16
GRS4-C 193
(cont’d)
GRS4-C 194
(cont’d)
GRS4-C 195
Dispense Controller 1 Inputs / Robot Outputs
DO[#] Description Signal Name DO[#] Description Signal Name DO[#] Description Signal Name
1025 Dispense1 Style Bit 1 doSL1StyleBit1 1041 Dispense1 Material Flow Command Bit 1 goSL1MatFlow1 1057 Not @ Purge Position Tooling Fixture doNotATPurgePos
1026 Dispense1 Style Bit 2 doSL1StyleBit2 1042 Dispense1 Material Flow Command Bit 2 goSL1MatFlow2 1058 (Reserved) (Reserved)
1027 Dispense1 Style Bit 4 doSL1StyleBit4 1043 Dispense1 Material Flow Command Bit 3 goSL1MatFlow3 1059 Dispense1 Area Volume Complete diSL1AreaVolCmp
1028 Dispense1 Style Bit 8 doSL1StyleBit8 1044 Dispense1 Material Flow Command Bit 4 goSL1MatFlow4 1060 Dispense1 Purge doSL1Purge
1029 Dispense1 Style Bit 16 doSL1StyleBit16 1045 Dispense1 Material Flow Command Bit 5 goSL1MatFlow5 1061 Dispense1 Shut down Command doSL1ShutDwnCmd
1030 Dispense1 Style Bit 32 doSL1StyleBit32 1046 Dispense1 Material Flow Command Bit 6 goSL1MatFlow6 1062 Dispense1 Fault Reset doSL1FaultReset
1031 Dispense1 Style Bit 64 doSL1StyleBit64 1047 Dispense1 Material Flow Command Bit 7 goSL1MatFlow7 1063 Dispense1 Remote Start doSL1RemoteStart
1032 Dispense1 Style Bit 128 doSL1StyleBit128 1048 Dispense1 Material Flow Command Bit 8 goSL1MatFlow8 1064 (Reserved)for 2k do2kRepairPosE1
1033 Dispense1 Style Strobe doSL1StyleStrobe 1049 Dispense1 Material Flow Command Bit 9 goSL1MatFlow9 1065 (Reserved)for 2k do2kMi1erChgE1
1034 Dispense1 Total Dispense Complete doSL1TotVolComp 1050 Dispense1 Material Flow Command Bit 10 goSL1MatFlow10 1066 (Reserved)for 2k do2kPurgePBE1
1035 Dispense1 Gun 1 ON doSL1Gun1On 1051 Dispense1 Material Flow Command Bit 11 goSL1MatFlow11 1067 (Reserved)for 2k (Reserved)
1036 Dispense1 Gun 2 ON doSL1Gun2On 1052 Dispense1 Material Flow Command Bit 12 goSL1MatFlow12 1068 Dispense1 Meter in Re-Fill Station doSL1StaRefRdy
1037 Dispense1 Gun 3 ON doSL1Gun3On 1053 Dispense1 Material Flow Command Bit 13 goSL1MatFlow13 1069 Dispense1 Meter in Docked Position doSL1MtrDocked
1038 Dispense1 Gun 4 ON doSL1Gun4On 1054 Dispense1 Material Flow Command Bit 14 goSL1MatFlow14 1070 (Reserved) (Reserved)
1039 (Reserved) Swirl Enable (Reserved) 1055 Dispense1 Material Flow Command Bit 15 goSL1MatFlow15 1071 Dispense1 Circulate Meter doSL1Circulate
1040 (Reserved) Pre-pressue Trigger (Reserved) 1056 Dispense1 Material Flow Command Bit 16 goSL1MatFlow16 1072 Dispense1 Fill Meter doSL1FillMeter
GRS4-C 196
(cont’d)
1073 Dispense1 Bead Shaping Command (bit 1) goSL1BeadShp1 1089 AreaNumberBit1 goSL1AreaNum1 1105 (Reserved) (SL1 Reserved)
1078 Dispense1 Bead Shaping Command (bit 6) goSL1BeadShp6 1094 (Reserved) (Reserved) 1110 (Reserved) (SL1 Reserved)
1080 Dispense1 Bead Shaping Command (bit 8) goSL1BeadShp8 1096 AreaNumber1Act doSL1AreaActive 1112 (Reserved) (SL1 Reserved)
1081 Dispense1 Bead Shaping Command (bit 9) goSL1BeadShp9 1097 1Data_Strobe process data to robot doSL1DataStrobe 1113 (Reserved) (SL1 Reserved)
1082 Dispense1 Bead Shaping Command (bit 10) goSL1BeadShp10 1098 (Reserved) (SL1 Reserved) 1114 (Reserved) (SL1 Reserved)
GRS4-C 197
(cont’d)
1121 (Reserved) (SL1 Reserved) 1137 (Reserved) (SL1 Reserved)
GRS4-C 198
1153 Dispense2 Style Bit 1 doSL2StyleBit1 1169 Dispense2 Material Flow Command Bit 1 goSL2MatFlow1 1185 Not @ Purge Position Tooling Fixture doNotATPurgePos
1154 Dispense2 Style Bit 2 doSL2StyleBit2 1170 Dispense2 Material Flow Command Bit 2 goSL2MatFlow2 1186 (Reserved) (Reserved)
1155 Dispense2 Style Bit 4 doSL2StyleBit4 1171 Dispense2 Material Flow Command Bit 3 goSL2MatFlow3 1187 Dispense2 Area Volume Complete diSL2AreaVolCmp
1156 Dispense2 Style Bit 8 doSL2StyleBit8 1172 Dispense2 Material Flow Command Bit 4 goSL2MatFlow4 1188 Dispense2 Purge doSL2Purge
1157 Dispense2 Style Bit 16 doSL2StyleBit16 1173 Dispense2 Material Flow Command Bit 5 goSL2MatFlow5 1189 Dispense2 Shut down Command doSL2ShutDwnCmd
1158 Dispense2 Style Bit 32 doSL2StyleBit32 1174 Dispense2 Material Flow Command Bit 6 goSL2MatFlow6 1190 Dispense2 Fault Reset doSL2FaultReset
1159 Dispense2 Style Bit 64 doSL2StyleBit64 1175 Dispense2 Material Flow Command Bit 7 goSL2MatFlow7 1191 Dispense2 Remote Start doSL2RemoteStart
1160 Dispense2 Style Bit 128 doSL2StyleBit128 1176 Dispense2 Material Flow Command Bit 8 goSL2MatFlow8 1192 (Reserved)for 2k do2kRepairPosE1
1161 Dispense2 Style Strobe doSL2StyleStrobe 1177 Dispense2 Material Flow Command Bit 9 goSL2MatFlow9 1193 (Reserved)for 2k do2kMi1erChgE1
1162 Dispense2 Total Dispense Complete doSL2TotVolComp 1178 Dispense2 Material Flow Command Bit 10 goSL2MatFlow10 1194 (Reserved)for 2k do2kPurgePBE1
1163 Dispense2 Gun 1 ON doSL2Gun1On 1179 Dispense2 Material Flow Command Bit 11 goSL2MatFlow11 1195 (Reserved)for 2k (Reserved)
1164 Dispense2 Gun 2 ON doSL2Gun2On 1180 Dispense2 Material Flow Command Bit 12 goSL2MatFlow12 1196 Dispense2 Meter in Re-Fill Station doSL2StaRefRdy
1165 Dispense2 Gun 3 ON doSL2Gun3On 1181 Dispense2 Material Flow Command Bit 13 goSL2MatFlow13 1197 Dispense2 Meter in Docked Position doSL2MtrDocked
1166 Dispense2 Gun 4 ON doSL2Gun4On 1182 Dispense2 Material Flow Command Bit 14 goSL2MatFlow14 1198 (Reserved) (Reserved)
1167 (Reserved) Swirl Enable (Reserved) 1183 Dispense2 Material Flow Command Bit 15 goSL2MatFlow15 1199 Dispense2 Circulate Meter doSL2Circulate
1168 (Reserved) Pre-pressue Trigger (Reserved) 1184 Dispense2 Material Flow Command Bit 16 goSL2MatFlow16 1200 Dispense2 Fill Meter doSL2FillMeter
GRS4-C 199
(cont’d)
1208 Dispense2 Bead Shaping Command (bit 8) goSL2BeadShp8 1224 AreaNumber1Act doSL2AreaActive 1240 (Reserved) (SL2 Reserved)
1209 Dispense2 Bead Shaping Command (bit 9) goSL2BeadShp9 1225 1Data_Strobe process data to robot doSL2DataStrobe 1241 (Reserved) (SL2 Reserved)
GRS4-C 200
(cont’d)
GRS4-C 201
Process Modes
1. The system will be able to toggle between the Process On (wet) mode
and the Process Off (dry) mode. In Process Off mode, all I/O on the
robot-dispense interface will be ignored.
2. In Teach or Isolate the dispense mode will be selectable from the teach
pendant.
3. In Interlock mode the status of the ‘Process X On Request’ input on the
cell interface will dictate the dispense mode. When the ‘Process X On
Request’ bit is set the Process On (wet) mode is selected for the
dispenser.
4. The status of dispense mode will be reflected to the PLC with the
‘Process X Enabled’ output.
GRS4-C 202
Flow On – Seal Start
1. The ‘Flow On’ instruction actuates the dispense applicator and starts the dispensing.
2. When used in conjunction with motion, the robot will move to a specified location
according to the motion parameters and start dispensing:
a. It will turn on the ‘Gun On’ and ‘Material Flow Command’ signals with respect to
the taught point and use anticipation time for the ‘Gun On’ signal.
b. It will turn on the ‘Bead Shaping Command’ signals with respect to the taught
point using the bead shaping anticipation time.
c. It will set pre-pressure time, which defines the relative timing between the analog
‘Material Flow Command’ and the digital ‘Gun On’ signals, when the dispensing
starts.
3. When used independent of the motion, the ‘Flow On’ instruction will turn the dispense
applicator on.
GRS4-C 203
Flow Off – Seal End
1. This instruction stops the dispensing process.
2. When used in conjunction with motion, the robot will move to a specified location
according to the motion parameters and stop dispensing.
a. It will turn off the ‘Gun On’ and ‘Material Flow Command’ signals with respect to
the taught point using gun off anticipation time.
b. It will turn off the ‘Bead Shaping Command’ signals with respect to the taught
point using the bead shaping off anticipation time.
c. It will apply the de-pressure time from the last executed Flow On command, which
defines the relative timing between the analog ‘Material Flow Command’ and the
digital ‘Gun On’ signals, when the dispensing ends.
GRS4-C 204
Begin Process
1. The Begin Process contains all pre-application checks of the dispense equipment. It initializes the
dispense process by setting the appropriate Style ID and the Style Strobe bit. At any point during
the sequence, if an incorrect I/O state is detected, the robot generates the appropriate fault. This
is run automatically before entering the dispense process
a. Check for ‘Dispense Ready’. If not detected, perform the ‘Remote Start / Purge’ sequence
b. Check for the ‘No Fault’ high, ‘Volume OK’ low, and ‘In Process’ low. Use the ‘Fault Reset’ if
any incorrect state is detected
c. Ensure the ‘Fault Reset’ bit is low
d. Set the ‘Task OK’ bit low
e. Set the ‘Style ID’ per style table
f. Set the ‘Style Strobe’ bit
g. Wait for the ‘In Process’ input
h. Reset the ‘Style ID’ bits
GRS4-C 205
Begin Process (cont'd)
2. The pre-application instruction is called prior to executing the dispense process
routine.
3. The following fault condition will be detected by this instruction. For each fault,
the recovery options ‘Recheck’ and ‘Abort’ will be available.
Major Fault from Dispenser: This fault occurs if the dispenser is ‘Ready’ and a
fault is detected after a ‘Fault Reset’ sequence has been attempted.
GRS4-C 206
Area Start (EQx, AreaNum)
Area Start is a macro that sends the PLC and process controller a specific number for dispensing a process into
32 potential individual areas. This gives the user the ability to check critical area’s with multiple Volume Checks
in the robotic process path. This macro is called in the dispense process path.
The Area Start (EQx, AreaNum) system function:

