DOCUMENTATION

REIS GMBH & CO MASCHINENFABRIK OBERNBURG

Welding

Title: Operating and Programming Instructions Arc Sensor

Author: Dr. Thomas Rienmüller

Date: 27.07.1999

Control version: RSV

Software: 4.0

Documentation for level: 2

Date: 07.04.2000

Release: Franz Som

Original: I:\Betriebsanleitungen\Doku_RSV\LIBOSEN_0400_GB.DOC
 RSV WELDING

1 TABLE OF CONTENTS

1 TABLE OF CONTENTS ________________________ 1

2 GENERAL DESCRIPTION ______________________ 3

2.1 Welding technological fundamentals_________________ 3
2.2 Fundamentals of the arc sensor _____________________ 4
2.3 Limits of the procedure ____________________________ 6

3 TARGET GROUP _____________________________ 8

4 SAFETY INSTRUCTIONS ______________________ 8

5 CONDITIONS: HARDWARE AND SOFTWARE _____ 9

6 ASSEMBLY/CONFIGURATION _________________ 10
6.1 Configuration of the analog inputs _________________ 10
6.2 Adjustment of the PSI shift ________________________ 10

7 OPERATION________________________________ 12
7.1 The parameters of the command "ARC_SENSOR" ____ 13
7.2 The meaning of the elements of the user variable Rvar[10]14
7.3 Determination of the K-factor ______________________ 15
7.4 Determination of reference values __________________ 16
7.5 Switch-on and -off the welding head guiding _________ 18
7.6 Additional remarks_______________________________ 19

8 PROGRAMMING ____________________________ 23
8.1 The system variables of the arc sensor ______________ 23
8.2 Connection of the arc sensor to the general sensor
function ________________________________________ 25
8.3 Side guiding by means of the oscillation function _____ 27

8.3.1 Example for a pure side guiding at symmetrical seam______ 30

8.3.2 Example for height and side guiding at an asymmetrical seam31

8.4 The machine data of the arc sensor _________________ 38

LIBOSEN 04_00 08/99 GB 1

 RSV WELDING

9 APPLICATION SOFTWARE ___________________ 40

10 ERROR MESSAGES/ TROUBLE SHOOTING _____ 41

10.1 Error messages______________________________ 41
10.2 Further messages ____________________________ 45

11 GLOSSARY _________________________________ 1

12 INDEX ______________________________________ 2

LIBOSEN 04_00 08/99 GB 2

 RSV WELDING

2 General Description

The arc sensor processes the electrical welding data current

and voltage as well as the mechanical oscillation movement of
the robot and produces a correction signal for height and side.
It consists of an adapting interface where the measured
voltages will be adapted to the analog inputs of the RSV and
the corresponding system software.

Prior to supply into the adapting interface the weld current first
must be converted into a proportionate voltage by means of a
suitable measuring transformer (Hall sensor). The weld voltage
can be calipered at the power source or directly at the torch
head and be given directly to the adapting interface.

Further transducers are not necessary. Thus, accessibility, e. g.

at narrow components, is maintained without any restrictions.

2.1 WELDING TECHNOLOGICAL

FUNDAMENTALS

A value is calculated from the parameters welding current and

welding voltage which is proportional to the arc length. For
calculation of the arc length, however, it is necessary to know
the slope of the characteristic curve of the process (arc
resistance) in the working point. The slope of the characteristic
curve of the process is called 'K-factor' in the following text.

This K-factor depends on the type of the welding process (short

arc, pulsed arc, spray arc), composition of gas etc.

After adjustment of a certain welding process therefore the K-

factor must be newly determined. In practical operation the
characteristic curve of the process is a bent curve, i.e. it has
different slopes at different positions.

However, for welding with constant voltage resp. constant

current in a fix working point it is absolutely sufficient to know
the slope of the characteristic curve of the process in the

LIBOSEN 04_00 08/99 GB 3

 RSV WELDING

working point or the average of the slope for pulsed arc

welding.

This is different for TIG-welding with pulsing of the welding

current at low frequency. Here the working point shuttles
periodically in the range of the oscillation frequency on the
process characteristic curve. For this dynamical process it may
perhaps not be sufficient to know the slope of the process
characteristic curve only in one working point. This operation
case may require the corresponding values about the desired
work envelope.

The arc sensor for side correction depends on the existence of

a shape of joint which can be scanned, such as fillet weld, V-
weld, X-weld, for instance. Thickness of sheet metal and arc
have to be chosen so that the flanks of the joint are not melted
off, since otherwise the basis for measurement for the sensor is
withdrawn.

2.2 FUNDAMENTALS OF THE ARC SENSOR

For sensor operation the arc is set into a periodical oscillation

movement which is transversal to the weld seam. If oscillation
is performed at an inclined sheet metal, for instance, the arc will
shorten and extend synchronously to the oscillation.

An arc which is compulsorily shortened will extend again due to

its internal regulation, however, it won't achieve its original
length. There remains a little difference in length which is
acquired and evaluated by the sensor calculator.

The average value of arc length (Li), measured over one

oscillation period, is a measure for the average arc length and
thus, a measure for the distance of the torch from the
workpiece, in the following called actual value of height 'Hi'.

Hi = average value(Li)

The lateral deviation 'Si' is calculated from the difference

between the arc length sums of the first oscillation half-wave
and the second oscillation half-wave.

LIBOSEN 04_00 08/99 GB 4

 RSV WELDING

Si = sum(L1i) - sum(L2i)

If the arc oscillates symmetrically to the center of a V-seam, the

sums of the arc lengths of the first and the second oscillation
half-wave will be equal, the lateral deviation 'Si' becomes zero.
Otherwise, 'Si' will adopt positive or negative values, depending
on direction and size of the lateral deviation.

In a teach-in procedure (definition of reference values) the

values for height and side are determined and stored at a sample
part. In seam sequential mode (welding head guiding) the
actually measured values for height and side are permanently
being compared with the reference values determined in the
teach-in procedure. Any deviation from the reference values is
transferred to the general sensor function as correction value.

Calculation and transfer of the correction values to the general

sensor function is done automatically. The dead time of the
sensor (reaction time) thus is independent from the selected
oscillation frequency.

In practical operation, a sine-shaped oscillation frequency of

3,0 Hz with +/- 1,5 mm amplitude often turned out to be a good
compromise between welding result and mechanical strain of
the machine.

