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Grs Master Rev6.2 New
Grs Master Rev6.2 New
1
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.
3
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. 4
2
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
5
GRS1
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6
GRS2
6
3
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.
7
GRS2
7
4
Global Robot Specifications Overview
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
9
GRS4
9
5
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
11
GRS1
11
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
12
GRS2
12
6
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)
13
GRS3
13
7
Various Safety Devices Used in a Robotic Cell
Robot Cell With Safety Mat Robot Cell With Area Scanner
15
GRS3
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8
Dual Check Safety (DCS) Zone Examples
17
GRS3
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18
GRS3
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9
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.
19
GRS3
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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.
20
GRS3
20
10
DCS Operator Zone
21
GRS3
21
22
GRS3
22
11
DCS Fence Zones
23
GRS3
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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.
24
GRS3
24
12
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.
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GRS3
25
Exercise 1.1
1. What is DCS?
26
GRS4
26
13
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
27
27
Exercise 1.1
4. What will be the result if the operator light
curtain is not 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
28
28
14
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 29
29
Exercise 1.1
Exercise Solutions
30
30
15
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
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31
32
16
Exercise 1.1: Solution
4. What will be the result if the operator light
curtain is not 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
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33
34
17
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.
Note: for more information see the Payload ID Application
Guidelines and the Payload Checker Tool on the next slide.
GRS2 35
35
GRS2 36
36
18
Robot Payload Analysis (Ref: GRS-2)
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 37
37
GRS2 38
38
19
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 39
GRS2
39
40
GRS2
40
20
Rough Cycle Time Rules
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
41
GRS2
41
21
Rough Cycle Time Rules
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
43
GRS2
43
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
44
GRS2
44
22
Rough Cycle Time Rules
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. 45
GRS2
45
46
GRS2
46
23
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
𝐑𝐨𝐮𝐠𝐡 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
47
GRS2
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48
GRS2
48
24
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
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GRS2
49
Exercise 1.2
Exercise Solutions
50
50
25
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
52
GRS2
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26
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.
54
GRS2
54
27
Robot Rules of Process
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.
55
GRS2
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56
GRS2
56
28
Tip Dressers
• Spot welding uses high
temperature and
pressure which alters the
copper weld tip shape
over a number of welds.
Tip dressing resets the
weld tip shape.
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 58
58
29
Tip Dressing Process
Moveable Shank Blade Holder
GRS2 59
59
GRS2 60
60
30
Global 4 Tip Dress Document
For Tip Dress information visit the Robotic
Standards page to access the Global 4 Tip
Dress Document:
https://supplier.body.gm.com/crw/production/
main/globalStandards/roboticStandards.cfm
61
61
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.
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GRS2
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31
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
63
GRS2
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32
Weld Gun Combinations
65
65
66
GRS2
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33
Stud Weld Gun
67
GRS2
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68
GRS2
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34
SCA Dispense Setup
69
GRS2
69
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
70
GRS2
70
35
Tool Changers GRS2
71
GRS2
71
Tool Changers
36
ATI Tool Changer Mechanism
73
GRS2
73
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
74
GRS2
74
37
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 75
GRS4
75
Style
Style Number 0-255 Style Number Echo 0-255
76
GRS3
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38
Style Numbers
77
GRS3
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78
GRS3
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39
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
79
GRS3
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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
80
GRS3
80
40
Path Segments
• Path Segment numbers shall be unique within a
style program
• Path Segment numbers are reused between
style programs
81
GRS3
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Path Segments
• Path segments definitions
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GRS3
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41
Path Segments
Path segments 10-59 and 110-149
Segment #
10-13
Usage
Pick 1
Segment # Usage
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
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GRS3
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42
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
85
GRS3 26
27 Auto Retry Pick 2
63 Return to Home
85
“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
86
GRS3
86
43
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
87
GRS3
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88
GRS3
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44
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
89
GRS3
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90
GRS3
90
45
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”
91
GRS3
91
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
S e g 6 2 : T o o l C le a r
“ O p tio n a l”
92
GRS3
92
46
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
S e g 6 2 : T o o l C le a r
O p tio n a l
Automatically taken care of as part of the
93
GRS3 ATPOUNCE program
93
Task O K on
T a s k O K o ff
S e g 5 0 : W e ld
W eld fa u lt
S eg 6 3 : A ll C le ar S k ip p e d o n te a ch p en d a n t
T a sk O K , tu rn e d o ff
In itia te 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
94
GRS3
94
47
Weld with Clamp Reposition
95
GRS3
95
48
Path Decision Control
• 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
97
GRS3
97
98
GRS3
98
49
Stamping Path Decision Control
99
GRS3
99
100
GRS3
100
50
Stamping Example
101
GRS3
101
Stamping Example -
Press to Press Application
102
GRS3
102
51
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)
103
GRS3
103
104
104
52
Exercise 1.3
Exercise Solutions
105
105
Decision 15 RTC
1 Decision 0
50
63
62
106
GRS3
106
53
Exercise 1.3: Solution
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
108
108
54
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
109
109
55
GRS
Global Robot Specifications
LMS # 34043
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
1
SCS MPS Robotic Cell
• Review this video for proper use of the MPS
and SCS systems.
• If you have difficulty opening the video open
GM Supply Power then use this link
https://players.brightcove.net/5511551936001/HyxtG9kIb_default/index.html?
videoId=5976824853001
3
GRS3
3
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”
4
GRS3
4
2
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”
5
GRS3
5
Note: See next slide for the GRS Robot Buyoff Checklist
access.
6
GRS3
6
3
On-line System Integration
For Integration Buyoff information visit the Robotic
Standards page to access the GRS 3 Robot
Integration Buyoff Check list:
https://supplier.body.gm.com/crw/production/main/
globalStandards/roboticStandards.cfm
7
GRS3
7
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
8
GRS3
8
4
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
9
GRS3
9
10
GRS3
10
5
Robot Programming Safety (cont’d)
• Bypass DCS Common Industrial Protocol
(CIP) safety
• Verify presence and function of light curtains
• Reference Safe Operating Procedures (SOP)
11
GRS3
11
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
6
Configuration of Robot (cont’d)
• Set date/time
• Load offline programs and run the TOOLDATA program
• Verify EOAT operation
13
GRS3
13
14
GRS3
14
7
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%
15
GRS3
15
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 16
GRS3
16
8
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
17
GRS3
17
18
GRS3
18
9
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
19
GRS3
19
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
20
GRS3
20
10
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
21
GRS3
21
22
GRS3
22
11
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 23
23
12
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
25
GRS3
25
13
Setup Weld Gun and Accessory Weld Equipment
27
GRS3
27
14
Robot Frames
29
GRS3 User frame
29
30
GRS3
30
15
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
31
GRS3
31
32
GRS3
32
16
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
33
GRS3
33
34
GRS3
34
17
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
35
GRS3
35
36
GRS3
36
18
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
37
GRS3
37
19
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
39
GRS3
39
40
GRS3
40
20
Material Handling Application (cont'd)
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
41
GRS3
41
42
GRS3
42
21
MH TCP Definition for robots Without Pin
43
GRS3
43
44
GRS3
44
22
Spot Weld Guns (Pictures are for Examples Only)
46
GRS3
46
23
Spot Weld Setup
47
GRS3
47
48
GRS3
48
24
Servo Gun Setup Manual
• For servo gun setup information, visit the
Robotic Standards page:
https://supplier.body.gm.com/crw/production/main
/globalStandards/roboticStandards.cfm
• Navigate to User Guides and Manuals then
Global 4 User Guides and Manuals
49
GRS3
49
50
GRS3
50
25
Standard TCP Definitions - Weldgun Application (cont'd)
51
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51
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.
52
GRS3
52
26
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
53
GRS3
53
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
54
GRS3
54
27
Stud Welding (cont'd)
Carried Stud TCP Definition for ALL robots
55
GRS3
55
56
GRS3
56
28
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
57
GRS3
57
58
GRS3
58
29
Sealing Application (cont'd)
• Pedestal Sealing TCP Definition for Fanuc
– Note that +X points toward the pedestal sealer base
59
GRS3
59
30
Recommended Move Speeds
61
GRS3
61
62
GRS3
62
31
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.)
63
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63
• 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
64
64
32
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
65
65
66
33
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
67
67
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?
68
S01PICK1
68
34
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
69
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69
70
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70
35
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.
71
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71
36
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)
73
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73
74
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74
37
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
*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.