- Verify the Equipment and Area Number are valid
- Verify tryout mode and or process mode is requested
- Assert to the PLC the area number
- Reset TASK_OK for Process(X)
- Verify the Area Volume / Total Volume are low, signal sequence check
- Enable / Disable the area based on PLC command
Area Enabled = DISP Process <WET>
Area Disabled = DISP Process <DRY>
GRS4-C 207
Area Complete (EQx, AreaNum)
This instruction indicates the dispense area is completed and will check the Area Volume OK
- Verify equipment and area numbers are valid

- Verify tryout and process mode requests
- Set the doSLXAreaVolComp signal
- Wait for diSLXAreaVolOK for up to 200ms
- If OK, set TASK_OK = ON, turn off doSLXAreaVolComp, send AREADATA(x) for
process data to the PLC, turn off goSLXAreaNumber to the process controller
- If not OK, set TASK_OK = OFF, turn off doSLXAreaVolComp, send AREADATA(x) for
process data to the PLC, turn off goSLXAreaNumber to the process controller
GRS4-C 208
Total Dispense Complete (EQx)
1. This instruction indicates the total dispense cycle is completed and handles all the post
dispensing handshakes with the dispense controller. It is not associated with any motion
instructions or parameters.
- Verify the equipment number is valid.
- Check for the ’In Process’ bit to be high and the ‘Volume OK’ bit to be low. The robot will
generate a fault if the wrong state is detected on either bit.
- Set the doSLXTotVolComp signal.
- Look for ‘Total Volume OK’ signal or a fault indication from the dispensing equipment.
The maximum wait time is 100 ms.
- If OK, set TASK_OK=ON, turn off doSLXTotVolComp, send TOTALDTA(x) to PLC, clear
the part ID, turn off the style strobe, reset process data sent to PLC.
- The ‘In Process’ bit will be reset when the robot output signals are turned off
GRS4-C 209
Total Dispense Complete (EQx) (cont’d)
2. The ‘Total Dispense Complete’ signal is set upon the completion of the dispense process
routine.
3. The following fault conditions will be detected by this instruction. For each fault the recovery
options will be available.
a. Program Interrupted while Dispensing: This signal occurs if any external condition causes the
robot motion to stop during the dispensing process.
b. Major Fault from Dispenser: This signal occurs if a fault is detected from the dispenser in
conjunction with a ‘Volume OK’ signal.
c. Dispense Volume Out Of Range: This signal occurs if a ‘Volume OK’ signal is not received
from the dispenser in conjunction with a fault.
d. Dispenser Not Responding: This signal occurs if neither a ‘Volume OK’ nor a ‘Fault’ is
detected from the dispenser.
4. There will be no remote recovery operation for faults occurring at dispense complete.
GRS4-C 210
Remote Start / Purge
1. This instruction handles the remote start and purge functionality.
2. This instruction is called from Utility Style 29 (Process 1) and /or Style 30 (Process 2) to
initiate a remote start and/or purge by the PLC.
a. The robot will set the ‘Remote Start’ output to the dispense controller.
b. The robot will receive the ‘Remote Start In Process’ bit from the dispense controller
within a configurable amount of time or generate a fault.
c. The dispense controller will re-pressurize or re-heat as required then execute the
purge operation per its configuration information.
d. The robot controller will wait until either the ‘Dispense Ready’ or fault indication are
received from the dispense controller. If neither is received within a configurable
amount of time the robot will generate a fault
Note: All purge characteristics (e.g. interval, duration, repetition, metered Vs. non-metered)
will be configured and stored within the dispense controller. A purge will be initiated
remotely from the robot by the ‘Remote Start’ input to the dispense controller.
GRS4-C 211
Remote Start / Purge (cont’d)
3. The following fault conditions will be detected by this instruction.
Dispenser Not Responding:

This signal occurs if:
The ‘Remote Start in Process’ signal is not received from the dispense controller
within a specified amount of time after the robot sends the ‘Remote Start’ output,
or the ‘Dispense Ready’ signal is not received within a specified amount of time after
the robot receives the ‘Remote Start in Process’ input.
Major Fault From Dispenser: This signal occurs if the robot receives a fault
indication (‘No Fault’ drops low) during the remote start operation.
GRS4-C 212
Programming Data
Flow Schedule
All parameters that affect timing will be capable of both positive and
negative timing shifts. Positive values imply triggering before the
taught point, whereas negative values imply triggering after the
taught point
GRS4-C 213
Flow Schedule
1. Flow type - 2 flow types are supported:
• a. Tool Center Point (TCP) and speed (bead width, volume)

• b. Direct Voltage
2. Flow rate - The units are dictated by the flow type selection.
3. Gun number - Up to 4 guns will be supported.
4. Flow control equipment delay –The time variable applies a time shift to the analog signal with respect to actual tool speed. It does not affect the ‘Gun On’
and ‘Gun Off’ signal trigger timing. It only affects the analog material flow command timing around the corners and applies to all the flow types.
5. Gun on anticipation time - Gun on anticipation time is in respect to the taught point. This variable applies to all digital ‘Gun On’ signals activated when the
gun is turned on.
GRS4-C 214
Flow Schedule (cont'd)
6. Gun off anticipation time - Gun off anticipation time is in respect to the taught point. This variable applies to all digital ‘Gun
Off’ signals activated when the gun is turned off. The effect is similar to the gun on anticipation time except that it applies to the
gun off point.
7. Pre-pressure time - This parameter determines the relative timing between the analog flow command signal and the digital
gun on signal when the flow is turned on.
8. De-pressure time - This parameter determines the relative timing between the analog flow command signal and the digital
gun off signal when the flow is turned off. The effect of this parameter is similar to the pre-pressure time shown in , except that
it applies to the gun off point.
9. Bead shaping command - This analog signal is used for atomizing air for dispense applications in the Paint Shops or
swirling in the Body Shops.
GRS4-C 215
Flow Schedule (cont'd)
10. Bead shaping on anticipation time - Bead shaping on

anticipation time is in respect to the taught point.
11. Bead shaping off anticipation time - Bead shaping off

anticipation time is in respect to the taught point. The timing is
similar to bead shaping on anticipation time.
GRS4-C 216
Style ID Table
A means will be provided to associate a style input from

the PLC with any desired style output to the dispense
controller
Default values will be 1=1, 2=2, etc
GRS4-C 217
Fault Handling and Recovery
1. Upon the detection of a fault, the robot will perform the following:
• Halt robot motion and process.
• Set the ‘Process # Fault’ signal to the PLC.
• Display and indicate the major fault(s) and recovery options on the teach pendant.
• Log all faults.
2. Upon the detection of an alert, the robot will perform the following:
• Continue execution of motion and process.
• Set the ‘Process # Alert’ signal to the PLC.
• Display and indicate minor fault(s) on the teach pendant.
• Log all alerts.
GRS4-C 218
Recovery Before Total Dispense Complete
Execution
Faults occurring during the dispense path will not require
intervention until the ‘Total Dispense Complete’ signal is
received
In cases where an interruption of the dispense program

has occurred, the robot will automatically continue with
process off until dispense complete execution
GRS4-C 219
Recovery At Total Dispense Complete
FFR is no longer used for dispense recovery on global 4 robots. Faults
will be evaluated after Total Dispense complete. The following options
will be available from the HMI:
a. Start Rerun – reruns faulted area. Select and press the DO button
b. Rerun All – reruns all areas in the process. Select Rerun All, Select Start
Rerun and press the DO button
c. Accept Part – sets process complete for that process and sends the part
to the next stage. Select and press the DO button
GRS4-C 220
Exercise 3.3: Dispense Interface
Dispense Interface
Complete the exercise in your book.
GRS4-C 221
Exercise 3.3
Exercise Solutions
GRS4-C 222
Exercise 3.3: Dispense Interface: Solutions
1. What is the signal response (two signals) from the
dispense controller to the robot, when
doSLXTotVolComp is turned on by the robot and the
process was completed successfully?
TOTAL Volume OK is set