Besides this, practical operation proved that the following items

should be observed especially for side guiding:

• The oscillation frequency must not be less than 1,0 Hz.

• The oscillation width should not be less than +/- 1,0 mm.

• The oscillation movement should be a plane movement, i. e.

it should not have any shares in direction of the welding
flame.

2.3 LIMITS OF THE PROCEDURE

The procedure doesn't work with materials where a

compulsorily shortened arc readjusts to the original length due

LIBOSEN 04_00 08/99 GB 5

 RSV WELDING

to the internal regulation (e.g. with aluminum), since there can't

be noted any modification of arc length in that case.

The procedure reaches its limits also in case of arc length

changes being so small that they are overlapped by the welding
process interference.

This may be the case:

• if the aperture angle of the welding groove is very big

• if the oscillation width is very small

(it should not be less than +/- 1 mm)

• if the arc width reaches the values of the welding groove

dimensions.

The arc sensor looses its side guiding when the flanks of the
welding groove are melted off see

no correction possible,
because arc too wide

correction possible

LIBOSEN 04_00 08/99 GB 6

 RSV WELDING

no correction possible,
because an edge is molten
off

correction possible

Fig. 1: Concerning the limits of the procedure

LIBOSEN 04_00 08/99 GB 7

 RSV WELDING

3 Target group

Setter (level 2)

Programmer (level 3)

4 Safety Instructions

Like for all works with sensors, particularly for start-up and
optimization of the sensor guiding, utmost caution is required.
Especially the reaction of the sensor in case of process
changes or changes in the control circuit amplification has to be
tested cautiously and carefully. In case of unsuccessful
attempts etc. there may result extremely fast and big correction
movements of the robot which may be a hazard to the operator
or the installation.

LIBOSEN 04_00 08/99 GB 8

 RSV WELDING

5 Conditions: Hardware
and Software

The functionality is available in the RSV system software from

V4.0 already.

Additional hardware in the form of galvanically isolated analog

inputs with +/- 10V input range and an adapting interface for the
corresponding power source is required.

The analog inputs may be brought into the I/O-circuit of the

RSV as an own node, but they also can be extensions to
existing nodes. For further information please refer to the
documentation "Configuration of the CAN circuits by the
user".

The standard adapting interface divides the welding voltage

down by the factor 5, in order to cover the input voltage range
of +/- 10V of the analog input modules. The current range is
accepted 1:1. Condition is a current measuring transformer
which supplies 10mv voltage per Ampere welding current.

LIBOSEN 04_00 08/99 GB 9

 RSV WELDING

6 Assembly/Configuration

6.1 CONFIGURATION OF THE ANALOG INPUTS

For configuration the corresponding analog inputs have to be

entered in the AWP "CAN_CNF". For details please refer to the
documentation "Configuration of the CAN circuits by the
user".

6.2 ADJUSTMENT OF THE PSI SHIFT

The exact adjustment of the oscillation synchronizing pulse

(PSI) is important for the side guiding of the arc sensor.
Oscillation is necessary for side guiding, see also chapter 8.
The PSI is given by the oscillation function at the end of each
oscillation period in order that the arc sensor can synchronize
again with the oscillation movement. This is important, in order
that the arc sensor can correctly allocate the measured values
to the side calculation.

Due to the inertia of the robot kinematics (tracking distance),

however, the arc processes the zero passage a little bit later
than indicated by the PSI. This delay depends on the
kinematics of the machine and also a little on the weight of the
torch and of the hose pack. In order to compensate temporal
delays, the PSI has to be delayed in time (see machine data
RPSI_SHIFT in chapter 8). The sensor calculator must know
the true zero passage (at the arc) of the oscillation movement,
since otherwise evaluation of the measurements gives wrong
results. Experience showed that a value of 80ms is suitable in
almost all cases.

This adjustment is made in Reis works for each machine to be

shipped. If changes are made at the machine afterwards
effecting the tracking distance of the machine, the adjusted
PSI-shift has to be checked by means of the arc sensor. For
this purpose a straight path in a fillet weld is programmed and
the arc sensor is calibrated for a side guiding on this. Doing so,
any filter function which may be active must be switched off
with the command "COPY 0,_IFILTER" before the definition of

LIBOSEN 04_00 08/99 GB 10

 RSV WELDING

reference values is requested. As a result, the measured side

reference value should be approximately "0". The side
reference value is set to "0" and guide trials are executed.
Doing so, the path end point one time is programmed away to
one side, and another time to the other side. If the arc sensor
makes the corrections equally well in both test runs, adjustment
of the PSI is correct.

Remark:

For normal welding procedures the PSI adjustment is not

critical. The arc sensor will make faulty reactions only if
RPSI_SHIFT is adjusted very roughly, e. g. deviation bigger
than +/- 15ms. However, for asymmetrical welding procedures
the PSI must be defined exactly. In this case several trials have
to be executed, if necessary.

LIBOSEN 04_00 08/99 GB 11

 RSV WELDING

7 Operation

The arc sensor is operated through the user command

ARC_SENSOR #par1, Variable: Rvar[10],

which has two parameters and is situated in the second menu

of the key "spec" in the status when the machine is shipped.
With this command, the measured value recording and the
correction value calculation are controlled. This command is
self-supporting and also becomes active after a step
preselection into a path. It is only evaluated during welding and
therefore must be programmed before welding is switched on.
The function of the arc sensor only takes place in automatic
and TEST2 operation and only during welding.

Whereas the operating mode of the arc sensor is adjusted with

the first parameter, further data such as e. g. K-factor and
reference values are transferred to the arc sensor in the
variable Rvar[10]. This allows new definition of K-factor or
reference values at intermediate positions also during welding.
For this purpose, new programming of the command
'ARC_SENSOR #ON,Rvarx1[10]' is sufficient, Rvarx1
containing the desired new parameters. It is also possible to
copy a new reference value into the currently valid real variable
by means of the COPY command, e. g. with "COPY 2.86,
Rvar[2]". For definition of a new K-factor, normally new
reference values are required, too, because the K-factor
represents the calculation basis for the reference values.

In addition, the general sensor function must be activated which

contains the correction values of the arc sensor as input values.
For programming of the general sensor function please refer to
the documentation "sensor function".