Flow
76
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76
38
Interference Zone Numbering Example 3
R1 1
R2 2
R3 3
Flow
R4 4
R5 5
R6 6
R1 R3 R5
77
GRS3
77
39
Teaching Interference Zones
79
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79
80
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80
40
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
81
GRS3
81
82
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82
41
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.
83
GRS3
83
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.
84
GRS3
84
42
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
85
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85
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)
86
GRS3
86
43
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
88
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88
44
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
89
GRS3
89
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
90
GRS3
90
45
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
91
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91
92
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92
46
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%
93
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93
94
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94
47
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
95
GRS3
95
96
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96
48
Module 2
Exercise Solutions
97
97
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.
98
98
49
Exercise 2.2: Solution
Carried Spot Weld TCP for all C guns
99
GRS3
99
100
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100
50
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.
101
GRS3
101
102
GRS3
102
51
Module 2: Review (cont’d)
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. 103
GRS3
103
104
GRS3
104
52
GRS
Global Robot Specifications
LMS # 34043
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
– Material handling interface.
Note: See slide 4 for more Robot Interface information 2
1
Robot Mechanical Unit
4
GRS4
4
2
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
5
GRS4
5
Robot IO
• For more information about Robot I/O consult the
appropriate document bellow:
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.
7
GRS4
7
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.
8
GRS4
8
4
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.
9
GRS4
9
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
10
GRS4
10
5
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.
11
GRS4
11
12
GRS4
12
6
Robot Outputs (cont’d)
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.
13
GRS4
13
14
GRS4
14
7
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
15
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15
16
GRS4
16
8
Robot Outputs (cont’d)
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).
17
GRS4
17
18
GRS4
18
9
Robot Outputs (cont’d)
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
19
GRS4
19
20
GRS4
20
10
Cell Controller / Robot Inputs (cont’d)
Robot Input Description Signal Name
In12 (Reserved) (Reserved)
In13 (Reserved) (Reserved)
In14 (Reserved) (Reserved)
In15 (Reserved) (Reserved)
In16 (Reserved) (Reserved)
In17 (Reserved) (Reserved)
In18 (Reserved) (Reserved)
In19 (Reserved) (Reserved)
In20 Option Bit A OptionBitA
In21 Option Bit B OptionBitB
In22 Option Bit C OptionBitC
21
GRS4
21
22
GRS4
22
11
Cell Controller / Robot Inputs (cont’d)
Robot Input Description Signal Name
In34 (Reserved) (Reserved)
In35 Initiate Style Program (Cycle Start) InitiateStyle
In36 Equipment Remote Reset EqptRemoteRes
In37 Interference Zone 1 Clear to Enter ClearToEntrZone1
In38 Interference Zone 2 Clear to Enter ClearToEntrZone2
In39 Interference Zone 3 Clear to Enter ClearToEntrZone3
In40 Interference Zone 4 Clear to Enter ClearToEntrZone4
In41 Interference Zone 5 Clear to Enter ClearToEntrZone5
In42 Interference Zone 6 Clear to Enter ClearToEntrZone6
In43 Interference Zone 7 Clear to Enter ClearToEntrZone7
In44 Interference Zone 8 Clear to Enter ClearToEntrZone8
23
GRS4
23
24
GRS4
24
12
Cell Controller / Robot Inputs (cont’d)
Robot Input Description Signal Name
In56 Path Segment Continue OK PathSegContOK
In57 Path Segment (Bit 1) PathSegmentBit1
In58 Path Segment (Bit 2) PathSegmentBit2
In59 Path Segment (Bit 4) PathSegmentBit4
In60 Path Segment (Bit 8) PathSegmentBit8
In61 Path Segment (Bit 16) PathSegmentBit16
In62 Path Segment (Bit 32) PathSegmentBit32
In63 Path Segment (Bit 64) PathSegmentBit64
In64 Path Segment (Bit 128) PathSegmentBit128
25
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25
26
GRS4
26
13
Cell Controller / Robot Inputs (cont’d)
Robot Input Description Signal name
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)
27
GRS4
27
28
GRS4
28
14
Cell Controller / Robot Outputs
Robot output Description Signal name Housekeeping
State
Out01 System Level Signals—Robot Specific -
Cmd enable
Out02 System Level Signals—Robot Specific -
System ready
Out03 System Level Signals—Robot Specific -
Prg running
Out04 System Level Signals—Robot Specific -
Prg paused
Out05 System Level Signals—Robot Specific -
Motion held
Out06 System Level Signals—Robot Specific -
Fault
Out07 System Level Signals—Robot Specific -
BatteryLowAlert
Out08 System Level Signals—Robot Specific -
TP enabled
Out09 (Reserved) (Reserved) -
Out10 Tryout Mode TryoutMode -
Out11 In Cycle InCycle Low
29
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29
15
Cell Controller / Robot Outputs (cont’d)
Robot output Description Signal name Housekeeping State
Out23 Manual Option Bit D ManualOptionBitD Low
Out24 Manual Option Bit E ManualOptionBitE Low
Out25 Manual Style (Bit 1) ManualStyleBit1 Low
Out26 Manual Style (Bit 2) ManualStyleBit2 Low
Out27 Manual Style (Bit 4) ManualStyleBit4 Low
Out28 Manual Style (Bit 8) ManualStyleBit8 Low
Out29 Manual Style (Bit 16) ManualStyleBit16 Low
Out30 Manual Style (Bit 32) ManualStyleBit32 Low
Out31 Manual Style (Bit 64) ManualStyleBit64 Low
Out32 Manual Style (Bit 128) ManualStyleBit128 Low
Out33 Fast Stop Acknowledge FastStopAck Low
31
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31
32
GRS4
32
16
Cell Controller / Robot Outputs (cont’d)
Robot output Description Signal name Housekeeping State
Out45 Robot Clear of Interference Zone 9 ClearOfZone9 High
Out46 Robot Clear of Interference Zone 10 ClearOfZone10 High
Out47 Robot Clear of Interference Zone 11 ClearOfZone11 High
Out48 Robot Clear of Interference Zone 12 ClearOfZone12 High
Out49 Manual Decision code (Bit 1) ManDecCodeBit1 Low
Out50 Manual Decision code (Bit 2) ManDecCodeBit2 Low
Out51 Manual Decision code (Bit 4) ManDecCodeBit4 Low
Out52 Manual Decision code (Bit 8) ManDecCodeBit8 Low
Out53 Manual Decision code (Bit 16) ManDecCodeBit16 Low
Out54 (Reserved) Low
Manual Decision code (Bit 32) (Reserved)ManDecCodeBit32
Out55 (Reserved) Low
Manual Decision code (Bit 64) (Reserved)ManDecCodeBit64
33
GRS4
33
34
GRS4
34
17
Cell Controller / Robot Outputs (cont’d)
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
35
GRS4
35
36
GRS4
36
18
Cell Controller / Robot Outputs (cont’d)
Robot Output Description Signal name
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
37
GRS4
37
38
GRS4
38
19
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
39
39
Modes
There are three types of modes the robot can use. They
are :
– Process Enable/Disable
– Tryout
– Interlock/Isolate
40
GRS4
40
20
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
41
GRS4
41
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
42
GRS4
42
21
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
43
GRS4
43
GRS4 44
44
22
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.
45
GRS4
45
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
46
GRS4
46
23
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
47
GRS4
47
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.
48
GRS4
48
24
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.
49
GRS4
49
Style Table
The robot will map the cell controller initiated style number
to any valid robot style program
50
GRS4
50
25
Style Program Structure
Program style structure will be implemented in a modular format
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
51
GRS4
51
2. SetSegment [2]
5. SetSegment [3]
52
GRS4
52
26
Cap Change (Style 27) Sequence
This routine will resets the steppers and water savers
3. Check for water saver tripped or bypassed. If neither is detected, generate a fault and prompt the user for acknowledgement prior to continuing.
6. <Automatically request tip dress style from cell controller if “tip dress on cap change” has been configured and use “New Cap TD Schedule”>
53
GRS4
53
Cap Changers
27
Pedestal Cap Change at the End of a Path Segment
55
GRS4
55
28
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 57
57
GRS4 58
58
29
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
7. <Automatically initiate tip wear measurement for servo guns>
GRS4 59
59
GRS4 60
60
30
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 61
61
GRS4 62
62
31
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 63
63
3. Set PathSegReqToCont
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 64
64
32
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
65
GRS4
65
66
GRS4
66
33
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 67
67
GRS4 68
68
34
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 69
69
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 70
70
35
Fast Fault Recovery
No-Process Modes
Application FFR Application Mode Comments
GRS4 71
71
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
GRS4 72
72
36
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 73
73
GRS4 74
74
37
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 75
75
GRS4 76
76
38
Student Exercise 3.1
Robot Cell Interface
Complete the exercise in your book.