Dispense in Process is reset
GRS4-C 223
(cont’d)
2. What signal is set from the robot controller to the
dispense unit to clear a fault?
Fault Reset
GRS4-C 224
(cont’d)
3. What is the purpose of the anticipation on the
material flow?
Compensates for delay in dispense equipment and process.
GRS4-C 225
(cont’d)
4. When a fault or alert is detected, what four things
should the robot do?
For Faults:
• Halt robot motion and process.
• Set the ‘Process # Fault’ signal to the PLC.
• Display and indicate the major fault(s) and recovery options on the teach
pendant.
• Log all faults.
For Alerts:
• Continue execution of motion and process.
• Set the ‘Process # Alert’ signal to the PLC.
• Display and indicate minor fault(s) on the teach pendant.
• Log all alerts.
GRS4-C 226
(cont’d)
5. Which signal indicates the robot has been idle too
long and needs to be purged?
Purge Request
GRS4-C 227
(cont’d)
6. What is the bit name and state of the bit that indicates
that the dispense controller should read the style
group output from the robot?
Style Strobe will be turned on
GRS4-C 228
Stud Weld Interface
229
Robot Inputs - Weld Controller Outputs
1. No Fault: This signal is set to indicate that there are no faults present. When the bit goes
low, the signal indicates a fault from the weld controller (A no-weld indication is not a fault).
The robot will read this signal after the ‘Weld In Progress’ bit goes low.
2. Weld Complete: This signal is normally low and indicates the requested schedule has
been completed and no faults were generated. The robot will read this bit after ‘Weld in
Progress’ bit goes low. The signal remains high until the ‘Initiate Head‘ signal goes low.
3. Weld In Progress: This signal is normally low and goes high to indicate a schedule is
being run. This signal drops low again after a ‘Weld Complete’ signal or a fault is detected.
This signal is a response to an initiate head signal.
GRS4-D 230
Robot Inputs - Weld Controller Outputs (cont'd)
4. Head Back: This signal indicates that the stud head is in the retracted position. The head
back signal for all valid stud heads will be checked at the beginning of the process
sequence and prior to robot motion after a stud weld (faulted or not faulted) has been
completed.
5. Weld Ready: This signal indicates the weld controller is in weld mode and ready to weld
in automatic. The robot will check the signal prior to an initiate weld, and it will not review
the signal during the weld. The robot will compare the signal to its output (weld mode) to
confirm that the weld controller is in the correct mode. The status of this bit will be
communicated to the cell controller by the ‘Process X Enabled’ output on the cell interface.
GRS4-D 231
GRS4-D
Robot Inputs - Weld Controller Outputs (cont'd)
6. Stud Low: This signal indicates that the feeder(s) is low. The ‘Stud Low’ signal is set to activate the ‘Process X
Alert’ signal on the cell controller interface.
7. No Alert: This signal goes low to indicate that one or more stud heads requires preventive maintenance, or that
the stud controller has detected an abnormal condition. The alert signal will not immediately halt or prevent the
welding operation. The ‘No Alert’ signal goes low to activate the ‘Process X Alert’ signal on the cell controller
interface.
8. In Tolerance: This signal goes low at the end of a invalid weld sequence. It indicates that the weld controller has
detected parameters outside programmable limits. The robot will read this bit after ‘Weld In Progress’ bit goes low.
GRS4-D 232
Robot Outputs - Weld Controller Inputs
1. Initiate Head: This signal is used to start the weld schedule and indicate that the schedule
data bits are valid.
2. Manual Advance Head: The weld controller extends the stud gun when the ‘Manual
Advance Head’ bit is high and returns the gun when the ‘Manual Advance Head’ bit is reset.
3. Schedule Bits (1,2,4,8,16,32): These six bit form a binary number that selects one of the
63 individual weld schedules at the weld controller.
4. Fault Reset: This signal resets the weld controller faults. If the cause of the fault has not
been removed then the fault will be re-sent after the release of the ‘Fault Reset’ signal.
GRS4-D 233
Robot Outputs - Weld Controller Inputs (cont’d)
5. Select Weld Mode: This signal indicates a request of

weld mode to the weld controller.
6. Select Part Mode: This signal specifies the operating