If side guiding shall be used, the filter function as to be

switched off at the time being. This is done with the COPY
command

COPY 0,_IFILTER

LIBOSEN 04_00 08/99 GB 12

 RSV WELDING

at the beginning of the programmed path. In any case a

suitable oscillation movement has to be activated for the side
guiding. In this context please refer to the documentation
"Oscillation Function: Programming and Use".

7.1 THE PARAMETERS OF THE COMMAND

"ARC_SENSOR"

For the first parameters a selection menu is given by the RSV

offering the entries #ON, #OFF, #K-FACTOR and
#REFERENCE for selection. The entry #PSI is not yet
implemented at the time being.

With the entry #ON the seam sequential mode resp. the
welding head guiding, is switched on.

With the entry #OFF the arc sensor is switched off.

With the entry #K-FACTOR the arc sensor is made determine

the slope of the characteristic curve of the process in the
operating point. The determined value is stored in the first
element of the variable indicated in the second parameter.

With the entry #REFERENCE the reference values of the arc

sensor in the operating point are determined. The determined
values for height and side are stored in the elements 2 and 3 of
the variable indicated in the second parameter.

As second parameter the name of a user variable is expected.

This must be of real array type and have 10 elements. The real
variable Rvar[10] with 10 elements must be programmed
manually. The rules of the program variable apply for it, i. e. it
must be defined at the beginning of a program as global
variable:

MPR “Name”

VAR Rvar[10]

....

LIBOSEN 04_00 08/99 GB 13

 RSV WELDING

7.2 THE MEANING OF THE ELEMENTS OF THE

USER VARIABLE RVAR[10]

The variable Rvarxx[10] has the following structure:

Element no. Format Significance

Element [1] real K-factor

Element [2] real height reference value

Element [3] real side reference value

Element [4] real waiting time for height/side

correction

Element [5] real reserved

Element [6] real reserved

Element [7] real reserved

Element [8] real reserved

Element [9] real reserved

Element [10] real operating mode

The elements1, 2, and 3 can either be described by the

methods of automatic parameter determination or they can be
pre-allocated by the command COPY during program run like
the other elements, see examples:

COPY RNAME,Rvarxx[y] RNAME must contain a

reasonable value

COPY decimal number, Rvarxx[y] Pre-allocates the element y

directly with a value

In element 1 the K-FACTOR for this process is stored.

The height reference value for this process is stored in

element 2, the side reference value in element 3.

LIBOSEN 04_00 08/99 GB 14

 RSV WELDING

The waiting time in element 4 offers the possibility to have the

two correction types height or side correction delayed to each
other. The indication is made in [ms] and has to be entered by
hand into the element 4 of the variable Rvarxx[10] by means of
the COY command.

Rvarxx[4] = 0 or not pre- height and side correction

allocated: become active at the same time

Rvarxx[4] > 0 : height correction will become

active x ms later than the side
correction

Rvarxx[4] < 0 : height correction will become

active x ms earlier than the side
correction

The operating mode in element 10 in standard procedure is

“1”. If this element is still invalid, this status is also taken as “1” .

7.3 DETERMINATION OF THE K-FACTOR

If 'ARC_SENSOR #K-FACTOR,Rvar[10]' is programmed and

processed in TEST2 or AUTOMATIC mode, the arc sensor is
requested to determine the K-factor.

Command Effect

ARC_SENSOR Request determination

#K-FACTOR,Rvarxx[10] of K-factor

Limits of the K-factor:

All values except 0 are allowed; values between approx. 0,8

and 2,5 proved to be useful up to now (rough reference values).

Example program for the K-factor determination:

Commands: Before: Afterwards

LIBOSEN 04_00 08/99 GB 15

 RSV WELDING

POS

ARC_SENSOR #K-FACTOR, K-factor invalid K-factor

Rvarxx[10] (or wrong) valid

WELDING #ON

POS

WELDING #OFF

: :

The arc sensor is set into operating mode 'determination of K-

factor' when welding is switched on. The K-factor is
permanently being calculated and averaged during welding.

When the averaged K-factors have stabilized after some time

(approx. 20 sec.), the value determined last is transferred to the
robot control and automatically entered into element 1 of the
real variable Rvar[10]. Then the message "K-factor determined,
value x.y" is displayed and welding is switched off.

If the welding time is too short for determination, a

corresponding error message will be displayed.

7.4 DETERMINATION OF REFERENCE VALUES

If 'ARC_SENSOR #REFERENCE,Rvar[10]' is programmed and

processed in TEST2 or AUTOMATIC mode, the arc sensor is
requested to determine the reference values for height and
side.

Command Effect

ARC_SENSOR Request
#REFERENCE,Rvar[10] determination of
reference values

Limits of the reference values:

LIBOSEN 04_00 08/99 GB 16

 RSV WELDING

All values except 0 are allowed for the height reference value.
The arc sensor is set into operating mode 'determination of
reference values' when welding is switched on.

Example program for determination of reference values:

Commands: Before: Afterwards:

POS

ARC_SENSOR Reference values Reference

#REFERENCE, Rvarxx[10] invalid (or wrong) values valid

WELDING #ON

OSCILLATE #ON,
oscillation pattern (option)

POS

WELDING #OFF

: :

The reference value is permanently being calculated and

averaged during welding. When welding is switched off, the
reference value determined last is automatically entered in to
the elements 2 (height) and 3 (side) of the real variable
Rvar[10]. Then the message "reference values determined,
height x.y, side a.b" is displayed on the teach pendant.

Like for determination of the K-factor, a minimum welding time

must also be observed for determination of reference values. It
depends on the programmed oscillation frequency and is
amounting to approx. 70 oscillation periods. If the welding time
is too short for determination, a corresponding error message
will be displayed.

For definition of a new K-factor, a new definition of the

reference values must be executed, because the K-factor
represents the calculation basis for the reference values.

LIBOSEN 04_00 08/99 GB 17

 RSV WELDING

The reference values should be determined at a suitable

sample part, the required torch distance and the lateral
deviation having to be exactly observed.

If determination of the reference values is not possible,

estimated or experimental values have to be entered for the
reference values which subsequently can be increased or
decreased during welding by modification of parameters via the
portable teach pendant (see operating manual of the "ONLINE
Parameter Modification").

Increase of the reference value for the height effects a greater

torch distance, i.e. correction in direction of the welding flame.