77
77
Exercise 3.1
Exercise Solutions
78
78
39
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
79
79
80
80
40
Exercise 3.1: Robot Cell Interface: Solutions
(cont’d)
Description Signal Name Robot Output
2. (Continued) Process 1 One Joint Made Proc1OneJntMade Out72
81
81
82
82
41
Exercise 3.1: Robot Cell Interface: Solutions
(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.
83
83
84
84
42
Exercise 3.1: Robot Cell Interface: Solutions
(cont’d)
6. What signal indicates to the robot that the style select
and option bits are valid?
Initiate Style
85
85
86
86
43
Exercise 3.1: Robot Cell Interface: Solutions
(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
87
87
88
88
44
Exercise 3.1: Robot Cell Interface: Solutions
(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 89
89
GRS4 90
90
45
Robot Software Requirements
91
91
GRS4-B1 19 92
92
46
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
39 SCN Tip Dresser Gun 3
40 SCN Tip Dresser Gun 4
41 SCN Integrated vision I/O Block 1
42 SCN Integrated vision I/O Block 2
43 SCN
44 SCN
GRS4-B1 93
93
GRS4-B1 94
94
47
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 95
95
GRS4-B1 96
96
48
Robot / PLC Inputs (Weld Controller Outputs)
(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 97
97
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 98
98
49
Robot / PLC Inputs (Weld Controller Outputs)
(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 99
99
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 100
100
50
Robot / PLC Outputs (Weld Controller Inputs)
(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 101
101
• 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 102
102
51
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 103
103
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)
1034 SW1 Approaching Cap Change Gun 2 diSW1ApprCpChgG2 1051 (Reserved) (Reserved)
1035 SW1 Approaching Cap Change Gun 3 diSW1ApprCpChgG3 1052 (Reserved) (Reserved)
1036 SW1 Approaching Cap Change Gun 4 diSW1ApprCpChgG4 1053 (Reserved) (Reserved)
1037 (Reserved) (Reserved) 1054 (Reserved) (Reserved)
1038 (Reserved) (Reserved) 1055 (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
1041 SW1 Stepper Is Reset For GUN3 diSW1StepResetG3 1058 SW1 Cap Change Request for Gun2 diSW1CChngeReqG2
GRS4-B1 104
104
52
Robot Inputs: SW 1 (cont’d)
EIP Scanner ‐ Slot 2 EIP Scanner ‐ Slot 2
DI[#] Description Signal Name DI[#] Description Signal Name
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
1061 (Reserved) (Reserved) 1078 (Reserved) (Reserved)
1062 (Reserved) (Reserved) 1079 (Reserved) (Reserved)
1063 SW1 Pressure Bit 1 diSW1Pressure1 1080 (Reserved) (Reserved)
1064 SW1 Pressure Bit 2 diSW1Pressure2 1081 (Reserved) (Reserved)
1065 SW1 Pressure Bit 4 diSW1Pressure4 1082 (Reserved) (Reserved)
1066 SW1 Pressure Bit 8 diSW1Pressure8 1083 (Reserved) (Reserved)
1067 SW1 Read Pressure diSW1ReadPrssre 1084 (Reserved) (Reserved)
1068 (Reserved) (Reserved) 1085 (Reserved) (Reserved)
1069 (Reserved) (Reserved) 1086 (Reserved) (Reserved)
1070 (Reserved) (Reserved) 1087 (Reserved) (Reserved)
1071 (Reserved) (Reserved) 1088 (Reserved) (Reserved)
1072 (Reserved) (Reserved)
1073 SW1 Weld Process Stop diSW1ProcessStop
1074 SW1 Adaptive Reguation Off diSW1AdaptRegOff
1075 SW1 Adaptive Monitoring Off diSW1AdaptMtrOff
105
GRS4-B1
105
Robot Inputs: SW 2
EIP Scanner ‐ Slot 3 EIP Scanner ‐ Slot 3
DI[#] Description Signal Name DI[#] Description Signal Name
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)
1161 SW2 Approaching Cap Change Gun 1 diSW2ApprCpChgG1 1178 (Reserved) (Reserved)
1162 SW2 Approaching Cap Change Gun 2 diSW2ApprCpChgG2 1179 SW2 Gun1 Is Tip Dress Reset diSW2G1TDReset
1163 SW2 Approaching Cap Change Gun 3 diSW2ApprCpChgG3 1180 SW2 Gun2 Is Tip Dress Reset diSW2G2TDReset
1164 SW2 Approaching Cap Change Gun 4 diSW2ApprCpChgG4 1181 SW2 Gun3 Is Tip Dress Reset diSW2G3TDReset
1165 (Reserved) (Reserved) 1182 SW2 Gun4 Is Tip Dress Reset diSW2G4TDReset
1166 (Reserved) (Reserved) 1183 (Reserved) (Reserved)
1167 SW2 Stepper Is Reset For GUN1 diSW2StepResetG1 1184 (Reserved) (Reserved)
1168 SW2 Stepper Is Reset For GUN2 diSW2StepResetG2 1185 SW2 Cap Change Request for Gun1 diSW2CChngeReqG1
1169 SW2 Stepper Is Reset For GUN3 diSW2StepResetG3 1186 SW2 Cap Change Request for Gun2 diSW2CChngeReqG2
106
GRS4-B1
106
53
Robot Inputs: SW 2 (cont’d)
EIP Scanner ‐ Slot 3 EIP Scanner ‐ Slot 3
DI[#] Description Signal Name DI[#] Description Signal Name
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
1189 (Reserved) (Reserved) 1206 (Reserved) (Reserved)
1190 (Reserved) (Reserved) 1207 (Reserved) (Reserved)
1191 SW2 Pressure Bit 1 diSW2Pressure1 1208 (Reserved) (Reserved)
1192 SW2 Pressure Bit 2 diSW2Pressure2 1209 (Reserved) (Reserved)
1193 SW2 Pressure Bit 4 diSW2Pressure4 1210 (Reserved) (Reserved)
1194 SW2 Pressure Bit 8 diSW2Pressure8 1211 (Reserved) (Reserved)
1195 SW2 Read Pressure diSW2ReadPrssre 1212 (Reserved) (Reserved)
1196 (Reserved) (Reserved) 1213 (Reserved) (Reserved)
1197 (Reserved) (Reserved) 1214 (Reserved) (Reserved)
1198 (Reserved) (Reserved) 1215 (Reserved) (Reserved)
1199 (Reserved) (Reserved) 1216 (Reserved) (Reserved)
1200 (Reserved) (Reserved)
1201 SW2WeldProcessStop diSW2ProcessStop
1202 SW2 Adaptive Reguation Off diSW2AdaptRegOff
1203 SW2 Adaptive Monitoring Off diSW2AdaptMtrOff
107
GRS4-B1
107
Robot Outputs: SW 1
EIP Scanner ‐ Slot 2 EIP Scanner ‐ Slot 2
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
1029 (Reserved) (Reserved) 1046 SW1 Binary Select 8192 goSW1BinS8192
1030 SW1 Request Pressure doSW1ReqPrssre 1047 SW1 Binary Select 16384 goSW1BinS16384
1031 SW1 Initiate Weld doSW1InitWeld 1048 SW1 Binary Select 32768 goSW1BinS32768
1032 (Reserved) (Reserved) 1049 SW1 Binary Select 65536 goSW1BinS65536
1033 SW1 Binary Select 1 goSW1BinS1 1050 SW1 Binary Select 131072 goSW1BnS131072
1034 SW1 Binary Select 2 goSW1BinS2 1051 SW1 Binary Select 262144 goSW1BnS262144
1035 SW1 Binary Select 4 goSW1BinS4 1052 SW1 Binary Select 524288 goSW1BnS524288
1036 SW1 Binary Select 8 goSW1BinS8 1053 SW1 Weld BodyID 1 goSW1WeldID1
1037 SW1 Binary Select 16 goSW1BinS16 1054 SW1 Weld BodyID 2 goSW1WeldID2
1038 SW1 Binary Select 32 goSW1BinS32 1055 SW1 Weld BodyID 4 goSW1WeldID4
1039 SW1 Binary Select 64 goSW1BinS64 1056 SW1 Weld BodyID 8 goSW1WeldID8
1040 SW1 Binary Select 128 goSW1BinS128 1057 SW1 Weld BodyID 16 goSW1WeldID16
1041 SW1 Binary Select 256 goSW1BinS256 1058 SW1 Weld BodyID 32 goSW1WeldID32
108
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108
54
Robot Outputs: SW 1 (cont’d)
EIP Scanner ‐ Slot 2 EIP Scanner ‐ Slot 2
DO[#] Description Signal Name DO[#] Description Signal Name
1059 SW1 Weld BodyID 64 goSW1WeldID64 1076 (Reserved) (Reserved)
1060 SW1 Weld BodyID 128 goSW1WeldID128 1077 (Reserved) (Reserved)
1061 SW1 Stepper Reset Gun 1 doSW1StprRstGn1 1078 (Reserved) (Reserved)
1062 SW1 Stepper Reset Gun 2 doSW1StprRstGn2 1079 (Reserved) (Reserved)
1063 SW1 Stepper Reset Gun 3 doSW1StprRstGn3 1080 (Reserved) (Reserved)
1064 SW1 Stepper Reset Gun 4 doSW1StprRstGn4 1081 (Reserved) (Reserved)
1065 (Reserved) (Reserved) 1082 (Reserved) (Reserved)
1066 (Reserved) (Reserved) 1083 (Reserved) (Reserved)
1067 (Reserved) (Reserved) 1084 (Reserved) (Reserved)
1068 (Reserved) (Reserved) 1085 (Reserved) (Reserved)
1069 (Reserved) (Reserved) 1086 (Reserved) (Reserved)
1070 (Reserved) (Reserved) 1087 (Reserved) (Reserved)
1071 (Reserved) (Reserved) 1088 (Reserved) (Reserved)
1072 (Reserved) (Reserved)
1073 SW1 Part Finished doSW1PrtFinished
1074 SW1 Gun Resistance Check doSW1GnResistChk
1075 SW1 Reweld‐Turn Off Adaptive doSW1Reweld
109
GRS4-B1
109
Robot Outputs: SW 2
EIP Scanner ‐ Slot 3 EIP Scanner ‐ Slot 3
DO[#] Description Signal Name DO[#] Description Signal Name
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
1156 (Reserved) (Reserved) 1173 SW2 Binary Select 4096 goSW2BinS4096
1157 (Reserved) (Reserved) 1174 SW2 Binary Select 8192 goSW2BinS8192
1158 SW2 Request Pressure doSW2ReqPrssre 1175 SW2 Binary Select 16384 goSW2BinS16384
1159 SW2 Initiate Weld doSW2InitWeld 1176 SW2 Binary Select 32768 goSW2BinS32768
1160 (Reserved) (Reserved) 1177 SW2 Binary Select 65536 goSW2BinS65536