mode of the weld controller when Weld Mode is not
selected.
GRS4-D 234
Hardware Interlocks
1. Control Stop: The ‘Control Stop’ signal is a 24V signal from the robot indicating motion power is
enabled for the cell. When the signal goes low the stud controller will remove all feeder, head, and
welding power over 50V and remove all motion power within 50ms
2. Feeder Power Interrupt: The feeder power interrupt is a stand-alone interface connector that
interrupts the power to each feeder (and therefore each head) independently. When the external
contacts are open for a given output device, the stud controller will remove all feeder, head, and
welding power over 50V, and all motion power within 50ms for the given output device.
GRS4-D 235
Stud Weld Controller/ Robot Inputs
EIP Scanner ‐ Slot 6 EIP Scanner ‐ Slot 6 EIP Scanner ‐ Slot 6 EIP Scanner ‐ Slot 6
DI[#] Description Signal Name DI[#] Description Signal Name DI[#] Description Signal Name DI[#] Description Signal Name
Weld Complete Head
1025 NO Fault Head #1 diST1NoFaultHd1 1041 #4 diST1WeldComp4 1057 (Reserved) (Reserved) 1073 (Reserved) (Reserved)
1026 Weld Complete Head #1 diST1WeldComp1 1042 Weld In Progress #4 diST1InProg4 1058 (Reserved) (Reserved) 1074 (Reserved) (Reserved)
1027 Weld In Progress #1 diST1InProg1 1043 Head Back #4 diST1HdBackHd4 1059 (Reserved) (Reserved) 1075 (Reserved) (Reserved)
1028 Head Back #1 diST1HdBackHd1 1044 (Reserved) (Reserved) 1060 (Reserved) (Reserved) 1076 (Reserved) (Reserved)
1029 (Reserved) (Reserved) 1045 (Reserved) (Reserved) 1061 (Reserved) (Reserved) 1077 (Reserved) (Reserved)
1030 NO Fault Head #2 diST1NoFaultHd2 1046 (Reserved) (Reserved) 1062 (Reserved) (Reserved) 1078 (Reserved) (Reserved)
1031 Weld Complete Head #2 diST1WeldComp2 1047 (Reserved) (Reserved) 1063 (Reserved) (Reserved) 1079 (Reserved) (Reserved)
1032 Weld In Progress #2 diST1InProg2 1048 (Reserved) (Reserved) 1064 (Reserved) (Reserved) 1080 (Reserved) (Reserved)
1034 (Reserved) (Reserved) 1050 Weld Mode On diST1WeldMode 1066 (Reserved) (Reserved) 1082 (Reserved) (Reserved)
1035 NO Fault Head #3 diST1NoFaultHd3 1051 Stud Low diST1StudLow 1067 (Reserved) (Reserved) 1083 (Reserved) (Reserved)
1036 Weld Complete Head #3 diST1WeldComp3 1052 No Alert diST1NoAlert 1068 (Reserved) (Reserved) 1084 (Reserved) (Reserved)
1037 Weld In Progress #3 diST1InProg3 1053 In Tolerance diST1InTol 1069 (Reserved) (Reserved) 1085 (Reserved) (Reserved)
1040 NO Fault Head #4 diST1NoFaultHd4 1056 (Reserved) (Reserved) 1072 (Reserved) (Reserved) 1088 (Reserved) (Reserved)
GRS4-D 236
Stud Weld Controller/ Robot Outputs
DO[#] Description Signal Name DO[#] Description Signal Name DO[#] Description Signal Name DO[#] Description Signal Name
1025 Initiate Head #1 doST1CycleHd1 1041 (Reserved) (Reserved) 1057 (Reserved) (Reserved) 1073 (Reserved) (Reserved)
1026 Initiate Head #2 doST1CycleHd2 1042 Reset Fault doST1FaultRes 1058 (Reserved) (Reserved) 1074 (Reserved) (Reserved)
1027 Initiate Head #3 doST1CycleHd3 1043 (Reserved) (Reserved) 1059 (Reserved) (Reserved) 1075 (Reserved) (Reserved)
1028 Initiate Head #4 doST1CycleHd4 1044 Select Weld Mode doST1WeldMode 1060 (Reserved) (Reserved) 1076 (Reserved) (Reserved)
1029 (Reserved) (Reserved) 1045 Select Part Mode doST1PartMode 1061 (Reserved) (Reserved) 1077 (Reserved) (Reserved)
1030 Manual Advance Head #1 doST1ManAdvHd1 1046 (Reserved) (Reserved) 1062 (Reserved) (Reserved) 1078 (Reserved) (Reserved)
1035 Schedule Bit 1 doST1Sched1 1051 (Reserved) (Reserved) 1067 (Reserved) (Reserved) 1083 (Reserved) (Reserved)
GRS4-D 237
Process Modes
Robot / PLC Interface Robot / Stud Weld Interface Weld Control Operation
Process Tryout Process Select Select Part Weld
On Mode Enabled Weld Mode Ready
Request Request (robot Mode (robot (robot
(robot (robot output) (robot Output) input)
input) input) output)
High Low High High High High Full automatic weld mode.
High High Low High Low Low Invalid state.
Low Low Low Low High Low Dry Cycle With Part: Weld control
cycles the stud gun, verifies stud
on work, performs all I/O
handshaking, and performs all
weld functions with the exception
of passing current.
Low High Low Low Low Low Dry Cycle Without Part: Weld
control cycles the stud gun and
performs all I/O handshaking.
GRS4-D 238
Process Modes
1. The system will be able to select between the Weld/No Weld and Part/No Part process modes as described in above.
2. In Teach or Isolate the process modes will be selectable from the teach pendant. In Interlock the status of the ‘Process X On
Request’ and ‘Tryout Mode Request’ inputs on the cell interface will dictate the process mode.
3. The status of the ‘Weld Ready’ signal from the weld controller will be sent to cell controller using the ‘Process X Enabled’
output.
4. In No Weld mode, the system will be able to select between Stroke and No Stroke modes. In No Stroke, all I/O on the stud
controller interface except ‘Head Back’ will be ignored. No Stroke will be used in interlock mode during Fast Fault Recovery.
GRS4-D 239
Stud Weld
1. This instruction will move the robot to a specified position and initiate a
stud weld.
2. Motion parameters for this instruction will have the ability to be edited
according to GM GRS-1, Technical Specifications for Production Robots.
The termination type for this command will always be “fine.”
3. The following parameters will be available:
a. Head / Head Set (if hot backup configured) selection
b. Weld schedule
GRS4-D 240
Programming Instructions (cont'd)
4. The stud weld instruction will perform the interface handshaking.
a. Set the weld schedule.
b. Initiate the weld by setting the appropriate ‘Initiate Head’ signal on.
c. Wait for the appropriate ‘Weld In Progress’ signal. If not received within a
configurable timeout, perform the error recovery routine.
d. Wait for the appropriate ‘Weld In Progress’ signal to drop low.
e. Read the status of ‘Weld Complete’, ‘No Fault’, and ‘In Tolerance’ signals.
5. When hot backup is used, the robot will determine which head (stud
welder channel) is active and fire the appropriate ‘Initiate Head’ signal.
For the carried process, the identification is based on tool ID from the tool
changer interface. For the pedestal process, the ID is based on the ‘Gun
Ready’ signal from the cell interface.
GRS4-D 241
Manual Functions
Manual Stud Weld
– This feature allows the operator to select a stud head and
manually initiate a weld sequence
– In Teach or Isolate the function will allow the user to select a
weld schedule. In Interlock, the function will not manipulate the
schedule outputs or any head that is not currently in the
backup position
GRS4-D 242
Out of Tolerance Handling
If Out of Tolerance is detected at the end of a weld (‘In Tolerance’
bit is low), the cell interface ‘Process X Out of Tolerance’ signal
will be set high until the beginning of the next style sequence
GRS4-D 243
Head Fault Recovery
On a head fault or timeout the following fault recovery
options will be supported:
1. Retry – The Retry selection will drop the ‘Initiate Head,’ signal, pulse the
‘Fault Reset’ signal and initiate a new weld cycle.
2. Skip – The Skip selection will drop ‘Initiate Head’ signal, pulse ‘Fault
Reset’ signal, drop ‘Task OK’ signal and move to the next stud location.
3. FFR – See the following section.
4. Abort – The Abort will cancel any user program execution, robot motion, or
process execution. No remote recovery capability will be provided for this
type of fault.
GRS4-D 244
Fast Fault Recovery Without Hot Backup
Prior to re-running the process cycle, the following process
specific recovery options will be available:
1. Continue Last – resume by placing stud at the point the fault has occurred.
2. Continue Next – resume by placing stud at the next point following the one
where the fault has occurred, with ‘Task OK’ signal low.
3. Abort – cancel any user program execution, robot motion, or process
execution.
GRS4-D 245
FFR with Carried Process, No Hot Backup
GRS4-D 246
FFR with Pedestal Process, No Hot Backup
GRS4-D 247
FFR with Carried Process, With Hot Backup
GRS4-D 248
FFR with Pedestal Process with Hot Backup
GRS4-D 249
Flow Drill Screw and Self Piercing Rivets
250
Flow Drill Screw Outputs – Robot Inputs
Spindle in Home
1025 Position diFDS1SpindHome 1041 FDS1 Error Code Bit9 diFDS1ErrCodeB9 1057 (Reserved) (Reserved) 1073 (Reserved) (Reserved)
1026 System OK diFDS1SysOK 1042 FDS1 Error Code Bit10 diFDS1ErrCodeB10 1058 (Reserved) (Reserved) 1074 FDS1 Last Step Bit1 diFDS1LastStepB1
1027 Ready to Start diFDS1Ready 1043 FDS1 Error Code Bit11 diFDS1ErrCodeB11 1059 (Reserved) (Reserved) 1075 FDS1 Last Step Bit2 diFDS1LastStepB2
1028 OK Signal diFDS1OK 1044 FDS1 Error Code Bit12 diFDS1ErrCodeB12 1060 (Reserved) (Reserved) 1076 FDS1 Last Step Bit3 diFDS1LastStepB3
1029 NOK Signal diFDS1NOK 1045 FDS1 Error Code Bit13 diFDS1ErrCodeB13 1061 (Reserved) (Reserved) 1077 FDS1 Last Step Bit4 diFDS1LastStepB4
1030 Level Control diFDS1LevelCntrl 1046 FDS1 Error Code Bit14 diFDS1ErrCodeB14 1062 (Reserved) (Reserved) 1078 FDS1 Last Step Bit5 diFDS1LastStepB5
1031 Part Ejected diFDS1PartEjectd 1047 FDS1 Error Code Bit15 diFDS1ErrCodeB15 1063 (Reserved) (Reserved) 1079 FDS1 Last Step Bit6 diFDS1LastStepB6
FDS1 Maintenace
1032 Request diFDS1MaintReq 1048 FDS1 Error Code Bit16 diFDS1ErrCodeB16 1064 (Reserved) (Reserved) 1080 FDS1 Last Step Bit7 diFDS1LastStepB7
1033 FDS1 Error Code Bit1 diFDS1ErrCodeB1 1049 (Reserved) (Reserved) 1065 (Reserved) (Reserved) 1081 FDS1 Last Step Bit8 diFDS1LastStepB8
1034 FDS1 Error Code Bit2 diFDS1ErrCodeB2 1050 (Reserved) (Reserved) 1066 (Reserved) (Reserved) 1082 (Reserved) (Reserved)
GRS4
251
Flow Drill Screw Inputs – Robot Outputs
1025 Automatic Signal doFDS1Auto 1041 (Reserved) (Reserved) 1057 (Reserved) (Reserved) 1073 (Reserved) (Reserved)
1026 Error Acknowledge doFDS1ErrorAck 1042 (Reserved) (Reserved) 1058 (Reserved) (Reserved) 1074 (Reserved) (Reserved)
1027 Start Signal doFDS1StartSignal 1043 (Reserved) (Reserved) 1059 (Reserved) (Reserved) 1075 (Reserved) (Reserved)
1028 Start Nullification doFDS1StartNull 1044 (Reserved) (Reserved) 1060 (Reserved) (Reserved) 1076 (Reserved) (Reserved)
1029 Simulation Mode doFDS1DryCycle 1045 (Reserved) (Reserved) 1061 (Reserved) (Reserved) 1077 (Reserved) (Reserved)
1030 Change Direction of Motor Rotation doFDS1ChngMtrRot 1046 (Reserved) (Reserved) 1062 (Reserved) (Reserved) 1078 (Reserved) (Reserved)
1031 Start Part Eject doFDS1PartEject 1047 (Reserved) (Reserved) 1063 (Reserved) (Reserved) 1079 (Reserved) (Reserved)
1032 Move Blank Holder in Work Position doFDS1MvWorkPos 1048 (Reserved) (Reserved) 1064 (Reserved) (Reserved) 1080 (Reserved) (Reserved)
1033 Code Number Bit 1 doFDS1CodeBit1 1049 (Reserved) (Reserved) 1065 (Reserved) (Reserved) 1081 (Reserved) (Reserved)
GRS4
252
Self Piercing Rivets Outputs – Robot Inputs
1025 Ready TO Cycle diSPR1RdyToCycle 1041 (Reserved) (Reserved) 1057 (Reserved) (Reserved) 1073 (Reserved) (Reserved)
1026 In Cycle diSPR1InCycle 1042 Auto Mode Selecter diSPR1AutoMode 1058 (Reserved) (Reserved) 1074 (Reserved) (Reserved)
1027 Finished diSPR1Finished 1043 Punch Maintenance Request diSPR1PunchMtn 1059 (Reserved) (Reserved) 1075 (Reserved) (Reserved)
1028 Fault diSPR1Faulted 1044 Die Maintenance Request diSPR1DieMtn 1060 (Reserved) (Reserved) 1076 (Reserved) (Reserved)
Cleaning Maintenance
1029 RivMon ON diSPR1RivMonON 1045 Request diSPR1CleanMtn 1061 (Reserved) (Reserved) 1077 (Reserved) (Reserved)
1030 Tool Off diSPR1ToolOff 1046 Million Cycle PM Request diSPR1_1M_CycMtn 1062 (Reserved) (Reserved) 1078 (Reserved) (Reserved)
1031 Rivets Low diSPR1RivetsLow 1047 Alert diSPR1Alert 1063 (Reserved) (Reserved) 1079 (Reserved) (Reserved)
1032 Tool Home diSPR1ToolHome 1048 Heartbeat diSPR1Heartbeat 1064 (Reserved) (Reserved) 1080 (Reserved) (Reserved)
1033 Tool Open diSPR1ToolOpen 1049 FaultCodeBit1 diSPR1FaultBit1 1065 (Reserved) (Reserved) 1081 (Reserved) (Reserved)
1034 Rivet Set diSPR1RivetSet 1050 FaultCodeBit2 diSPR1FaultBit2 1066 (Reserved) (Reserved) 1082 (Reserved) (Reserved)
1035 (Reserved) (Reserved) 1051 FaultCodeBit4 diSPR1FaultBit4 1067 (Reserved) (Reserved) 1083 (Reserved) (Reserved)
1036 (Reserved) (Reserved) 1052 FaultCodeBit8 diSPR1FaultBit8 1068 (Reserved) (Reserved) 1084 (Reserved) (Reserved)
1037 Fault - Before Riveting diSPR1BfrRivetFlt 1053 FaultCodeBit16 diSPR1FaultBit16 1069 (Reserved) (Reserved) 1085 (Reserved) (Reserved)
1038 Fault - During Riveting diSPR1DurRivetFlt 1054 FaultCodeBit32 diSPR1FaultBit32 1070 (Reserved) (Reserved) 1086 (Reserved) (Reserved)
1039 Fault - After Riveting diSPR1AftRivetFlt 1055 FaultCodeBit64 diSPR1FaultBit64 1071 (Reserved) (Reserved) 1087 (Reserved) (Reserved)
1040 Fault - System diSPR1SystemFlt 1056 FaultCodeBit128 diSPR1FaultBit128 1072 (Reserved) (Reserved) 1088 (Reserved) (Reserved)
GRS4
253
Self Piercing Rivets Inputs – Robot Outputs
1025 Tool Select Bit1 doSPR1ToolSelct1 1041 Dry Cycle doSPR1DryCycle 1057 (Reserved) (Reserved) 1073 (Reserved) (Reserved)
1026 Tool Select Bit2 doSPR1ToolSelct2 1042 No Home Allowed doSPR1NoHmAlowed 1058 (Reserved) (Reserved) 1074 (Reserved) (Reserved)
1027 Tool Select Bit4 doSPR1ToolSelct4 1043 Tool Moved doSPR1ToolMoved 1059 (Reserved) (Reserved) 1075 (Reserved) (Reserved)
1028 Tool Select Bit8 doSPR1ToolSelct8 1044 EqualizerBit1 doSPR1Equalizer1 1060 (Reserved) (Reserved) 1076 (Reserved) (Reserved)
1029 Manual Slow Close doSPR1SlowClose 1045 EqualizerBit2 doSPR1Equalizer2 1061 (Reserved) (Reserved) 1077 (Reserved) (Reserved)
1030 Manual Slow Open doSPR1SlowOpen 1046 No Man Cycle doSPR1NoManCycle 1062 (Reserved) (Reserved) 1078 (Reserved) (Reserved)
1031 Gun Opening Bit1 doSPR1GunOpen1 1047 (Reserved) (Reserved) 1063 (Reserved) (Reserved) 1079 (Reserved) (Reserved)
1032 Gun Opening Bit2 doSPR1GunOpen2 1048 Heartbeat doSPR1Heartbeat 1064 (Reserved) (Reserved) 1080 (Reserved) (Reserved)
1033 (Reserved) (Reserved) 1049 JointNumber1 doSPR1JntNum1 1065 (Reserved) (Reserved) 1081 (Reserved) (Reserved)
1035 Cycle Tool doSPR1CycleTool 1051 JointNumber4 doSPR1JntNum4 1067 (Reserved) (Reserved) 1083 (Reserved) (Reserved)
1036 Goto Opening doSPR1GotoOpn 1052 JointNumber8 doSPR1JntNum8 1068 (Reserved) (Reserved) 1084 (Reserved) (Reserved)
1038 Cut Tape doSPR1Cut Tape 1054 JointNumber32 doSPR1JntNum32 1070 (Reserved) (Reserved) 1086 (Reserved) (Reserved)
1039 Fault Acknowledge doSPR1FltAck 1055 JointNumber64 doSPR1JntNum64 1071 (Reserved) (Reserved) 1087 (Reserved) (Reserved)
GRS4
254
Material Handling Interface
255
Material Handling Configuration Items
The following options will be configurable for material handling robots:
1. Specify the size of the input module
2. Select if a vacuum pump is being used
3. Select if the vacuum valves are being used
a. Specify the number of valves
b. Specify if vacuum feedback is available
4. Select if the cylinder valves are used
a. Specify the number of valves
b. Specify which cylinders (2-position devices) are controlled by which
valve
c. Specify if cylinder position feedback is available
GRS4-E 256
MH Valves Setup
MH Valves are
Valve 1 – Common - Clamps 1-4 and PP 1-2
used on FANUC
Robots to
associate clamps
Valve 2 – Style 1 Specific – Clamp 5 and PP 3
and part presents
with valves. Valve 3 – Style 2 Specific – Clamp 6 and PP 4
C PP3
5
C C
1 2
PP1
C C
3 4
PP2
GRS4
C 257
PP4 6
MH Valves Setup (cont’d)
Press MENU – 6: Setup – MH Valves
To setup the valves:
Select the tool to setup and press F2 Detail
Select the valve number and press F2 Detail
GRS4
258
• Enter a name for the valve – VALVE 1
• Choose the Valve Type – Clamp
• Set the number of clamps – 4
Choose to check the open and closed states and
set timeout values – YES, 750ms
• Choose the number of part presents – 2
Set Continuous Checking – NO
• Toggle Retry Enabled (Grip or Release) – YES
– allows the auto retry option for that valve
and sets the number of retries
Make Sure to Press F3 APPLY
Auto Retry (Grip or Release) – 2
• Cancel/Recover Option (Grip or Release) –
when Finished
YES – allows the Cancel/Recover option for
GRS4
259
the valve gripping or releasing
• Press NEXT and Choose Signals to setup input
numbers for clamps, part presents, and
vacuums. Valve outputs can also be set. Press
F2 DETAIL to bring up the association screen.
• The association screen ties an input or output
to a signal description.
For example, di801PH01PX1 is the clamp open
cylindicator for part holder 1 that is tied to DI[801]
GRS4
260
Press PREV to return to the Valve Setup screen. Scroll to No of Clamps and
press F5 Config.
Highlight the input signal for clamp one and press F4 [CHOICE] to choose
what input the clamp open signal is tied to.
The clamp closed should automatically populate.
Continue until all clamp inputs are defined
Do the same for part presents
Press F3 IN/OUT to set the valve outputs
Repeat the process for the remaining valves to be configured
GRS4
261
If vacuum is being used, choose vacuum on the
valve setup screen
• Enter the name for the valve – VALVE4
• Choose the Valve Type – Vacuum
– Set the number of vacuum sensor – 1
– Set if there is Vac Feedback, how long to delay before
checking and if the check is continuous
– Set the Max Feedback Delay
– Set the Blow off time
• Set the number of part present switches
– Set if the part presents are continuously monitored
Make Sure to Press F3 APPLY