A positive reference value for the side usually effects correction

to the right, with view to path direction. A negative reference
value for the side usually effects correction to the left, with view
to path direction. "Usually" refers to the way of programming of
the appropriate oscillation movement. It applies if programming
with the first direction in normal direction is done as described
in the operating manual for the oscillation function.

7.5 SWITCH-ON AND -OFF THE WELDING HEAD

GUIDING

The welding head guiding is switched on with the command

'ARC_SENSOR #ON,Rvar[10]'. The arc sensor changes to
operating mode 'welding head guiding' and delivers correction
data to the general sensor function.

With the command 'ARC_SENSOR #OFF,Rvarxx[10]' the

welding head guiding is switched off. The arc sensor is set non-
operative. It doesn't deliver any correction data to the general
sensor function.

In order that the correction values delivered by the arc sensor in

fact will be evaluated by the general sensor function, this must
be programmed in addition with the command 'SENSOR #ON'.

For the detailed initialization of the general sensor function

please refer to the description of the general sensor function.
Additional explanations on it are given in chapter 8, as far as
the arc sensor is concerned.

LIBOSEN 04_00 08/99 GB 18

 RSV WELDING

Example program for the welding head guiding:

Commands: Condition:

POS

CALL ARC_SEN_INIT_1

ARC_SENSOR #ON, Rvarxx[10] K-factor valid

reference values valid

SENSOR #ON

WELDING #ON

OSCILLATE #ON, oscillation pattern

(option)

POS

SENSOR #OFF

ARC_SENSOR #OFF, Rvar[ ]

OSCILLATE #OFF (option)

WELDING #OFF

: :

7.6 ADDITIONAL REMARKS

This chapter summarizes again the most important issues

completed by some remarks.

• The order for measuring-in new processes is always

determination of K-factor, determination of reference values,
welding head guiding

• For all three operating modes 'K-factor determination',

'determination of reference values' and 'welding head
guiding' it is necessary that a welding process takes place.

• If only height guiding is required, oscillation is not

necessary.
LIBOSEN 04_00 08/99 GB 19
 RSV WELDING

• For determination of reference values and welding head

guiding with side calculation, oscillation must be done. As a
matter of principle, for this purpose oscillation patterns
should be chosen which don't strain the mechanics too
much. This is the case with a sine movement, for instance.

• If a side guiding shall take place, at present a filter function

which may be active must be switched off with the
command "COPY 0,_IFILTER" before the arc sensor is
requested.

• Oscillation must not be done during determination of K-

factor. If oscillation has been programmed, it is
automatically suppressed during determination of K-factor.

• A K-factor must be defined for determination of reference

values.

• A K-factor and a reference value must be defined for

welding head guiding.

• The commands

− ''ARC_SENSOR #K-FACTOR,Rvar[10]'

− 'ARC_SENSOR #REFERENCE,Rvar[10]'

− 'ARC_SENSOR #ON,Rvar[10]'

− 'ARC_SENSOR #OFF,Rvar[10]'

− are self-supporting.

• These commands may be situated at any position in the

program. However, only the last command before the seam
will become effective on the following weld seam.

Example:

POS .....

COPY 0,_IFILTER

LIBOSEN 04_00 08/99 GB 20

 RSV WELDING

ARC_SENSOR #K-FACTOR,Rvar[10]

ARC_SENSOR #REFERENCE,Rvar[10]

WELDING #ON

POS

WELDING #OFF

In this case a determination of reference values would

be executed.

• With some particular frequencies during high-frequent

pulsing above approx. 40 Hz there may occur a height
vibration in guiding. A little modification of the oscillation
frequency may help here. If no side guiding is needed,
oscillation may be completely renounced.

• It has to be observed that the height correction always

points in direction of the arc. For height correction direction
usually the binormal direction of the PCS (path coordinate
system) is used.

• If oscillation is used, the binormal of the active BKS should

always point in direction of the arc, since the height
correction usually is also effective in this direction. Also the
normal of the BKS must be square to the path tangent,
since the side correction usually is done in direction of the
normal, see Fig. 2: Concerning the position of the PCS.

T=
Path N B

Correct Correct

LIBOSEN 04_00 08/99 GB 21

 RSV WELDING

T
Path

B
N
N

Wrong Wrong

Fig. 2: Concerning the position of the PCS

• The higher the pre-gain factor of the general sensor function

is selected, the more sensitively the arc sensor will react.
Under bad welding conditions (e.g. unfavorable seam
geometry) the gain factor has to be selected small; then the
system will react more slowly in case of failures.

LIBOSEN 04_00 08/99 GB 22

 RSV WELDING

8 Programming

Programming of the arc sensor is made in several system

variables which are described in the following. The function of
the arc sensor is closely related to the oscillation function due
to the side guiding, though pure height guiding can be executed
without oscillation function. As the arc sensor just delivers
correction values, the conversion of these correction values into
a robot reaction is left to the general sensor function. An
example for its programming/parameterization is also given in
this chapter.

8.1 THE SYSTEM VARIABLES OF THE ARC

SENSOR

First of all the arc sensor must know where it gets the
measured values from. As input values, exclusively the
contents of the variable _RANA_IN[] containing the analog
inputs are used. In the system variable array _IARC_IN[]
therefore just the number of the corresponding array element of
_RANA_IN[] is entered. Meaning of the contents of:

• _IARC_IN[1]: this array element of _RANA_IN[] contains the

welding current

• _IARC_IN[2]: this array element of _RANA_IN[] contains the

welding voltage

• _IARC_IN[3]: this array element of _RANA_IN[] directly

contains the arc length

The following entries are allowed:

• 0: no input is provided for this parameter

• 1 - 22: for this input the analog input in the system variable
_RANA_IN[1 – 22] is active

LIBOSEN 04_00 08/99 GB 23

 RSV WELDING

The first two elements always shall have a reasonable default,

since their values are also necessary for the determination of
the current welding data for a possible PDA. The third element
represents a special case, if the current source directly supplies
a value for the arc length (not implemented at the time being!).
Besides the values 1 -22 there exist the following special
meanings:

• 0: Actual value calculation from measured U/I values

• -1: Actual value calculation only from measured U values

• -2: Actual value calculation only from measured I values (not

implemented at the time being!)

• 1 - 22: for this input the analog input in the system variable
_RANA_IN[1 – 22] is active (not implemented at the time
being!)