1161 SW2 Binary Select 1 goSW2BinS1 1178 SW2 Binary Select 131072 goSW2BnS131072
1162 SW2 Binary Select 2 goSW2BinS2 1179 SW2 Binary Select 262144 goSW2BnS262144
1163 SW2 Binary Select 4 goSW2BinS4 1180 SW2 Binary Select 524288 goSW2BnS524288
1164 SW2 Binary Select 8 goSW2BinS8 1181 SW2 Weld BodyID 1 goSW2WeldID1
1165 SW2 Binary Select 16 goSW2BinS16 1182 SW2 Weld BodyID 2 goSW2WeldID2
1166 SW2 Binary Select 32 goSW2BinS32 1183 SW2 Weld BodyID 4 goSW2WeldID4
1167 SW2 Binary Select 64 goSW2BinS64 1184 SW2 Weld BodyID 8 goSW2WeldID8
1168 SW2 Binary Select 128 goSW2BinS128 1185 SW2 Weld BodyID 16 goSW2WeldID16
1169 SW2 Binary Select 256 goSW2BinS256 1186 SW2 Weld BodyID 32 goSW2WeldID32
110
GRS4-B1
110
55
Robot Outputs: SW 2 (cont’d)
EIP Scanner ‐ Slot 3 EIP Scanner ‐ Slot 3
DO[#] Description Signal Name DO[#] Description Signal Name
1187 SW2 Weld BodyID 64 goSW2WeldID64 1204 (Reserved) (Reserved)
1188 SW2 Weld BodyID 128 goSW2WeldID128 1205 (Reserved) (Reserved)
1189 SW2 Stepper Reset Gun 1 doSW2StprRstGn1 1206 (Reserved) (Reserved)
1190 SW2 Stepper Reset Gun 2 doSW2StprRstGn2 1207 (Reserved) (Reserved)
1191 SW2 Stepper Reset Gun 3 doSW2StprRstGn3 1208 (Reserved) (Reserved)
1192 SW2 Stepper Reset Gun 4 doSW2StprRstGn4 1209 (Reserved) (Reserved)
1193 (Reserved) (Reserved) 1210 (Reserved) (Reserved)
1194 (Reserved) (Reserved) 1211 (Reserved) (Reserved)
1195 (Reserved) (Reserved) 1212 (Reserved) (Reserved)
1196 (Reserved) (Reserved) 1213 (Reserved) (Reserved)
1197 (Reserved) (Reserved) 1214 (Reserved) (Reserved)
1198 (Reserved) (Reserved) 1215 (Reserved) (Reserved)
1199 (Reserved) (Reserved) 1216 (Reserved) (Reserved)
1200 (Reserved) (Reserved)
1201 SW2 Part Finished doSW2PrtFinished
1202 SW2 Gun Resistance Check doSW2GnResistChk
1203 SW2 Reweld-Turn Off Adaptive doSW2Reweld
111
GRS4-B1
111
GRS4-B1 112
112
56
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.
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113
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114
57
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
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115
Programming Instructions
The following programming instructions need to conform to
specifications set forth by GM:
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116
58
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
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117
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118
59
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
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119
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.
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120
60
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
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In-Weld Functions
During the weld the robot will perform the following steps:
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122
61
Post-Weld Functions
The robot will perform the following steps after the weld is completed:
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123
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.
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124
62
Cap Loss Detection and Flow Monitoring
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125
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.
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126
63
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
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127
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.
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128
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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 robot will communicate each retry to the PLC via the ‘Process
X Alert’ signal and post a message to the teach pendant
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129
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
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130
65
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.
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131
Carried Application
If the application is carried only:
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.
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66
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.
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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.
• 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.
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134
67
FFR with Dual Pedestal Process
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135
136
136
68
Exercise 3.2
Exercise Solutions
137
137
138
69
Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
2. Complete the Table
Description Signal Name Robot Output
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139
140
70
Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
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
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141
GRS4-B1 142
142
71
Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
6. Which robot controller outputs are used to set the
weld schedule?
– Binary Select Bits
– Initiate Weld
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143
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144
72
Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
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 145
145
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146
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Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
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.
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147
GRS4-B1 148
148
74
Robot Software Requirements
149
149
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.
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75
Water Saver Inputs / Robot Outputs
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.
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151
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152
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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.
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153
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.
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154
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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
1480 (Reserved) (Reserved) 1496 (Reserved) (Reserved) 1512 Motor Current Bit 8 diTD1Current
1481 (Reserved) (Reserved) 1497 Phase Imbalance diTD1PhaseImb 1513 Motor Current Bit 9 diTD1Current
1482 (Reserved) (Reserved) 1498 (Reserved) (Reserved) 1514 Motor Current Bit 10 diTD1Current
1483 (Reserved) (Reserved) 1499 (Reserved) (Reserved) 1515 Motor Current Bit 11 diTD1Current
1484 (Reserved) (Reserved) 1500 (Reserved) (Reserved) 1516 Motor Current Bit 12 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
1487 (Reserved) (Reserved) 1503 (Reserved) (Reserved) 1519 Motor Current Bit 15 diTD1Current
1488 (Reserved) (Reserved) 1504 (Reserved) (Reserved) 1520 Motor Current Bit 16 diTD1Current
GRS4-B2 155
155
GRS4-B2 156
156
78
Robot Outputs: Tip Dresser 1-4
EIP Scanner ‐ Slot 20 EIP Scanner ‐ Slot 38
DO[#] Description Signal Name DO[#] Description Signal Name
1473 Motor On doTD1MotorOn 1521 Motor On doTD2MotorOn
1474 (Reserved) (Reserved) 1522 (Reserved) (Reserved)
1475 Fault Reset doTD1FaultReset 1523 Fault Reset doTD2FaultReset
1476 (Reserved) (Reserved) 1524 (Reserved) (Reserved)
1477 (Reserved) (Reserved) 1525 (Reserved) (Reserved)
1478 (Reserved) (Reserved) 1526 (Reserved) (Reserved)
1479 Blow Off On doTD1BlowOffOn 1527 Blow Off On doTD2BlowOffOn
1480 (Reserved) (Reserved) 1528 (Reserved) (Reserved)
157
GRS4-B2 158
158
79
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
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159
Servo Guns
160
160
80
Integrated Servo Gun
GRS4-B3 161
161
GRS4-B3 162
162
81
Drive System Requirements
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).