when Finished
GRS4
262
Fault Handling
The following requirements apply to both

Material Handling and Tool Changing:
• A fault will be generated whenever an expected input state
is not detected within a configurable amount of time.
• Faults will be indicated to the cell controller using the
‘Material Handling Fault’ output.
GRS4-E 263
MH Recovery
Can recover from TP and HMI
– Check I/O Again – recheck signal, no movement
– Disable Alarm: 20 Cycles
– Disable Alarm: 1 Cycle
– Toggle Gripper and Retry – toggles states and re-
checks
– Cancel and Recover – will un-grip and recover if
gripping or will grip and recover if un-gripping
GRS4
264
Material Handling Input Block 1-4 / Robot Inputs
MH Input Block 1 MH Input Block 2 MH Input Block 3 MH Input Block 4
801 Cylinder 01 PX1 di801PH01PX1 817 Cylinder 07 PX1 di817PH07PX1 833 Cylinder 13 PX1 di833PH13PX1 849 Cylinder 19 PX1 di849PH19PX1
805 Cylinder 03 PX1 di805PH03PX1 821 Cylinder 09PX1 d821PH09PX1 837 Cylinder 15 PX1 di837PH15PX1 853 Cylinder 21 PX1 di853PH21PX1
806 Cylinder 03 PX2 di806PH03PX2 822 Cylinder 09PX2 di822PH09PX2 838 Cylinder 15 PX2 di838PH15PX2 854 Cylinder 21 PX2 di854PH21PX2
813 Part Present 01 di813PartPres01 829 Part Present 05 di829PartPres05 845 Part Present 09 di845PartPres09 861 Part Present 13 di861PartPres13
GRS4-E 265
Material Handling Vacuum Pump 1-2 /
Robot Inputs
MH Vacuum Pump 1 MH Vacuum Pump 2
865 VP Vacuum Made 1 di865VPVacMade1 873 VP Vacuum Made 3 di873VPVacMade3
866 VP Vacuum Made 2 di866VPVacMade2 874 VP Vacuum Made 4 di874VPVacMade4

GRS4-E 266
Material Handling Valve Block 1-3 / Robot
Outputs
MH Valve Block 1 MH Valve Block 2 MH Valve Block 3
do801Valve01T
801 Valve 1 to A Position / Vacuum 1 On oA 817 Valve 6 to A Position / Vacuum 1 On do817Valve06ToA 833 Valve 11 to A Position / Vacuum 1 On do833Valve11ToA
do802Valve01T
802 Valve 1 to B Position / Vacuum 1 Blow-Off oB 818 Valve 6 to B Position / Vacuum 1 Blow-Off do818Valve06ToB 834 Valve 11 to B Position / Vacuum 1 Blow-Off do834Valve11ToB
do803Valve02T
do804Valve02T
do805Valve03T
805 Valve 3to A Position / Vacuum 3 On oA 821 Valve 8 to A Position / Vacuum 3 On do821Valve08ToA 837 Valve 13 to A Position / Vacuum 3 On do837Valve13ToA
do806Valve03T
do807Valve04T
do808Valve04T
do809Valve05T
do810Valve05T
811 (Reserved) (Reserved) 827 (Reserved) (Reserved) 843 (Reserved) (Reserved)
GRS4-E 267
Material Handling Vacuum Pump 1-2 / Robot
Outputs
MH Vacuum Pump 1 MH Vacuum Pump 2
865 Vacuum 1 On do865Vacuum1on 873 Vacuum 3 On do873Vacuum3on
866 Vacuum 1 Blow-Off do866Vac1BlowOn 874 Vacuum 3 Blow-Off do874Vac3BlowOn
867 Vacuum 2 On do867Vacuum2on 875 Vacuum 4 On do875Vacuum4on
868 Vacuum 2 Blow-Off do868Vac2BlowOn 876 Vacuum 4 Blow-Off do876Vac4BlowOn
869 (Reserved) (Reserved) 877 Reserved) (Reserved)
GRS4-E 268
Material Handling Robot Software Requirements
Tryout Mode
1. The system will be able to change between Part and No Part mode.
2. In Teach or Isolate, the Part/No Part mode will be selectable from the teach pendant.
3. In Interlock the ‘Tryout Mode Request’ bit on the cell interface will determine Part/No Part mode.
Selecting ‘Tryout Mode’ will select No Part mode.
4. The status of Part/No Part Mode will be sent to the cell controller using the ‘Tryout Mode’ output.
GRS4-E 269
Programming Instructions -Cylinders
Prepare To Pickup
This instruction verifies that all cylinders of the selected
valves are in the B (Opened) position and that no part is
detected at the associated part present inputs.
GRS4-E 270
Programming Instructions - Cylinders
Grip Part
1. Setting the ‘Grip Part’ instruction will shift the selected valves to the A (Closed)
position.
2. Feedback from any of the 24 available cylinders and/or 16 available part present
inputs will be used with the specified valve(s) to verify successful completion of
the gripping operation.
3. Program execution will resume when the “closed” state of all associated clamps
are detected or after the programmable time delay (if clamp feedback is not
assigned).
4. The ‘Grip Part’ instruction will support both discrete and continuous checking of
the part present input(s). If continuous monitoring is selected, the monitoring will
remain in effect until a ‘Release Part’ instruction is executed for the associated
input.
GRS4-E
5. In No Part mode the robot will ignore the state of all part present inputs. 271
Release Part
1. The ‘Release Part’ instruction will shift one or more of the 15 available
valves to the B (Opened) position.
2. Feedback from any of the 24 available cylinders and/or 16 available part
present inputs will be used with the specified valve(s) to verify
successful completion of the gripping operation.
3. Program execution will resume when the “open” state of all associated
clamps are detected or after the programmable time delay if clamp
feedback is not assigned.
4. The ‘Release Part’ instruction will terminate continuous monitoring of
any associated part present input(s).
GRS4-E 272
Vacuums
• The vacuum on, vacuum off, and blow off instructions will support both
simple vacuum and vacuum pump systems
• The vacuum remains on as long as the ‘Vacuum On’ signal is set and
blow-off remains on as long as the ‘Blow-Off On’ signal is set
• Up to five total valves including clamp and simple vacuum will be
supported
• Vacuum pumps do not limit the number of available cylinder valves
GRS4-E 273
Vacuum On
• This instruction will turn on the vacuum to pick-up the part.
• This instruction will initiate continuous monitoring of the
‘Vacuum Made’ input after a configurable time delay.
• In No Part mode the specified vacuum channels are not
activated and no feedback will be monitored from the
specified vacuum channels.
GRS4-E 274
Vacuum Off
• This instruction will turn off the vacuum and turn on the blow-off
function.
• This instruction will terminate continuous monitoring of the ‘Vacuum
Made’ input.
• In No Part mode, the specified vacuum channels will not be
activated, blow-off will not be activated, and no feedback will be
monitored from the specified vacuum channels.
GRS4-E 275
Check Part Present
• This instruction will check that state of the part present switch at one or more of the 16
available inputs.
• This instruction will support both discrete and continuous checking of the specified
input(s) as a programming option. If continuous monitoring is selected, the monitoring
will remain in effect until a ‘Release Part’ instruction is executed for the associated input.
Check No Part Present