Start-up the RSV in the program "AUTOEXEC", in the start

program of the customer's application or in the initialization
program of the general sensor function for the arc sensor. An
example for the latter possibility is given in the following chapter
8.2

The arc sensor makes available the currently determined

correction values in the system variables _RARC_L and
_RARC_S as input parameters for the general sensor function.

In the system variables _RARC_ACT_LENGTH and

_RARC_ACT_SIDE there are the currently determined actual
values of the arc length and side position above the seam
available.

In the system variables _SARC_L and _SARC_S the names of

(AWP) variables can be indicated by means of which temporary
offsets can be added to the height resp. side reference values
of the arc sensor. Integer or REAL variables are admissible for
this purpose, the values of these variables are directly added to
the reference values. This may be executed by the TECHIPO
function, for instance.

LIBOSEN 04_00 08/99 GB 24

 RSV WELDING

8.2 CONNECTION OF THE ARC SENSOR TO THE

GENERAL SENSOR FUNCTION

This chapter explains especially the requirements of the arc

sensor, for further information about the general sensor
function please refer to its documentation.

For the height and side guiding, each one channel of the
general sensor function has to be selected and initialized. This
may be done in a subprogram, e. g. ARC_SEN_INIT_1.

In the following example the general sensor channels 1 and 2

were taken for the binormal (height correction) and for the
normal direction (side correction). In addition, the system
variables mentioned in chapter 8.1 are described.

Command Parameters Effect

SPR “ARC_SEN_INIT_1

C announce inputs of the arc sensor

COPY 1,_IARC_IN[1] _RANA_IN[1] contains the

measured current value

COPY 3,_IARC_IN[2] _RANA_IN[2] contains the

measured voltage value

COPY 0,_IARC_IN[0] calculation is made from the

measured voltage and
current values

C initialization of the general sensor function

COPY “_RARC_L”, arc length correction as input

_SINPUT[1] value for channel 1

COPY “_RARC_S”, arc side correction as input

_SINPUT[2] value for channel 2

COPY “B”, _SDIRECT[1] define channel 1 for correction

in binormal direction

COPY “N”, _SDIRECT[1] define channel 2 for correction

in normal direction

LIBOSEN 04_00 08/99 GB 25

 RSV WELDING

COPY “”, _SDIRECT[1] cancel other channels

COPY “”, _SDIRECT[1] cancel other channels

COPY “”, _SDIRECT[1] cancel other channels

COPY “”, _SDIRECT[1] cancel other channels

COPY 2.0, _RGAIN[1] adjust pre-gain binormal

COPY 0.1,_RPGAIN[1] adjust P-share binormal

COPY 3.0,_RIGAIN[1] adjust I-share binormal

COPY 1.5,_RGAIN[2] adjust pre-gain normal

COPY 0.02,_RPGAIN[2] adjust P-share binormal

COPY 0.3,_RIGAIN[2] adjust I-share normal

END

The following remarks apply for this example program:

• The higher the pre-gain factor is selected, the more

sensitively the arc sensor will react. Under bad welding
conditions (e.g. unfavorable seam geometry) the gain factor
has to be selected small; then the system will react more
slowly in case of failures.

• The values indicated here are non-committal proposals.

For a concrete application they may serve as basic values
for optimization. For this optimization, the pre-gain factors in
_RGAIN[x] should be used preferably.

• Adjustment of the normal correction (side) with 1.0 applies

for V-seams and similar forms of seams, as far as
programming of the oscillation pattern is made according to
the following chapter. If a flanged seam has to be welded, a
negative number has to be entered for _RGAIN[x] of the
normal correction, in order to invert the sense of the rule.

The correction data of the arc sensor then are directed

internally to the two channels 'BINORMAL' and 'NORMAL' of
the general sensor function, so that all other channels of the
sensor function remain operable without any restrictions.

LIBOSEN 04_00 08/99 GB 26

 RSV WELDING

However, it is not reasonable still to activate further channels in

arc sensor mode.

8.3 SIDE GUIDING BY MEANS OF THE

OSCILLATION FUNCTION

As a matter of principle, side guiding through the arc sensor is

only possible in conjunction with an oscillation movement, see
explanations in chapter 2.2. Since the oscillation pattern can be
freely defined, now for each oscillation pattern position its
contribution to height or side calculation of the arc sensor must
be determined. This allocation is made with I-steps in the
oscillation pattern program. These I-steps start with the
keyword $ARC followed by further indications. These are:

• $LENGTH: Keyword for the height calculation

• $A_SIDE: Keyword for the side calculation. Defines the first

oscillation half-wave

• $B_SIDE: Keyword for the side calculation. Defines the

second oscillation half-wave

First and second oscillation half-wave refer to the explanations

in chapter 2.2.

These further indications may be contained individually or

together in an I-step, just $A_SIDE and $B_SIDE exclude one
another. An allocation remains valid so long until a new
allocation will be made. The following examples illustrate this:

Programming Effect

POS allocation to the height and first

I $ARC $LENGTH $A_SIDE half-wave calculation
POS

POS allocation to the height and

I $ARC $LENGTH $B_SIDE second half-wave calculation
POS

POS allocation only to the first half-

I $ARC $LENGTH wave calculation, height

LIBOSEN 04_00 08/99 GB 27

 RSV WELDING

I $ARC $A_SIDE calculation will be overwritten by

POS the following allocation!

POS allocation only to the height

I $ARC $LENGTH calculation
POS

If a side correction shall take place, a complete allocation has

to be programmed in the oscillation pattern program . The first
allocation must be made after the first position of the oscillation
pattern. Indications of this position are ignored, future
indications won't allocate the first sample positions.

The following example shows how an allocation looks like by a

simple symmetrical plane oscillation pattern with 5 oscillation
positions. This example is suitable for height and side guiding
at symmetrical forms of seams (V-seam, HV-seam, I-seam).
For detailed explanations on the oscillation function please
refer to the corresponding documentation.