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163
GRS4-B3 164
164
82
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.
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165
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166
83
Seventh-Axis Control Software Requirements
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 167
167
GRS4-B3 168
168
84
Seventh-Axis Control Software Requirements
GRS4-B3 169
169
GRS4-B3 170
170
85
Seventh-Axis Control Software Requirements
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.
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171
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172
86
Seventh-Axis Control Software Requirements
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.
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173
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174
87
Seventh-Axis Control Software Requirements
GRS4-B3 175
175
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176
88
Seventh-Axis Control Software Requirements
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.
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177
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178
89
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.
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.
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179
Process Modes
Tryout Mode
180
90
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.
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181
Process Modes
Stroke / No Stroke
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182
91
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.
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183
184
92
Robot Software Requirements
Dispense Interface
185
185
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 186
186
93
Robot Inputs - Dispense Controller Outputs
(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.
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187
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.
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188
94
Robot Inputs - Dispense Controller Outputs
(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 189
189
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.
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Robot Outputs - Dispense Controller Inputs
(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
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• This is a binary representation of an analog signal that is proportional to the TCP speed of the robot.
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96
Robot Outputs - Dispense Controller Inputs
(cont’d)
8. Remote Start: This signal restarts the dispense system from any “not-ready”
state.
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
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Dispense Controller 1 Outputs / Robot Inputs
EIP Scanner ‐ Slot 4 EIP Scanner ‐ Slot 4 EIP Scanner ‐ Slot 4
DI[#] Description Signal Name DI[#] Description Signal Name DI[#] Description Signal Name
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
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98
Dispense Controller 1 Outputs / Robot Inputs
(cont’d)
EIP Scanner ‐ Slot 4 EIP Scanner ‐ Slot 4
DI[#] Description Signal Name DI[#] Description Signal Name
1121 Dispense1 Fault Data Bit 1 diSL1FaultBit1 1137 (Reserved) (SL1 Reserved)
1122 Dispense1 Fault Data Bit 2 diSL1FaultBit2 1138 (Reserved) (SL1 Reserved)
1123 Dispense1 Fault Data Bit 3 diSL1FaultBit3 1139 (Reserved) (SL1 Reserved)
1124 Dispense1 Fault Data Bit 4 diSL1FaultBit4 1140 (Reserved) (SL1 Reserved)
1125 Dispense1 Fault Data Bit 5 diSL1FaultBit5 1141 (Reserved) (SL1 Reserved)
1126 Dispense1 Fault Data Bit 6 diSL1FaultBit6 1142 (Reserved) (SL1 Reserved)
1127 Dispense1 Fault Data Bit 7 diSL1FaultBit7 1143 (Reserved) (SL1 Reserved)
1128 Dispense1 Fault Data Bit 8 diSL1FaultBit8 1144 (Reserved) (SL1 Reserved)
1129 Dispense1 Fault Data Bit 9 diSL1FaultBit9 1145 (Reserved) (SL1 Reserved)
1130 Dispense1 Fault Data Bit 10 diSL1FaultBit10 1146 (Reserved) (SL1 Reserved)
1131 Dispense1 Fault Data Bit 11 diSL1FaultBit11 1147 (Reserved) (SL1 Reserved)
1132 Dispense1 Fault Data Bit 12 diSL1FaultBit12 1148 (Reserved) (SL1 Reserved)
1133 Dispense1 Fault Data Bit 13 diSL1FaultBit13 1149 (Reserved) (SL1 Reserved)
1134 Dispense1 Fault Data Bit 14 diSL1FaultBit14 1150 (Reserved) (SL1 Reserved)
1135 Dispense1 Fault Data Bit 15 diSL1FaultBit15 1151 (Reserved) (SL1 Reserved)
1136 Dispense1 Fault Data Bit 16 diSL1FaultBit16 1152 (Reserved) (SL1 Reserved)
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Dispense Controller 2 Outputs / Robot Inputs
(cont’d)
EIP Scanner ‐ Slot 5 EIP Scanner ‐ Slot 5 EIP Scanner ‐ Slot 5
DI[#] Description Signal Name DI[#] Description Signal Name DI[#] Description Signal Name
1201 Process2 Data Area Volume Bit 1 diSL2AreaVolB1 1217 Process2 Data System Pressure Bit 1 diSL2PressureB1 1233 Process2 Data Temp Set Point Bit 1 diSL2TempSetB1
1202 Process2 Data Area Volume Bit 2 diSL2AreaVolB2 1218 Process2 Data System Pressure Bit 2 diSL2PressureB2 1234 Process2 Data Temp Set Point Bit 2 diSL2TempSetB2
1203 Process2 Data Area Volume Bit 3 diSL2AreaVolB3 1219 Process2 Data System Pressure Bit 3 diSL2PressureB3 1235 Process2 Data Temp Set Point Bit 3 diSL2TempSetB3
1204 Process2 Data Area Volume Bit 4 diSL2AreaVolB4 1220 Process2 Data System Pressure Bit 4 diSL2PressureB4 1236 Process2 Data Temp Set Point Bit 4 diSL2TempSetB4
1205 Process2 Data Area Volume Bit 5 diSL2AreaVolB5 1221 Process2 Data System Pressure Bit 5 diSL2PressureB5 1237 Process2 Data Temp Set Point Bit 5 diSL2TempSetB5
1206 Process2 Data Area Volume Bit 6 diSL2AreaVolB6 1222 Process2 Data System Pressure Bit 6 diSL2PressureB6 1238 Process2 Data Temp Set Point Bit 6 diSL2TempSetB6
1207 Process2 Data Area Volume Bit 7 diSL2AreaVolB7 1223 Process2 Data System Pressure Bit 7 diSL2PressureB7 1239 Process2 Data Temp Set Point Bit 7 diSL2TempSetB7
1208 Process2 Data Area Volume Bit 8 diSL2AreaVolB8 1224 Process2 Data System Pressure Bit 8 diSL2PressureB8 1240 Process2 Data Temp Set Point Bit 8 diSL2TempSetB8
Process2 Data Actual Temp Set Point Bit
1209 Process2 Data Area Volume Bit 9 diSL2AreaVolB9 1225 Process2 Data System Pressure Bit 9 diSL2PressureB9 1241 1 diSL2ActTempB1
Process2 Data Actual Temp Set Point Bit
1210 Process2 Data Area Volume Bit 10 diSL2AreaVolB10 1226 Process2 Data System Pressure Bit 10 diSL2PressureB10 1242 2 diSL2ActTempB2
Process2 Data Actual Temp Set Point Bit
1211 Process2 Data Area Volume Bit 11 diSL2AreaVolB11 1227 Process2 Data System Pressure Bit 11 diSL2PressureB11 1243 3 diSL2ActTempB3
Process2 Data Actual Temp Set Point Bit
1212 Process2 Data Area Volume Bit 12 diSL2AreaVolB12 1228 Process2 Data System Pressure Bit 12 diSL2PressureB12 1244 4 diSL2ActTempB4