• This instruction will check that no part is present at the specified switches.
GRS4-E 276
Module 3 Review – Material Handling
• A MH robot can be recovered from TP and HMI, what
actions can be done?
– Check I/O Again – recheck signal, no movement
– Disable Alarm: 20 Cycles
– Disable Alarm: 1 Cycle
– Toggle Gripper and Retry – toggles states and re-checks
– Cancel and Recover – will un-grip and recover if gripping or
will grip and recover if un-gripping
GRS4-E 277
Module 3 Review – Material Handling
• This instruction verifies that all cylinders of the selected
valves are in the B (Opened) position and that no part
is detected at the associated part present inputs.
Prepare to Pickup
GRS4-E 278
Tool Change Configuration Items
The following options will be

configurable for tool changing robots:
• Specify the number of tools that will be used
• Select if the tool changer nests will utilize lids
• Select if the nest in position signals will be used
GRS4-E 279
Tool Changer Interface Signals
Robot Inputs (Robot End)
• Tool Plate Latched: This signal indicates that the tool changer’s engagement mechanism
is latched.
• Tool Plate Unlatched: This signal indicates that the tool changer’s engagement
mechanism is unlatched.
• Unlatch Solenoid Energized: This signal is set to indicate the unlatch tool switch is made
and the unlatch output is energized. If the unlatch switch jumper is installed, this signal
will be true whenever the unlatch output is true.
• Aux Power Available: This signal indicates that auxiliary power (24VDC) is available.
GRS4-E 280
Tool Changer End Of Arm (Tool End)
Robot Inputs (Tool End)
• Tool Number: An 8 bit binary number that indicates the tool number.
It is used to identify the number of the end effector (1,2,3, etc).
• Robot Number: A 4 bit binary number that indicates the robot
number. It is used to identify robot so that the end effector is not
inadvertently swapped between robots.
• Line Number: A 4 bit binary number that indicates the application
type being used. (1-MH, 2-Spot, 3-Spot/MH, 4-Stud, 5-SPR)
GRS4-E 281
GRS4-E
Tool Changer End of Arm / Robot Inputs
Tool Changer Robot End Tool Changer Tool End
905 Tool Plate Latched diToolLatched 913 Tool Number (bit 1) giToolNumber
906 Tool Plate Unlatched diToolUnlatched 914 Tool Number (bit 2) giToolNumber
907 Ok to Latch diOktoLatch 915 Tool Number (bit 4) giToolNumber
908 Ok to Unlatch diOktoUnlatch 916 Tool Number (bit 8) giToolNumber
909 Tool Plate Found diToolPresent 917 Tool Number (bit 16) giToolNumber
910 Safe Switch Missing diSafeSwMissing 918 Tool Number (bit 32) giToolNumber
911 (Reserved) (Reserved) 919 Tool Number (bit 64) giToolNumber
912 (Reserved) (Reserved) 920 Tool Number (bit 128) giToolNumber
921 Robot Number (bit 1) giRobotNumber
925 Line Number (bit 1) giLineNumber
GRS4-E 282
Tool Changer End of Arm / Robot Outputs
Tool Changer Robot End
EIP Scanner ‐ Slot 54
DO[#] Description Signal Name
905 Latch Tool Plate doLatchTool
906 Unlatch Tool Plate doUnlatchTool
907 Tool Changer Fault Reset doTCFaultReset
GRS4-E 283
Tool Changer Robot Software Requirements
Latch Tool Plate

The ‘Latch Tool Plate’ instruction cycles the tool changer
to the latched position and verifies the correct state of
the associated feedback.
Unlatch Tool Plate

The ‘Unlatch Tool Plate’ instruction cycles the tool
changer to the unlatched position and verifies the correct
state of the associated feedback.
GRS4-E 284
Tool Changer Robot Software Requirements
Check For Head Present

• This instruction will check if a particular head is present on the
tool changer.
Check For No Head Present

• This instruction will verify that there is no head present on the
tool changer.
GRS4-E 285
Tool Changer Nest (Robot Controlled)
Robot Inputs
• Nest Closed: This signal indicates that the tool changer nest is closed.
• Nest Open: This signal indicates that the tool changer nest is open.
• Head In Nest: This signal indicates that there is an end-effector in the
nest.
• Nest In Position: This signal indicates the tool nest is in position and
locked.
GRS4-E 286
Robot Outputs
• Close Nest: This signal commands the tool nest to close the lid.
• Open Nest: This signal commands the tool nest to open the lid.
GRS4-E 287
GRS4-E
Tool Changer Nest / Robot Inputs
Tool Change Nest 1 Tool Change Nest 2 Tool Change Nest 3 Tool Change Nest 4
929 Nest 1 Open diNest1Open 937 Nest 2 Open diNest2Open 945 Nest 3 Open diNest3Open 953 Nest 4 Open diNest4Open
930 Nest 1 Closed diNest1Closed 938 Nest 2 Closed diNest2Closed 946 Nest 3 Closed diNest3Closed 954 Nest 4 Closed diNest4Closed
931 Head 1 In Nest diHead1InNest 939 Head 2 In Nest diHead2InNest 947 Head 3 In Nest diHead3InNest 955 Head 4 In Nest diHead4InNest
932 Nest 1 In Position diNest1InPos 940 Nest 2 In Position diNest2InPos 948 Nest 3 In Position diNest3InPos 956 Nest 4 In Position diNest4InPos
GRS4-E 288
Tool Nest 1- 4 / Robot Outputs
Tool Change Nest 1 Tool Change Nest 2 Tool Change Nest 3 Tool Change Nest 4
929 Open Nest 1 doOpenNest1 937 Open Nest 2 doOpenNest2 945 Open Nest 3 doOpenNest3 953 Open Nest 4 doOpenNest4
930 Close Nest 1 doCloseNest1 938 Close Nest 2 doCloseNest2 946 Close Nest 3 doCloseNest3 954 Close Nest 4 doCloseNest4
GRS4-E 289
Robot Controlled Tool Nests
Check For Nest Empty
• This instruction will verify that a specific tool changer nest is empty.
Check For Head In Nest

• This instruction will verify that a specific tool changer nest is occupied.
Open Nest
• This instruction will open a tool changer nest.
Close Nest
• This instruction will close a tool changer nest.
GRS4-E 290
The maximum number of robot controlled nests is 4.
The robot will control nests where the end-effector can not be serviced
without entering the cell. The robot will not control the tool nests in
applications where tool changers are implemented as a means of backup,
and a faulted end effector can be removed from the nest without entering
the cell.
Instead, the robot will communicate with the cell controller for indication of
nest empty and related signals using the path segments.
GRS4-E 291
Robot Controlled Tool Nests
Pickup/Dropoff Routines
• Path routines will be provided for the exchange of tool changer
heads during both in-path and back-up tool changing situations.
• These routines will initiate the proper checks for dropping or
picking up a tool changer head.
• It will be possible to utilize these routines to send the robot to
exchange tools automatically.
GRS4-E 292
Tool Exchange Utility (Style 26)
While the robot is in interlock mode, selecting Style 26

from the cell controller will execute the functions described
below.
The Pick Tool function drops off the currently installed gun
in the appropriate nest before picking up the requested
tool.
GRS4-E 293
Tool Change Decisions
DECISION CODE AT POUNCE FUNCTION
0 Swap with backup

1 pick tool from nest 1
5 Drop tool in nest
GRS4-E 294
Path Segments for PLC Operated
Tool Nests
PRE-NEST TO LIFT TO EXIT ROBOT INPUT TO
HOME TO LIFT NEST CHECK
PRE-NEST
Head 1 pickup 10 11 12 diGun1Rdy (In61)
GRS4-E 295
Path Segments for PLC Operated
Tool Nests (cont’d)
PRE-NEST TO LIFT TO EXIT ROBOT INPUT TO
HOME TO LIFT NEST CHECK
PRE-NEST
Head 1 dropoff 30 31 32
GRS4-E 296
Module 3: Review – Tool Change Configuration Items
What options will be configurable for tool changing robots?
1. Specify the number of tools that will be used
2. Select if the tool changer nests will utilize lids
4. Select if the nest in position signals will be used
For both material handling and tool changing, what is generated

whenever an expected input state is not detected within a
configurable amount of time?
A Fault
GRS4-E 297
GRS
LMS # 34043
Module 4: Robot Set-up Procedures