MPR "oscillation pattern"

TOOL T

I $FREQ 3.0

I $AMPL 1.5

C OCS definition:

POS #N, Frame:0, X:0.0,Y:0.0,Z0.0

POS #P, Frame:0, X:0.0,Y:0.0,Z100.0

POS #N, Frame:0, X:0.0,Y:0.0,Z0.0

C definition of the oscillation pattern, start

position:

POS #N, Frame:0, X:0.0,Y:0.0,Z0.0

C indications for the first oscillation half-wave:

I $ARC $LENGTH $A_SIDE

POS #N, Frame:0, X:10.0,Y:10.0,Z0.0

POS #N, Frame:0, X:0.0,Y:20.0,Z0.0

LIBOSEN 04_00 08/99 GB 28

 RSV WELDING

C indications for the second oscillation half-

wave:

I $ARC $LENGTH $B_SIDE

POS #N, Frame:0, X:10.0,Y:30.0,Z0.0

POS #N, Frame:0, X:0.0,Y:40.0,Z0.0

END

The allocation of measured values to the side calculation used

in this example effects that the gain of the side correction of the
general sensor function requires positive values for V-seams.
For corrections at I-seams the gain factor in _RGAIN[] must be
negative. These indications apply for the correction direction
"NORMAL" and programmed PCS.

If you exchange in the above example the allocations $A_SIDE

and $B_SIDE against each other, also the sign of the gain
factor in _RGAIN[] must be reverted.

If no oscillation movement is programmed or an oscillation

pattern without allocation to the arc sensor is active, the arc
sensor executes a pure height guiding. In this case it is not
necessary to observe a bottom limit of the oscillation frequency,
either.

In the following, examples for solution of some special

problems are shown.

Besides this, for operation of this procedure the instructions in

chapter 7 apply.

8.3.1 Example for a pure side guiding at symmetrical seam

Also a pure side guiding is possible with the arc sensor. The
following example shows how the allocation looks like for this
purpose with the simple oscillation pattern from chapter 8.2:

MPR "oscillation pattern"

TOOL T

I $FREQ 3.0
LIBOSEN 04_00 08/99 GB 29
 RSV WELDING

I $AMPL 1.5

C OCS definition:

POS #N, Frame:0, X:0.0,Y:0.0,Z0.0

POS #P, Frame:0, X:0.0,Y:0.0,Z100.0

POS #N, Frame:0, X:0.0,Y:1000.0,Z0.0

C definition of the oscillation pattern, start

position:

POS #N, Frame:0, X:0.0,Y:0.0,Z0.0

C indications for the first oscillation half-wave:

I $ARC $A_SIDE

POS #N, Frame:0, X:10.0,Y:10.0,Z0.0

POS #N, Frame:0, X:0.0,Y:20.0,Z0.0

C indications for the second oscillation half-

wave:

I $ARC $B_SIDE

POS #N, Frame:0, X:-10.0,Y:30.0,Z0.0

POS #N, Frame:0, X:0.0,Y:40.0,Z0.0

END

In this example no height calculation by the arc sensor takes

place.

Besides this, for operation of this procedure the instructions in

chapter 7 apply.

8.3.2 Example for height and side guiding at an

asymmetrical seam

Some special forms of seams, like e. g. corner seams and lap

seams, cannot be guided safely enough with the procedure of
arc sensor evaluation described so far. For seams where an
oscillation movement is admitted, a good height and side

LIBOSEN 04_00 08/99 GB 30

 RSV WELDING

correction can be achieved with the procedures described in

the following even without additional distance sensor. If an
oscillation movement is absolutely inadmissible, procedures
with one or several external distance sensors are suitable.

If an asymmetrical oscillation movement is mandatory, e. g.

because much less energy may be applied to one of the joining
partners, also in this case despite long holding times you an
reach an oscillation movement with little strain to the mechanics
by choosing a low oscillation frequency.

While in the procedures for symmetrical seams described so far

the measured values of the arc sensor are related with the
oscillation width via the equations in chapter 2.2:
"Fundamentals of the Arc Sensor", this allocation is no longer
applicable for the procedures with asymmetrical seams, see
also Fig. 3a: Course of the side and height values with constant
height and change of the side position.

Basis for this procedure is rather the random allocation of

individual parts of the oscillation period to the height or side
evaluation. Depending on the selected procedure, it has to be
observed during allocation that the arc will surely pass over the
edge of the seam. A suitable oscillation pattern has to be
defined for this purpose. Usually you will take for side
evaluation the sections of the oscillation width that get
positioned on the edge, and for height evaluation those
sections being placed more on the material. Doing so, an
average arc length is formed as height value and as side value
analog to the procedure described in chapter 2.2:
"Fundamentals of the Arc Sensor".

Consequently in this case the determined side value directly

depends on the adjusted height. For function of the procedure it
is therefore absolutely mandatory that the measured height
values in the range of an oscillation half-wave are independent
from the lateral deviation of the torch. This range is the range
which can be used, where the ARC sensor can control the
desired height and thus, will also keep the adjusted side.

For a better understanding, the first oscillation half-wave will be

completely taken for height evaluation and in the second
oscillation half-wave the side evaluation will take place. A
trapezoidal pattern is taken as oscillation pattern this time.
Doing so, during the extended first oscillation direction the

LIBOSEN 04_00 08/99 GB 31

 RSV WELDING

measured value only for side calculation will be recorded. The

measured value recording for height calculation only takes
place in the oscillation direction, see following sample program
"trapezoid".

MPR "trapezoid"

TOOL T

I $FREQ 3.0

I $AMPL 1.5

C OCS definition:

POS #N, Frame:0, X:0.0,Y:0.0,Z0.0

POS #P, Frame:0, X:0.0,Y:0.0,Z100.0

POS #N, Frame:0, X:0.0,Y:1000.0,Z0.0

C definition of the oscillation pattern, start

position:

POS #N, Frame:0, X:0.0,Y:0.0,Z0.0

C indications for the first oscillation half-wave:

I $ARC $A_SIDE

POS #N, Frame:0, X:10.0,Y:10.0,Z0.0

POS #N, Frame:0, X:10.0,Y:20.0,Z0.0

POS #N, Frame:0, X:0.0,Y:30.0,Z0.0

C indications for the second oscillation half-

wave:

I $ARC $LENGTH

POS #N, Frame:0, X:-10.0,Y:40.0,Z0.0

POS #N, Frame:0, X:-10.0,Y:50.0,Z0.0

POS #N, Frame:0, X:0.0,Y:60.0,Z0.0

END

LIBOSEN 04_00 08/99 GB 32

 RSV WELDING

measured height value

working range
measured side value

side position

welding flame

higher seam
lower
section

LIBOSEN 04_00 08/99 GB 33

 RSV WELDING

BI TA = welding direction

2nd oscillation width

No

1st oscillation width

Fig. 3a: Course of the side and height values with constant
height and change of the side position
Figure 3b: Concerning the definition of the work area with
asymmetrical form of seam by the example
of a symmetrical oscillation movement

Due to the asymmetrical form of seam, the effective direction of

the side correction has to be adapted during guiding to the
position of the higher seam section to the movement direction.
Adaptation is made with the command "COPY
Value,_RGAIN[x]" in the appropriate initialization program of
the general sensor function. For the examples shown in the
following illustration with correction in normal, binormal direction
it applies that a positive gain factor (V > 0) is required if the
upper seam section is situated on the right hand side in
movement direction (Fig. 4: Examples for adjustment of the
side gain direction).