Process2 Data Actual Temp Set Point Bit
1213 Process2 Data Area Volume Bit 13 diSL2AreaVolB13 1229 Process2 Data System Pressure Bit 13 diSL2PressureB13 1245 5 diSL2ActTempB5
Process2 Data Actual Temp Set Point Bit
1214 Process2 Data Area Volume Bit 14 diSL2AreaVolB14 1230 Process2 Data System Pressure Bit 14 diSL2PressureB14 1246 6 diSL2ActTempB6
Process2 Data Actual Temp Set Point Bit
1215 Process2 Data Area Volume Bit 15 diSL2AreaVolB15 1231 Process2 Data System Pressure Bit 15 diSL2PressureB15 1247 7 diSL2ActTempB7
Process2 Data Actual Temp Set Point Bit
1216 Process2 Data Area Volume Bit 16 diSL2AreaVolB16 1232 Process2 Data System Pressure Bit 16 diSL2PressureB16 1248 8 diSL2ActTempB8
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Dispense Controller 1 Inputs / Robot Outputs
EIP Scanner ‐ Slot 4 EIP Scanner ‐ Slot 4 EIP Scanner ‐ Slot 4
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
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DO[#] Description Signal Name DO[#] Description Signal Name DO[#] Description Signal Name
1073 Dispense1 Bead Shaping Command (bit 1) goSL1BeadShp1 1089 AreaNumberBit1 goSL1AreaNum1 1105 (Reserved) (SL1 Reserved)
1074 Dispense1 Bead Shaping Command (bit 2) goSL1BeadShp2 1090 AreaNumberBit2 goSL1AreaNum2 1106 (Reserved) (SL1 Reserved)
1075 Dispense1 Bead Shaping Command (bit 3) goSL1BeadShp3 1091 AreaNumberBit3 goSL1AreaNum3 1107 (Reserved) (SL1 Reserved)
1076 Dispense1 Bead Shaping Command (bit 4) goSL1BeadShp4 1092 AreaNumberBit4 goSL1AreaNum4 1108 (Reserved) (SL1 Reserved)
1077 Dispense1 Bead Shaping Command (bit 5) goSL1BeadShp5 1093 AreaNumberBit5 goSL1AreaNum5 1109 (Reserved) (SL1 Reserved)
1078 Dispense1 Bead Shaping Command (bit 6) goSL1BeadShp6 1094 (Reserved) (Reserved) 1110 (Reserved) (SL1 Reserved)
1079 Dispense1 Bead Shaping Command (bit 7) goSL1BeadShp7 1095 (Reserved) (Reserved) 1111 (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)
1083 Dispense1 Bead Shaping Command (bit 11) goSL1BeadShp11 1099 (Reserved) (SL1 Reserved) 1115 (Reserved) (SL1 Reserved)
1084 Dispense1 Bead Shaping Command (bit 12) goSL1BeadShp12 1100 (Reserved) (SL1 Reserved) 1116 (Reserved) (SL1 Reserved)
1085 Dispense1 Bead Shaping Command (bit 13) goSL1BeadShp13 1101 (Reserved) (SL1 Reserved) 1117 (Reserved) (SL1 Reserved)
1086 Dispense1 Bead Shaping Command (bit 14) goSL1BeadShp14 1102 (Reserved) (SL1 Reserved) 1118 (Reserved) (SL1 Reserved)
1087 Dispense1 Bead Shaping Command (bit 15) goSL1BeadShp15 1103 (Reserved) (SL1 Reserved) 1119 (Reserved) (SL1 Reserved)
1088 Dispense1 Bead Shaping Command (bit 16) goSL1BeadShp16 1104 (Reserved) (SL1 Reserved) 1120 (Reserved) (SL1 Reserved)
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Dispense Controller 1 Inputs / Robot Outputs
(cont’d)
EIP Scanner ‐ Slot 4 EIP Scanner ‐ Slot 4
DO[#] Description Signal Name DO[#] Description Signal Name
1121 (Reserved) (SL1 Reserved) 1137 (Reserved) (SL1 Reserved)
1122 (Reserved) (SL1 Reserved) 1138 (Reserved) (SL1 Reserved)
1123 (Reserved) (SL1 Reserved) 1139 (Reserved) (SL1 Reserved)
1124 (Reserved) (SL1 Reserved) 1140 (Reserved) (SL1 Reserved)
1125 (Reserved) (SL1 Reserved) 1141 (Reserved) (SL1 Reserved)
1126 (Reserved) (SL1 Reserved) 1142 (Reserved) (SL1 Reserved)
1127 (Reserved) (SL1 Reserved) 1143 (Reserved) (SL1 Reserved)
1128 (Reserved) (SL1 Reserved) 1144 (Reserved) (SL1 Reserved)
1129 (Reserved) (SL1 Reserved) 1145 (Reserved) (SL1 Reserved)
1130 (Reserved) (SL1 Reserved) 1146 (Reserved) (SL1 Reserved)
1131 (Reserved) (SL1 Reserved) 1147 (Reserved) (SL1 Reserved)
1132 (Reserved) (SL1 Reserved) 1148 (Reserved) (SL1 Reserved)
1133 (Reserved) (SL1 Reserved) 1149 (Reserved) (SL1 Reserved)
1134 (Reserved) (SL1 Reserved) 1150 (Reserved) (SL1 Reserved)
1135 (Reserved) (SL1 Reserved) 1151 (Reserved) (SL1 Reserved)
1136 (Reserved) (SL1 Reserved) 1152 (Reserved) (SL1 Reserved)
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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
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102
Dispense Controller 2 Inputs / Robot Outputs
(cont’d)
EIP Scanner ‐ Slot 5 EIP Scanner ‐ Slot 5 EIP Scanner ‐ Slot 5
DO[#] Description Signal Name DO[#] Description Signal Name DO[#] Description Signal Name
1201 Dispense2 Bead Shaping Command (bit 1) goSL2BeadShp1 1217 AreaNumberBit1 goSL2AreaNum1 1233 (Reserved) (SL2 Reserved)
1202 Dispense2 Bead Shaping Command (bit 2) goSL2BeadShp2 1218 AreaNumberBit2 goSL2AreaNum2 1234 (Reserved) (SL2 Reserved)
1203 Dispense2 Bead Shaping Command (bit 3) goSL2BeadShp3 1219 AreaNumberBit3 goSL2AreaNum3 1235 (Reserved) (SL2 Reserved)
1204 Dispense2 Bead Shaping Command (bit 4) goSL2BeadShp4 1220 AreaNumberBit4 goSL2AreaNum4 1236 (Reserved) (SL2 Reserved)
1205 Dispense2 Bead Shaping Command (bit 5) goSL2BeadShp5 1221 AreaNumberBit5 goSL2AreaNum5 1237 (Reserved) (SL2 Reserved)
1206 Dispense2 Bead Shaping Command (bit 6) goSL2BeadShp6 1222 (Reserved) (Reserved) 1238 (Reserved) (SL2 Reserved)
1207 Dispense2 Bead Shaping Command (bit 7) goSL2BeadShp7 1223 (Reserved) (Reserved) 1239 (Reserved) (SL2 Reserved)
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)
1210 Dispense2 Bead Shaping Command (bit 10) goSL2BeadShp10 1226 (Reserved) (SL2 Reserved) 1242 (Reserved) (SL2 Reserved)
1211 Dispense2 Bead Shaping Command (bit 11) goSL2BeadShp11 1227 (Reserved) (SL2 Reserved) 1243 (Reserved) (SL2 Reserved)
1212 Dispense2 Bead Shaping Command (bit 12) goSL2BeadShp12 1228 (Reserved) (SL2 Reserved) 1244 (Reserved) (SL2 Reserved)
1213 Dispense2 Bead Shaping Command (bit 13) goSL2BeadShp13 1229 (Reserved) (SL2 Reserved) 1245 (Reserved) (SL2 Reserved)
1214 Dispense2 Bead Shaping Command (bit 14) goSL2BeadShp14 1230 (Reserved) (SL2 Reserved) 1246 (Reserved) (SL2 Reserved)
1215 Dispense2 Bead Shaping Command (bit 15) goSL2BeadShp15 1231 (Reserved) (SL2 Reserved) 1247 (Reserved) (SL2 Reserved)
1216 Dispense2 Bead Shaping Command (bit 16) goSL2BeadShp16 1232 (Reserved) (SL2 Reserved) 1248 (Reserved) (SL2 Reserved)
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Robot Software Requirements
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.
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Programming Instructions
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.
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104
Programming Instructions
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.
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Programming Instructions
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
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105
Programming Instructions
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.
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Programming Instructions
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.