Revision 6.1

All Rights Reserved
Objectives
• The student will explain the “Cold Start” and
“Controlled Start” procedure.
• The student will define the Fanuc Setup Wizard use.
• The student will explain the “Backup All” procedure.
• The student will define the “Create and restore a
backup image” procedures.
• The student will explain the “Robot Held Servo
Wizard” setup procedure.
• Understand GM Custom Screens
2
Controlled Start
The Controlled Start procedure is similar to booting in Safe Mode on
a windows PC. It allows the user to load software options and
configure the robot's settings. Use the following steps to perform the
Controlled Start:
1. Turn off the Power to the Robot Controller.
– If the controller is on. Press the "on/off" button to select "off". (Make
sure robot and cell are at the end of cycle)
2. Perform Controlled Start.
– Press and hold the "PREV" button and "NEXT" keys on the teach
pendent while you press the "On/Off" button on the controller.
– Press the "3" button to select menu option "3 Controlled Start".
– Press the Enter button.
3
GRS4
Controlled Start (cont’d)
On the FANUC R-30iB Controller, a controlled start can also be done
from the cycle power menu.
1. Press FCTN – 0: Next – 8: Cycle Power
2. Select OPTIONS from the pop up menu
3. Choose Controlled Start
4
GRS4
Cold Start
Cold Start:
Used to initialize changes to I/O and System Variable
Boots back up with the program aborted
Use the following steps to perform a Cold Start:
1. Turn off the Power to the Robot Controller.
– If the controller is on. Press the "on/off" button to select "off". (Make
sure robot and cell are at the end of cycle)
2. Perform Cold Start.
– Press and hold the "PREV" button and "NEXT" keys on the teach
pendent while you press the "On/Off" button on the controller.
– Press the “2" button to select menu option “2 Cold Start".
– Press the Enter button.
GRS4
5
Cold Start (cont’d)
On the FANUC R-30iB Controller, a cold start can also be done from
the cycle power menu.
1. Press FCTN – 0: Next – 8: Cycle Power
2. Select OPTIONS from the pop up menu
3. Choose Cold Start
6
GRS4
GM Setup Wizard - Overview
• The Fanuc Setup Wizard aids the user in setting up
robots used at General Motors for all projects using
Global 4 generation of Fanuc robots with SpotTool+
8.33 with the GRS4 Customization.
• Typically, the wizard needs to be executed only when
the robot is first installed or if the robot has to be
configured for a different application.
– Depending on the application change, software may need to
be reloaded.
GRS4
7
What Does the Setup Wizard Do?
Provides the programmer menus to aid in configuration and setup of
FANUC robots with GM GRS4 customization during a controlled
start. It prompts the user with an intuitive series of questions about
the robots application, and based on the user’s input to the questions
the Wizard will:
• Map and configure I/O for the application.
• Set GM customized variables.
• Load standard and application specific programs/templates.
GRS4
8
What the Wizard Does Not Do?
The Wizard will not:
• Reconfigure the core software personality (this is not a normal
procedure as robots are delivered with the correct software
personality for their hardware configurations). If reconfiguring a
robot, users need to be educated to determine what software
personality is required.
• Add software options.
• Perform Servo Gun Setup (calibration, parameter setting)
GRS4
9
GRS-4 Global 4 Customization Menu
Select from the Customization Steps listed below:
10
Select English, German
• This section allows the Setup Wizard utility to be run in
various languages (English, Spanish, German).
• Current supported languages are English and German.
– The default language for all controllers loaded from FRA or
FANUC is English.
– If the user would like to have the Setup Wizard utility run in
another language, execute this step first.
• In order to change the language, “Select English,
German” before “Run Robot Configuration Tool”.
GRS4
11
Select English, German (cont’d)
• Then select under SETUP/General to change base
controller language.
– The secondary language will be changed here.
• All changed language components have been agreed

to by FANUC Robotics America and GM N/A MAAC to
cover a complete GRS-4 software option set.
• Please note NOT all WIZARD items or CORE
Spottool+ v8.33 items are translated.
GRS4 12
Display Current Robot Configuration
Displays the current configuration of the robot
• What manufacturing area is it in? – Body shop, Metal
Forming, Powertrain, Paint shop
• What application is it running? – Spot Welding, MH,
etc.
Note: Feature to be included in the next robot

software release.
GRS4
13
Run Robot Configuration Tool
• This selection is used to setup of the robot. Under this selection
the wizard will prompt the user for the IP address, manufacturing
area, number of processes, and what each process is (Spot, Stud,
Dispense, Multi-Process or Material Handling).
• Depending on the robot configuration the wizard will go through a
variety of questions asking for user input for setup questions.
• These questions will configure system settings, system variables,
robot I/O, and load application specific template TP programs and
Macros.
GRS4
14
Load Configuration
Allows for the configuration file to be loaded to
multiple robots
Note: Feature to be included in the next robot

software release.
GRS4
15
Exit
• Exit will exit the Setup Wizard and finish any GRS4
Customized settings.
• Once the Wizard is finished setting parameters perform
a Cold Start.
GRS4
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Robot Held Servo Gun Welding Example
This is a complete example of running the setup wizard
Robot Held Servo Gun.
– The user should only select the equipment relevant to the
application.
– If your application requires a language other than English, set
the Wizard language first, and then move to “Run Robot
Configuration Tool ”.
– NOTE: If your setup will require more than 1 SERVO GUN the
FULL LOAD Media Card must be inserted in the robot
controller prior to RUNNING THE SETUP WIZARD.
17
GRS4
Robot Held Servo Gun Welding Example (cont’d)
1. Select 3. Run Robot Configuration Tool
GRS4 18
2. If running for the first time this menu may not appear.
If running it again it will ask to clear the configuration
GRS4 19
3. Select 1 to setup the Safe I/O
GRS4 20
4. Select 1 to set the IP address of the robot
GRS4 21
5. Select the Manufacturing area, <BodyShop>.
GRS4 22
6. Select the number of robot processes. <1>.
23
GRS4
7. Select the robot process. <Spotwelding>.
24
GRS4
8. Preset GLOBAL 3/4
Equipment EIP Settings. If
the devices are not
GLOBAL 3/4 STANDARD
the user should answer
NO.
Note: This does set the
device EIP address, as the
watersaver is on the robot
LOCAL network.
GRS4
25
9. Select the weld gun configuration. <Robot Held Gun>
26
GRS4
10. Select Servo Gun welding application <Servo Gun
YES>
GRS4 27
11. Select Axis Data Step
<YES>.
Note: A selection of
<NO> will be required
only if the wizard is run
and the user does not
want to modify gun setup
parameters.
GRS4
28
12. Select the motor type from the list.
<5 GSWA/XXX/XXX/IMA44 – Tol >.
Note: If the user motor
selection is not listed, select
motor number 1. Then
change the motor type
following the Spottool +
Setup and operations menu
at CONTROLLED START
menus.
GRS4
29
13. From the servo gun tag, Enter the maximum pressure for the servo gun
<XXXX nwt> from the gun tag and NOT the motor tag.
Note: This value will

be used to determine
servo gun calibration
table and pressure
table settings.
30
GRS4
14.Select the gun design type or shape
< C-Gun >
C - Gun X - Gun
31
GRS4
15. Default Press/Bkup/Distance Setup <1 = YES>
Usually answer yes if this is

a first time setup
32
GRS4
16. Select Tip Dresser option.
GRS4
33
17. Select if dress verification is used
GRS4
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18. Select if Servo Tip Dresser is used. If no is selected the default
electric dresser is configured
GRS4
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19. Select transformer over-temp switch, if present. Typically NO.
36
GRS4
20. Is a Tool Changer(s) Present? Typically NO.
GRS4
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21. Press 1 to Execute Setup
GRS4
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22. If the setup has already been run it will ask if you want to
acknowledge each change or accept all changes. In this case
enter 1 to RESET
GRS4
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23. The screen will flash as the changes are being made and it will
return to the Wizard Menu. Select 5 and press enter to Exit. Then
Press FCTN – 1 Cold Start to return to reboot the robot
GRS4
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Backup All
The Backup All procedure should be performed
every time you reprogram the robot. This is an
archive procedure that allows you to retrieve the
current settings.
GRS4
41
Backup All (cont’d)
Step 1. Access File Screen
1. Turn on the robot controller by pressing the on/off switch.
2. Press the "MENU" button on the teach pendent after boot is
complete.
3. Select "7 File".
4. Press the "ENTER" button.
5. The File screen will appear.
GRS4
42
Step 2. Set up the backup device.
6. Insert a Memory Card into the PCMCIA slot inside the
controller, a USB Drive into the port on the front of the
controller or into the port on the TP
7. Press "F5 [UTIL]". The backup device menu will appear.
8. Select "1 Set Device".
10. Select “Mem Card (MC:)“, “USB Disk (UD1:)” or press 8 to go
to the next page to access “USB on TP (UT1:)”.
GRS4
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Step 3. Start the backup
12. Press "F4 [BACKUP]". The file type menu will appear.
13. Select "All of the above".
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Step 4. Maintenance and back up files.
15. Answer On-Screen question "Delete MC: \\ before backup
files?"
16. Press "F4" for Yes. Files are deleted on memory card.
17. Press "F5" for No. Will not delete files on memory card
You have completed the Backup All procedure. Your current