LIBOSEN 04_00 08/99 GB 34

 RSV WELDING

TA
BI TA
BI

NO
NO

higher higher
lower lower
seam section seam section

a.) Higher seam section at the left b.) Higher seam section at the right
of the edge: of the edge:
COPY V,_GAIN[x], V negative COPY V,_GAIN[x], V positive

Fig. 4: Examples for adjustment of the side gain direction

8.3.2.1 Programming with symmetrical oscillation

movement

The higher seam section acc. to fig. 4a shall be at the right of

the seam, so that work is done with positive side gain. Doing
so, during the extended first oscillation direction the measured
value only for side calculation will be recorded. Recording of
measured values for the height calculation will take place only
in the second oscillation direction. For better separation of
height and side evaluation, the measurements in the "oscillation
zero passages" won't be taken into consideration, so that the
following extended programming of the trapezoidal sample
results (trapezoid_1):

MPR "trapezoid_1"

TOOL T

I $FREQ 3.0

I $AMPL 1.5

LIBOSEN 04_00 08/99 GB 35

 RSV WELDING

C OCS definition:

POS #N, Frame:0, X:0.0,Y:0.0,Z0.0

POS #P, Frame:0, X:0.0,Y:0.0,Z100.0

POS #N, Frame:1000,0, X:0.0,Y:0.0,Z0.0

C definition of the oscillation pattern, start

position:

POS #N, Frame:0, X:0.0,Y:0.0,Z0.0

C indications for the first oscillation half-wave:

I $ARC (No!! allocation)

POS #N, Frame:0, X:5.0,Y:5.0,Z0.0

I $ARC $A_SIDE

POS #N, Frame:0, X:10.0,Y:10.0,Z0.0

POS #N, Frame:0, X:10.0,Y:20.0,Z0.0

POS #N, Frame:0, X:5.0,Y:25.0,Z0.0

I $ARC (No!! allocation)

POS #N, Frame:0, X:0.0,Y:30.0,Z0.0

C indications for the second oscillation half-

wave:

POS #N, Frame:0, X:-5.0,Y:35.0,Z0.0

I $ARC $LENGTH

POS #N, Frame:0, X:-10.0,Y:40.0,Z0.0

POS #N, Frame:0, X:-10.0,Y:50.0,Z0.0

POS #N, Frame:0, X:-5.0,Y:55.0,Z0.0

I $ARC (No!! allocation)

POS #N, Frame:0, X:0.0,Y:60.0,Z0.0

END
LIBOSEN 04_00 08/99 GB 36
 RSV WELDING

Besides this, for operation of this procedure the instructions in

chapter 7 apply.

8.3.2.2 Programming with asymmetrical oscillation

movement

The upper seam section acc. to Fig. 4: Examples for

adjustment of the side gain direction a shall be at the right of
the seam, so that work is done with positive side gain. Doing
so, during the extended first oscillation direction the measured
value only for side calculation will be recorded. Recording of
measured values for the height calculation will take place only
in the second oscillation direction which is reduced to "0". For
better separation of height and side evaluation, the
measurements between the "oscillation zero passages" and the
oscillation maximums won't be taken into consideration, so that
the following one-side triangular sample (oscillation pattern
triangle) results:

MPR "triangle"

TOOL T

I $FREQ 3.0

I $AMPL 1.5

C OCS definition:

POS #N, Frame:0, X:0.0,Y:0.0,Z0.0

POS #P, Frame:0, X:0.0,Y:0.0,Z100.0

POS #N, Frame:0, X:0.0,Y:1000.0,Z0.0

C definition of the oscillation pattern, start

position:

POS #N, Frame:0, X:0.0,Y:0.0,Z0.0

C indications for the first oscillation half-wave:

I $ARC (No! allocation)

POS #N, Frame:0, X:5.0,Y:1.0,Z0.0

LIBOSEN 04_00 08/99 GB 37

 RSV WELDING

I $ARC $A_SIDE

POS #N, Frame:0, X:10.0,Y:20.0,Z0.0

POS #N, Frame:0, X:10.0,Y:10.0,Z0.0

I $ARC (No! allocation)

POS #N, Frame:0, X:5.0,Y:11.0,Z0.0

POS #N, Frame:0, X:0.0,Y:12.0,Z0.0

C indications for the second oscillation half-wave:

I $ARC $LENGTH

POS #N, Frame:0, X:0.0,Y:40.0,Z0.0

END

Remark:

If the welding process requires longer holding times or higher

oscillation frequencies, the oscillation movement becomes
rather 'clumsy' and unharmonious. Thus, it does not only strain
the robot mechanics very much, but this uneven movement
also impairs the function safety of the arc sensor.

In this case you may try to harmonize the robot movement by

sine shaped or sine-square shaped oscillation patterns.

Besides this, for operation of this procedure the instructions in

chapter 7 apply.

8.4 THE MACHINE DATA OF THE ARC SENSOR

RPSI_SHIFT

In the machine data the time between electrical oscillation

preset and the mechanical reaching of this preset is entered in
milliseconds. . Range of values: >= 0 ms. Default = 80ms

RARC_I_ABS_MIN, RARC_U_ABS_MIN

LIBOSEN 04_00 08/99 GB 38

 RSV WELDING

In these machine data the absolute bottom limit values for the
measured value acquisition (noise cancellation) are entered.
The range is 0 – 100 % of the analog inputs, 1% is entered as
default. For analog inputs of +/- 10V this corresponds to 10A
(10mv / Ampere measuring transformer) welding current resp.
0,5V – 2V welding voltage, depending on the desired
measuring range of 50V – 200V. Internally the range
RARC_x_ABS_MIN to 99% of the final value of a measuring
range is used at maximum for valid measured values.