212
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Programming Instructions
Area Complete (EQx, AreaNum)
This instruction indicates the dispense area is completed and will check the Area Volume OK
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Programming Instructions
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
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107
Programming Instructions
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 215
215
Programming Instructions
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 216
216
108
Programming Instructions
Remote Start / Purge (cont’d)
3. The following fault conditions will be detected by this instruction.
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 217
217
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 218
218
109
Flow Schedule
1. Flow type - 2 flow types are supported:
2. Flow rate - The units are dictated by the flow type selection.
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 219
219
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 220
220
110
Flow Schedule (cont'd)
GRS4-C 221
221
Style ID Table
GRS4-C 222
222
111
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 223
223
GRS4-C 224
224
112
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 225
225
GRS4-C 226
226
113
Exercise 3.3
Exercise Solutions
GRS4-C 227
227
GRS4-C 228
228
114
Exercise 3.3: Dispense Interface: Solutions
(cont’d)
2. What signal is set from the robot controller to the
dispense unit to clear a fault?
Fault Reset
GRS4-C 229
229
GRS4-C 230
230
115
Exercise 3.3: Dispense Interface: Solutions
(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 231
231
GRS4-C 232
232
116
Exercise 3.3: Dispense Interface: Solutions
(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 233
233
234
234
117
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 235
235
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 236
236
118
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 237
237
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 238
238
119
Robot Outputs - Weld Controller Inputs (cont’d)
GRS4-D 239
239
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 240
240
120
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)
1033 Head Back #2 diST1HdBackHd2 1049 (Reserved) (Reserved) 1065 (Reserved) (Reserved) 1081 (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)
1038 Head Back #3 diST1HdBackHd3 1054 (Reserved) (Reserved) 1070 (Reserved) (Reserved) 1086 (Reserved) (Reserved)
1039 (Reserved) (Reserved) 1055 (Reserved) (Reserved) 1071 (Reserved) (Reserved) 1087 (Reserved) (Reserved)
1040 NO Fault Head #4 diST1NoFaultHd4 1056 (Reserved) (Reserved) 1072 (Reserved) (Reserved) 1088 (Reserved) (Reserved)
GRS4-D 241
241
GRS4-D 242
242
121
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 243
243
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 244
244
122
Programming Instructions
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 245
245
246
123
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 247
247
GRS4-D 248
248
124
Fault Handling and Recovery
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 249
249
GRS4-D 250
250
125
FFR with Carried Process, No Hot Backup
GRS4-D 251
251
GRS4-D 252
252
126
FFR with Carried Process, With Hot Backup
GRS4-D 253
253
GRS4-D 254
254
127
Robot Software Requirements
255
255
1040 FDS1 Error Code Bit8 diFDS1ErrCodeB8 1056 (Reserved) (Reserved) 1072 (Reserved) (Reserved) 1088 (Reserved) (Reserved)
256
GRS4
256
128
Flow Drill Screw Inputs – Robot Outputs
EIP Scanner ‐ Slot 11 EIP Scanner ‐ Slot 11 EIP Scanner ‐ Slot 11 EIP Scanner ‐ Slot 11
DO[#] Description Signal Name DO[#] Description Signal Name DO[#] Description Signal Name DO[#] Description Signal Name
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)
1034 Code Number Bit 2 doFDS1CodeBit2 1050 (Reserved) (Reserved) 1066 (Reserved) (Reserved) 1082 (Reserved) (Reserved)
1035 Code Number Bit 3 doFDS1CodeBit3 1051 (Reserved) (Reserved) 1067 (Reserved) (Reserved) 1083 (Reserved) (Reserved)
1036 Code Number Bit 4 doFDS1CodeBit4 1052 (Reserved) (Reserved) 1068 (Reserved) (Reserved) 1084 (Reserved) (Reserved)
1037 Code Number Bit 5 doFDS1CodeBit5 1053 (Reserved) (Reserved) 1069 (Reserved) (Reserved) 1085 (Reserved) (Reserved)
1038 Code Number Bit 6 doFDS1CodeBit6 1054 (Reserved) (Reserved) 1070 (Reserved) (Reserved) 1086 (Reserved) (Reserved)
1039 Code Number Bit 7 doFDS1CodeBit7 1055 (Reserved) (Reserved) 1071 (Reserved) (Reserved) 1087 (Reserved) (Reserved)
1040 Code Number Bit 8 doFDS1CodeBit8 1056 (Reserved) (Reserved) 1072 (Reserved) (Reserved) 1088 (Reserved) (Reserved)
257
GRS4
257
258
GRS4
258
129
Self Piercing Rivets Inputs – Robot Outputs
EIP Scanner ‐ Slot 9 EIP Scanner ‐ Slot 9 EIP Scanner ‐ Slot 9 EIP Scanner ‐ Slot 9
DO[#] Description Signal Name DO[#] Description Signal Name DO[#] Description Signal Name DO[#] Description Signal Name
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)
1034 (Reserved) (Reserved) 1050 JointNumber2 doSPR1JntNum2 1066 (Reserved) (Reserved) 1082 (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)
1037 (Reserved) (Reserved) 1053 JointNumber16 doSPR1JntNum16 1069 (Reserved) (Reserved) 1085 (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)
1040 (Reserved) (Reserved) 1056 JointNumber128 doSPR1JntNum128 1072 (Reserved) (Reserved) 1088 (Reserved) (Reserved)
259
GRS4
259
260
260
130
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 261
261
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
C 262
GRS4 PP4 6
262
131
MH Valves Setup (cont’d)
Press MENU – 6: Setup – MH Valves
To setup the valves:
Select the tool to setup and press F2 Detail
263
GRS4
263
132
MH Valves Setup (cont’d)
• 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]
265
GRS4
265
Highlight the input signal for clamp one and press F4 [CHOICE] to choose
what input the clamp open signal is tied to.
266
GRS4
266
133
MH Valves Setup (cont’d)
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
Fault Handling
GRS4-E 268
268
134
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
269
GRS4
269
GRS4-E 270
270
135
Material Handling Vacuum Pump 1-2 /
Robot Inputs
MH Vacuum Pump 1 MH Vacuum Pump 2
EIP Scanner ‐ Slot 29 EIP Scanner ‐ Slot 30
DI[#] Description Signal Name DI[#] Description Signal Name
865 VP Vacuum Made 1 di865VPVacMade1 873 VP Vacuum Made 3 di873VPVacMade3
866 VP Vacuum Made 2 di866VPVacMade2 874 VP Vacuum Made 4 di874VPVacMade4
867 (Reserved) (Reserved) 875 (Reserved) (Reserved)
868 (Reserved) (Reserved) 876 (Reserved) (Reserved)
GRS4-E 271
271
GRS4-E 272
272
136
Material Handling Vacuum Pump 1-2 / Robot
Outputs
MH Vacuum Pump 1 MH Vacuum Pump 2
EIP Scanner ‐ Slot 29 EIP Scanner ‐ Slot 30
GRS4-E 273
273
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 274
274
137
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 275
275
276
138
Programming Instructions - Cylinders
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 277
277
GRS4-E 278
278
139
Programming Instructions - Cylinders
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 279
279
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 280
280
140
Programming Instructions - Cylinders
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.
GRS4-E 281
281
GRS4-E 282
282
141
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 283
283
284
142
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 285
285
GRS4-E 286
286
143
GRS4-E
Tool Changer End of Arm / Robot Inputs
Tool Changer Robot End Tool Changer Tool End
EIP Scanner ‐ Slot 54 EIP Scanner ‐ Slot 54
DI[#] Description Signal Name DI[#] Description Signal Name
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
922 Robot Number (bit 2) giRobotNumber
923 Robot Number (bit 4) giRobotNumber
924 Robot Number (bit 8) giRobotNumber
925 Line Number (bit 1) giLineNumber
926 Line Number (bit 2) giLineNumber
927 Line Number (bit 4) giLineNumber
928 Line Number (bit 8) giLineNumber
GRS4-E 287
287
GRS4-E 288
288
144
Tool Changer Robot Software Requirements
289
290
145
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 291
291
GRS4-E 292
292
146
GRS4-E
Tool Changer Nest / Robot Inputs
Tool Change Nest 1 Tool Change Nest 2 Tool Change Nest 3 Tool Change Nest 4
EIP Scanner ‐ Slot 56 EIP Scanner ‐ Slot 57 EIP Scanner ‐ Slot 58 EIP Scanner ‐ Slot 59
DI[#] Description Signal Name DI[#] Description Signal Name DI[#] Description Signal Name DI[#] Description Signal Name
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
933 (Reserved) (Reserved) 941 (Reserved) (Reserved) 949 (Reserved) (Reserved) 957 (Reserved) (Reserved)
934 (Reserved) (Reserved) 942 (Reserved) (Reserved) 950 (Reserved) (Reserved) 958 (Reserved) (Reserved)
935 (Reserved) (Reserved) 943 (Reserved) (Reserved) 951 (Reserved) (Reserved) 959 (Reserved) (Reserved)
936 (Reserved) (Reserved) 944 (Reserved) (Reserved) 952 (Reserved) (Reserved) 960 (Reserved) (Reserved)
GRS4-E 293
293
GRS4-E 294
294
147
Robot Controlled Tool Nests
Check For Nest Empty
• This instruction will verify that a specific tool changer nest is empty.