settings are saved for future reference on the memory card.
GRS4
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MD: Copy
An MD: Copy backup copies both compiled and
non-compiled files from the robot to the backup
device. This is helpful for viewing files offline in a
text editor.
GRS4
46
MD: Copy (cont’d)
1. Turn on the robot controller by pressing the on/off switch.
2. Press the "MENU" button on the teach pendent after boot is
complete.
3. Select "7 File".
5. The File screen will appear.
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47
MD: Copy (cont’d)
6. Insert a Memory Card into the PCMCIA slot inside the
controller, a USB Drive into the port on the front of the
controller or into the port on the TP
10. Select “Mem Card (MC:)“, “USB Disk (UD1:)” or press 8 to go
to the next page to access “USB on TP (UT1:)”.
GRS4
48
MD: Copy (cont’d)
Step 3. Set the MD:
15. Select “Mem Device (MD:)“
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MD: Copy (cont’d)
16. Press NEXT to change the function key options
17. Press F2 COPY
18. Scroll down to the To Device: field and press F4 [CHOICE]
19. Choose the device to copy to. Usually MC: or UD1:
20. Press F1 DO_COPY
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MD: Copy (cont’d)
Step 5. Maintenance and back up files.
21. Answer On-Screen question “Overwrite?"
22. Press "F4" for Yes or "F5" for No.
You have completed the MD: Copy procedure. Compiled and non-
compiled files should be stored to the selected removable memory
device.
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Controller Image - Backup
Use this procedure to backup the controller as an image.
1. Turn off power to the robot controller
2. Press and hold F1 and F5 keys on the teach pendant
3. Continue to hold F1 and F5. Turn the power back on to the
robot controller. The robot will boot to the BMON menu on
the teach pendant.
4. Release all the keys when the BMON menu appears.
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Controller Image – Backup (cont’d)
5. From the BMON menu, select Controller backup/restore
(press the 4 button then the ENTER button).
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6. Select Backup controller as Images (press 2 then press
Enter).
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54
7. Select Memory Card (MC:) or USB (UD1:) and press ENTER.
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55
8. Insert a memory card or USB flash drive with enough free
space to hold the full controller image.
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9. Type 1 and press ENTER. The memory files will
be written to the memory card. You should see
messages similar to the following:
GRS4
57
10. When the backup is complete, press ENTER to
display the BMON menu.
11.Press 1 to return to the Configuration Menu
12.Select Cold Start to boot back into the normal
mode
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On newer software versions an Image Backup can be
taken from the normal file menu:
– Press MENU – 7 File – F4 [BACKUP] – select Image Backup
– The controller will then cycle power, go into boot monitor,
backup the image files, and re-boot into normal mode
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Controller Image – Restore
3. Continue to hold F1 and F5. Turn the power back on to
the robot controller. The robot will boot to the BMON
menu on the teach pendant.
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Controller Image – Restore (cont’d)
5. Select Controller backup/restore and press the 4 button
then the ENTER button.
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61
6. Select restore controller images press the 3 button then
press Enter.
62
GRS4
7. Insert a memory card or USB flash drive with the
controller image.
8. Select (1) Memory Card (MC:) or (3) USB (UD1:) and
press ENTER.
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63
9. Type 1 and press ENTER. The memory card files will be
written to the robot memory.
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64
10. When the restore is complete, press ENTER to display the
BMON menu.
11. Press 1 to return to the Configuration Menu
12. Select Cold Start to boot back into the normal mode
13. Load the “Backup All” files from the file menu to restore the
latest TP programs.
The image should be restored.
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65
GM Customized Screens
GM has created customized screens to assist with robot
programming and troubleshooting. These screens include:
• Production Home, GM Manuals, Production Speed
• Servo Gun Hints
• Tip Dress Status
• Tool Changer Status
• Proteus Web Application
• WTC Weld Controller WebDep
• GM Setup Top Menu – Wizard Top Menu
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66
Production Home, GM Manuals, Production Speed
The Production Home screen is accessed from the Menu
Favorites bar. Press MENU button for the bar to appear and
select PROD HOME
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(cont’d)
The Production Home screen gives information on the IP
address, style, segments, decision codes, and the status of the
robot. It also give access to the Production Speed Page and GM
Robot Manual page
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(cont’d)
The Production Speed Control Page summarizes robot speed settings. It gives the
selection to allow the PLC to control the speed after the paths have been validated
at 100%. For continuous processes the speed override will be set to 100% all the
time. This is used for dispense robots.
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69
(cont’d)
The Manuals page gives links to the GM Setup guides. The documents can be saved
to Memory Card or USB drives so they can be viewed on a PC. The application
specific documents are loaded based on the application selected in the wizard.
Pressing the Production Home button takes you back.
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Servo Gun Setup Hints
This screen gives a reference for servo gun activities.
This page is accessed by pressing MENU – UTILITIES –
F1 [TYPE] – Servo Gun Hints
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71
Tip Dresser Status
This screen gives a summary of the tip dresser data. To access this page press STATUS –
F1[Type] – Tip dresser #1.
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72
Tool Changer Status
This screen gives a summary of the I/O used for tool changing. To access this page press
STATUS – F1[Type] – Tool Change Status.
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73
Proteus Web Application
This screen connects to the water saver’s device web page. The communication should
be setup through Ethernet port #2. To access this page press MENU ‐ BROWSER –
F1[Type] – PROTEUS #1 or PROTEUS #2. It can be used to setup dual water savers. See
the Wizard Manual for more details.
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WTC Weld Controller WebDep
This screen connects to the weld controller’s device web page. The communication
should be setup through Ethernet port #1 of the PLC switch. To access this page press
MENU ‐ BROWSER – F1[Type] – WTC1 or WTC2. It can be used to setup dual water
savers. See the Wizard Manual for more details.
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GM Setup Top Menu
1. By pressing the i‐key and the MENU
button at the same time the GM
Setup menu will appear. This
provides links to the menus that are
necessary for setting up a robot with
the GM customization.
2. It also has a link the Wizard Top
Menu which gives information on 2
how to get to the setup wizard.
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Wizard Top Menu
3. Wizard Top Menu
GRS4
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Module 4: Review
How do you perform the “Cold Start” procedure?
– Step 1: Press PREV and NEXT while rebooting
– Step 2: Select “2 Cold Start” from the configuration menu
– Step 3: Press the "ENTER" button.
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Module 4: Review
How do you backup the controller as an image?
3. Continue to hold F1 and F5. Turn the power back on to the
robot controller. The robot will boot to the BMON menu on
the teach pendant.
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Module 4: Review
How do you backup the controller as an image? (cont’d)
5. From the BMON menu, select Controller backup/restore
(press the 4 button then the ENTER button).
6. Select Backup controller as Images (press 2 then press
Enter).
7. Select Memory Card (MC:) or USB (UD1:) and press ENTER.
8. Insert a memory card or USB flash drive with enough free
space to hold the full controller image.
9. Type 1 and press ENTER. The memory files will be written to
the memory card.
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Module 4: Review
How do you restore the controller image?
3. Continue to hold F1 and F5. Turn the power back on to the robot
controller. The robot will boot to the BMON menu on the teach
pendant.
5. Select Controller backup/restore and press the 4 button then the
ENTER button.
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Module 4: Review
How do you restore the controller image? (cont’d)
6. Select restore controller images press the 3 button then press
Enter.
7. Select (1) Memory Card (MC:) or (3) USB (UD1:) and press ENTER.
8. Insert a memory card or USB flash drive with the controller image.
9. Type 1 and press ENTER. The memory card files will be written to
the robot memory.
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Module 4: Review
How do you restore the controller image? (cont’d)
10. When the restore is complete, press ENTER to display the BMON
menu.
11.Press 1 to return to the Configuration Menu
12. Select Cold Start to boot back into the normal mode
13. Load the “Backup All” files from the file menu to restore the latest
TP programs.
The image should be restored.
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Module 4: Review
What are some guidelines for Robot Held Servo Gun Setup?
– The user should only select the equipment relevant to the
application.
– If your application requires a language other than English, set the
Wizard language first, and then move to “Run Robot Configuration”
– NOTE: If your setup will require more than 1 SERVO GUN the
FULL LOAD Media Card must be inserted in the robot controller
prior to RUNNING THE SETUP WIZARD.
– Use the wizard as shown in the Robot Held Servo Gun Setup
procedure to setup for your application.
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Module 4: Review
How do you perform a Backup all procedure?
Step 4. Maintenance and back up files
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Module 4: Review
What does the Setup Wizard do?
Provides the programmer menus to aid in configuration and setup of
FANUC robots with GM GRS4 customization during a controlled
start. It prompts the user with an intuitive series of questions about
the robots application, and based on the user’s input to the questions
the Wizard will:
• Map and configure I/O for the application.
• Set GM customized variables.
• Load standard and application specific programs/templates.
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Module 4: Review
What does the Wizard not do?
The Wizard will not:
• Reconfigure the core software personality (this is not a normal
procedure as robots are delivered with the correct software
personality for their hardware configurations). If reconfiguring a
robot, users need to be educated to determine what software
personality is required.
• Add software options.
• Add Ethernet/IP devices to the scan list
• Perform Servo Gun Setup (calibration, parameter setting)
87

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Global Robot Specifications

Module 1: Robot Processing

© 2017 General Motors Company.

2. Can DCS replace a light curtain or a robot axis

Bead Length in mm 200 mm

2.5 sec Out

• Projection nut welding robots

• Calculate the rough cycle time for a material

DC Welding requires use of 1 SCR and 1 Weld Gun.

• Style Numbers (1 to 24) identify different robot paths required by

• The option bits (A, B, C, D and E) identify minor

paths are required within Request to Continue

Seg12: Clear Pick 1 Seg32: Clear Drop 1

DC =15 Seg10: To Pick 1 Seg30: To Drop 1

*No Part check

Module 2: Robot Integration

© 2017 General Motors Company.

• The integrator shall also configure the following during integration

• The TCP shall not move more than 2 mm in

For rocker-type guns, the origin of the TCP shall be the

• The +X and +Y direction shall be square to the stud

COMMENT “Enter I-Zone with F120-R4 in Z1”

MOVE L P2 100mm/s CONT100

Zone 3 Zone 2 Zone 3

* Path segment control from the PLC is preferred.

Zone 1 Zone 1 Zone 2 Zone 1

R2 R4 R6 Interference with Robot # Use zone number

Module 3: Robot Interfaces

© 2017 General Motors Company.

Robot Input Description Signal name

GIN# Signals Description Signal Name

GOUT# Signals Description Signal Name

A template will be provided containing the standard logic

1. Echo Style 31 (move to repair) to the cell controller

3. <User to program the path from home to repair here>

4. Wait for continue (cell controller or user input to the robot)

6. <User to program the path from repair to home here>

1. Echo Style 27 to cell controller

2. Set Segment [6]

4. <Automatically reset steppers>

5. <Automatically reset water savers>

7. <Automatically reset cap change request bits>

8. <Automatically initiate tip wear measurement for servo guns>

The robot will respond to a cap change command at any

Decision code 14 has been allocated for this purpose. This

If the “Tipdress on Cap Change” signal is set it also sets the

2. Wait for the PathSegContOK to be reset

4. Post the message ”Waiting for Continue” on the teach pendant

5. Wait for the PathSegContOK to be set by the cell controller

Spot Welding No-stroke & No-Weld Activate Retract normally,

Stud Welding No-stroke & No-Weld

Arc Welding No-weld & No-weave

For a combination of material handling with a carried process, FFR will be

Style (bit 8) StyleBit8 In28

Tryout Mode Request TryoutModeReq In10

Initiate Style Program InitiateStyle In35

Path Segment Continue OK PathSegContOk In56

Interference Zone 1 Clear to ClearToEntrZone1 In37

Decision Code (Bit 1) DecisionCodeBit1 In49

Process 1 On Request Process1OnReq In65

Tryout Mode TryoutMode Out10

In Cycle InCycle Out11

Path Segment (Bit1) PathSementBit1 Out57