RARC_U_REL_LIM

In these machine data a relative bottom voltage limit in the

range 1% - 99% can be entered, default = 50 %. This limit is
dynamically calculated from the average value of the current
welding and fades out measured values inferior to the adjusted
percentage of the average value from the sensor guiding. For
MAG welding this may improve the guiding behavior, for TIG-
pulsed welding the value should be adjusted to 1%.

RARC_WAIT_COR

In these machine data the time is entered in seconds during

which correction values are not yet recorded after ignition. The
correction effect of the arc sensor only starts after that time.
Range of values: >= 0 sec. default = 0sec.

RARC_RECRE_TIME

In these machine data the "recreation time" is entered in

seconds during which the arc normalizes again after a short-
circuit and consequently no sensor measured values are
recorded.
Range of values: >= 0 sec. default = 0 sec.

LIBOSEN 04_00 08/99 GB 39

 RSV WELDING

9 Application Software

Various oscillation patterns with allocations for arc sensor are

available as application software. Suitable initialization
programs for the general sensor function are also available.

LIBOSEN 04_00 08/99 GB 40

 RSV WELDING

10 Error Messages/ Trouble shooting

10.1 ERROR MESSAGES

Error No. Error description Cause Remedy

S741 ARC sensor: • Operating mode in element 10 of • Check operating mode and describe it
undefined operating mode Rvar[10] is incorrectly allocated correctly

• PSI-determination selected, not • Select correct operating mode

implemented at the time being

S742 ARC sensor: Ravr[10] is no array or has less Program Rvar[10] correctly and then
variable VARNAME too small than 10 elements describe anew

S745 ARC sensor: • Welding process was too much • Optimize welding process
NO K-factor determined, time troubled to deliver sufficient
too short useful measured values • Take a longer path for determination of
the K-factor. The trouble-free welding

LIBOSEN 04_00 08/99 GB 41

 RSV WELDING

Error No. Error description Cause Remedy

time should be approx. 20 sec.
• Welding time was too short

S746 ARC sensor: • Welding process was too much • Optimize welding process
NO reference values troubled to deliver sufficient
determined, time too short useful measured values • Take a longer path for determination of
the reference values. The trouble-free
• Welding time was too short welding time should be approx. 30 sec.

S747 ARC sensor: Element 1 in Rvar[10] contains no Determine new K-factor (and
Invalid K-factor during valid value or is "0" subsequently also the reference values)
determination of reference or enter a suitable known K-factor
values or guiding

S748 ARC sensor: Element 2 in Rvar[10] contains no Determine new reference values or enter
Invalid height reference value valid value or is "0" known height reference value
during guiding

S749 ARC sensor: Element 3 in Rvar[10] contains no Determine new reference values or enter
Invalid side reference value valid value known side reference value
during guiding

LIBOSEN 04_00 08/99 D 42

 RSV WELDING

Error No. Error description Cause Remedy

S750 ARC sensor: Oscillation frequency chosen too Increase oscillation frequency. For
Oscillation frequency too small small in the oscillation pattern sufficient side guiding the oscillation
for sensor guiding, it must be program frequency should be selected higher than
bigger than x.y 1 Hz.

S751 ARC sensor: No analog input or a wrong analog Check variable content and describe
Number of the analog input in input written in this variable correctly, see chapter 8.1
the variable VARNAME is
invalid or not in the range 0 –
22

S752 ARC sensor: The indicated Rvar[10] was not • Indicate correct variable
Variable VARNAME not found found
• Adapt search path for variable

• Introduce variable anew and describe

it correctly

S753 ARC sensor: No analog input or a wrong analog Check variable content and describe
Number of the analog input in input written in this variable correctly, see chapter 8.1

LIBOSEN 04_00 08/99 D 43

 RSV WELDING

Error No. Error description Cause Remedy

the variable VARNAME is
invalid or not in the range -3 –
22

S755 ARC sensor: Element 9 in Rvar[10] contains no Determine current limit anew or enter
Current limit for pulse valid value known value
procedure must be valid for
determination of reference
values or guiding

S756 ARC sensor: Element 9 in Rvar[10] contains the Determine current limit anew or enter
Current limit for pulsed valid value "0" known value
procedure must not be 0

S757 ARC sensor: PSI-determination requested, it is Don't perform PSI-determination, if

PSI determination not released not implemented at the time being necessary adapt RPSISHIFT manually,
see chapter 8.4

LIBOSEN 04_00 08/99 D 44

 RSV WELDING

10.2 FURTHER MESSAGES

Message No. Description Cause Remedy

S743 ARC sensor:

K-factor determined, value: x.y

S744 ARC sensor:

reference values determined,
height: x.y side:a.b

LIBOSEN 04_00 08/99 D 45

 RSV WELDING

11 Glossary

Letter Term Explanation

A AWP user program

O OCS oscillation coordinate system

P PCS path coordinate system,

usually identical with the OCS

P PDA process data acquisition

P PSI oscillation synchronizing pulse

LIBOSEN 04_00 08/99 D 1

 RSV WELDING

12 Index
K-FACTOR 15

#
O
#K-FACTOR 13
#OFF 13 operating mode 15
#ON 13 oscillation pattern 27
#REFERENCE 13 oscillation pattern program 28
oscillation synchronizing pulse 10

$
P
$A_SIDE 27
$ARC 27 PSI 10
$B_SIDE 27
$LENGTH 27
R
_ RARC_I_ABS_MIN 40
RARC_RECRE_TIME 40
_IARC_IN[] 23 RARC_U_ABS_MIN 40
_RARC_ACT_LENGTH 24 RARC_U_REL_LIM 40
_RARC_ACT_SIDE 24 RARC_WAIT_COR 40
_RARC_L 24 RPSI_SHIFT 10, 39
_RARC_S 24
_SARC_L 24
_SARC_S 24 S
seam sequential mode 5, 13
D side reference value 15

definition of reference values 5

T
H teach-in procedure 5

height reference value 15

W
I waiting time 15
welding head guiding 5, 13
I-steps 27

K
keyword 27
K-factor 3

LIBOSEN 04_00 08/99 D 2