Open Nest
• This instruction will open a tool changer nest.
Close Nest
• This instruction will close a tool changer nest.
GRS4-E 295
295
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 296
296
148
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 297
297
The Pick Tool function drops off the currently installed gun
in the appropriate nest before picking up the requested
tool.
GRS4-E 298
298
149
Tool Change Decisions
DECISION CODE AT POUNCE FUNCTION
GRS4-E 299
299
GRS4-E 300
300
150
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
Head 2 dropoff 34 35 36
Head 3 dropoff 38 39 40
Head 4 dropoff 42 43 44
GRS4-E 301
301
GRS4-E 302
302
151
GRS
Global Robot Specifications
LMS # 34043
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
1
Robot Teach Pendent
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.
4
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4
2
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
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5
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. 6
GRS4
6
3
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
7
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7
4
GM Setup Wizard – Additional Information
• For GM Setup Wizard information, visit the
Robotic Standards page:
https://supplier.body.gm.com/crw/production/main
/globalStandards/roboticStandards.cfm
• Navigate to User Guides and Manuals then
Global 4 User Guides and Manuals
9
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9
10
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10
5
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)
11
GRS4
11
12
12
6
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”.
13
GRS4
13
14
7
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.
16
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16
8
Load Configuration
Allows for the configuration file to be loaded to
multiple robots
Exit
• Exit will exit the Setup Wizard and finish any GRS4
Customized settings.
• Once the Wizard is finished setting parameters perform
a Cold Start.
18
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18
9
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.
19
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19
GRS4 20
20
10
Robot Held Servo Gun Welding Example (cont’d)
2. If running for the first time this menu may not appear.
If running it again it will ask to clear the configuration
GRS4 21
21
GRS4 22
22
11
Robot Held Servo Gun Welding Example (cont’d)
4. Select 1 to set the IP address of the robot
GRS4 23
23
GRS4 24
24
12
Robot Held Servo Gun Welding Example (cont’d)
6. Select the number of robot processes. <1>.
25
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25
26
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26
13
Robot Held Servo Gun Welding Example (cont’d)
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.
27
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27
28
GRS4
28
14
Robot Held Servo Gun Welding Example (cont’d)
10. Select Servo Gun welding application <Servo Gun
YES>
GRS4 29
29
30
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30
15
Robot Held Servo Gun Welding Example (cont’d)
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.
31
GRS4
31
32
GRS4
32
16
Robot Held Servo Gun Welding Example (cont’d)
14.Select the gun design type or shape
< C-Gun >
C - Gun X - Gun
33
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33
34
GRS4
34
17
Robot Held Servo Gun Welding Example (cont’d)
16. Select Tip Dresser option.
35
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35
36
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36
18
Robot Held Servo Gun Welding Example (cont’d)
18. Select if Servo Tip Dresser is used. If no is selected the default
electric dresser is configured
37
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37
38
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38
19
Robot Held Servo Gun Welding Example (cont’d)
20. Is a Tool Changer(s) Present? Typically NO.
39
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39
40
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40
20
Robot Held Servo Gun Welding Example (cont’d)
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
41
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41
42
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42
21
Storage Devices
43
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43
MD Backup Procedure
• Set device as where USB/MC is loaded & Create a
new directory with folder name as robot name
• Set device to ‘MD’ & *.* , press ‘enter’
• Select ‘all files’ by moving curser up or down
• Press ‘prev’ or ‘next button’ & press ‘copy’
• Verify the origin / destination files are correct
• Confirm to copy
44
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44
22
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.
45
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45
46
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46
23
Backup All (cont’d)
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".
9. Press the "ENTER" button.
10. Select “Mem Card (MC:)“, “USB Disk (UD1:)” or press 8 to go
to the next page to access “USB on TP (UT1:)”.
11. Press the "ENTER" button.
47
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47
48
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48
24
Backup All (cont’d)
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
49
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49
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.
50
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50
25
MD: Copy (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.
51
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51
26
MD: Copy (cont’d)
Step 3. Set the MD:
12. Press "F5 [UTIL]". The backup device menu will appear.
13. Select "1 Set Device".
14. Press the "ENTER" button.
15. Select “Mem Device (MD:)“
16. Press the "ENTER" button.
53
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53
54
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54
27
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.
55
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55
56
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56
28
Controller Image – Backup (cont’d)
5. From the BMON menu, select Controller backup/restore
(press the 4 button then the ENTER button).
57
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57
58
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58
29
Controller Image – Backup (cont’d)
7. Select Memory Card (MC:) or USB (UD1:) and press ENTER.
59
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59
60
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60
30
Controller Image – Backup (cont’d)
9. Type 1 and press ENTER. The memory files will
be written to the memory card. You should see
messages similar to the following:
61
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61
62
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62
31
Controller Image – Backup (cont’d)
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
63
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63
64
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64
32
Controller Image – Restore (cont’d)
5. Select Controller backup/restore and press the 4 button
then the ENTER button.
65
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65
66
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66
33
Controller Image – Restore (cont’d)
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.
67
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67
68
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68
34
Controller Image – Restore (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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69
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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35
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
71
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71
72
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72
36
Production Home, GM Manuals, Production Speed
(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.
73
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74
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37
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
75
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75
76
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76
38
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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78
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39
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.
79
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79
1
80
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80
40
Wizard Top Menu
3. Wizard Top Menu
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81
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.
82
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41
Module 4: Review
How do you 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.
83
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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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42
Module 4: Review
How do you restore the controller 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.
5. Select Controller backup/restore and press the 4 button then the
ENTER button.
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85
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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43
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.
88
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88
44
Module 4: Review
How do you perform a Backup all procedure?
Step 1. Access File Screen
Step 2. Set up the backup device.
Step 3. Start the backup
Step 4. Maintenance and back up files
89
89
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.
90
90
45
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)
91
91
46
GRS
Global Robot Specifications
LMS # 34043
Review
Revision 6.2
Review
What is the rough cycle time for a carried stud
welder that must make 9 stud welds with a SWT
of 2.2?
A. 19 seconds
B. 23.4 seconds
C. 29.3 seconds
D. 34.7 seconds
1
Review
What decision code returns the robot to the home
position from pounce?
A. 12
B. 13
C. 14
D. 15
Review
The option bits are transferred between the cell
controller and the robot are used to:
A. Select the program style
B. Determine which of two pick up points to select
the part from
C. Modify the program to perform backup routines
D. Run a variation of a style program based on
features unique to this part
4
2
Review
What bit to the robot indicates that the PLC is
sending valid style and option bits?
A. Initiate style bit
B. Start bit
C. Select bit
D. Option bit
Review
What are the steps the robot should complete
upon returning to the home position?
A. Execute the home check
B. Execute the housekeeping function
C. Terminate the style program
D. All of the above
3
Review
What style is used for moving the robot to the
repair position?
A. 29
B. 30
C. 31
D. 25
Review
At the end of a normal cycle, what two signals should be
received from dispense controller 1 at the robot?
A. Dispense 1 TOTAL Volume OK is On and Dispense 1 in
Process is Off
B. Dispense 1 Fault is On and Dispense 1 Area Volume OK is
On
C. Dispense 1 Process Alert is On and Dispense Complete is
Off
D. Dispense 1 TOTAL Volume OK is On and Dispense 1 End of
Cycle is On
8
4
Review
If Decision Code 3 is sent, the tool will be picked out of
what nest?
A. Nest 1
B. Nest 2
C. Nest 3
D. Nest 4
Review
What signal will the robot wait for from the cell controller
when at the pounce position?
A. Start
B. Decision code
C. Path segment 1
D. Ok to Continue
10
10
5
Review
Which of the following is not a choice when running Fast
Fault Recovery?
A. Re-Weld
B. Abort
C. Continue Last
D. Continue Next
11
11