Matuschek Meßtechnik GmbH . Alsdorf .

Germany
Resistance Welding . Controlling . Monitoring . Measuring . Processing

BMW Project LU

Special

Robot Routines
for

SPATZ+ Welding Equipment

2012-10-15 Version 1.0

Matuschek Meßtechnik GmbH y Werner-Heisenberg-Str. 14 y 52477 Alsdorf y Germany

E-Mail: info@matuschek.com y Internet: www.matuschek.com
Phone: +49 2404 / 676 - 0 y Fax: +49 2404 / 676 - 111
Copyright © 2012 by Matuschek Meßtechnik GmbH

Edited by Matuschek Messtechnik GmbH, Alsdorf, Germany. All rights reserved. No part of this publication
may be reproduced, stored in a retrieval system, or transmitted, in any form or by means without the prior
permission in writing of the publisher. The examples given in this manual describe only the product and do
not represent a legally binding guarantee. Subject to alteration. Matuschek Messtechnik GmbH does not
accept any liability whatever for the correctness of the contents. This manual was compiled with the great-
est care and every effort has been made to avoid errors. However, as errors can never be completely
eradicated we shall be very grateful for your comments and suggestions for improvement.

MASTER® and MASDAT® are registered trademarks of Matuschek Meßtechnik GmbH.

MASDAT® weld gun identification system is patented in US-Patent 6,072,146

Matuschek Messtechnik GmbH

Werner-Heisenberg-Strasse 14
52477 Alsdorf
Germany

Phone: +49 / 24 04 / 676 - 0

Fax: +49 / 24 04 / 676 - 111
E-mail: info@matuschek.com
Internet: www.matuschek.com
SPATZ+ Special Robot Routines
Content
1 Roboter Routines ........................................................................................................................... 1
2 Robot Routines for Service Programs ........................................................................................... 1
2.1 Robot routine for current scaling ............................................................................................1
2.2 Robot routine for gun resistance adjustment .........................................................................2
2.3 Robot routine for short circuit weld after tip dressing .............................................................3
2.3.1 Robot routine for short circuit weld after First Tip Dress ............................................................... 3
2.3.2 Robot routine for short circuit weld after Tip Dress........................................................................ 3

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SPATZ+ Special Robot Routines
1 Robot Routines
For welding applications with SPATZ+ weld timers and for the usage of the MASTER Data Base MDB
the following robot routines will make the work for the maintenance people more easy and will help to
avoid mistakes due to wrong usage.

2 Robot Routines for Service Programs

2.1 Robot routine for current scaling
In order to check the function and sensitivity of the current sensor (toroidal coil) the SPATZ+ weld timer
service programs 111-115 for gun1 to gun 5 are used. This must be done after repair of gun or change
of transformer. The service programs are predefined weld programs with squeeze time, current time
(KSR1) and hold time.
For this service program tip dress and tip change are not necessary.
The robot routine should have the following steps:
1. Move gun to a position, where the current control coil of an external current meter can be adapt to
the gun arm easily.
2. Message: Put in current coil of external meter and activate Current Calibration Routine in the weld
timer software.
3. Do a weld with Spot No. 111 for gun 1, 112 for gun 2 ….
4. Message: Put the value of the external meter into the weld timer software.
5. Do an other weld with Spot No. 111 for gun 1, 112 for gun 2 ….
6. Message: Check the current values of the weld timer and of the external current meter. Deviation
should not be more than ± 30 A.
7. If deviation is more than ± 30 A: Back to step 2. If deviation is less, current calibration is finished.
8. Message: Current calibration ready. Remove current coil of external meter.
9. Move robot to home position

1
: KSR = Konstant-Strom-Regelung = Constant Current Regulation

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SPATZ+ Special Robot Routines
2.2 Robot routine for gun resistance adjustment
To adjust the gun used in production to the MDA (Master Data Base), a weld gun reference routine pro-
gram has to be executed once for each weld gun before usage in production.
In addition this routine has to be executed after every repair of the secondary circuit of the gun, e.g. re-
pair or change of complete gun or gun components (transformer, electrode arm …). The SPATZ+ weld
timer service programs 121-125 for gun1 to gun 5 are used. This service programs are predefined weld
programs with squeeze time, current time (KSR) and hold time. The gun related data like gun resistance
are automatically stored in the SPATZ+ weld timer during this routine.
For this service program tip change and tip dress are mandatory!
The robot routine should have the following steps:
1. Execute Tip Change routine
2. Execute First Tip Dress routine
3. Execute Robot routine for current scaling (2.1)
4. Do about 20 welds with Spot No. 111 for gun 1, 112 for gun 2 ….
5. Execute tip dress routine
6. Message: Check tip dress result. Have a look to both cap surfaces
7. If tip dress result is ok, continue with step 8. If not, back to step 5.
8. Do a weld with Spot No. 121 for gun 1, 122 for gun 2 ….
9. Message: Check short circuit resistance in the weld timer software.
10. Do an other weld with Spot No. 121 for gun 1, 121 for gun 2 ….
11. Message: Check short circuit resistance in the weld timer software.
12. Repeat step 9 and 10 until the short circuit resistance stays stable (± 1µOhm). The values for the
adjustment are stored at the weld timer automatically after each weld.
13. Message: Gun resistance adjustment ready.
14. Move robot to home position

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SPATZ+ Special Robot Routines
2.3 Robot routine for short circuit weld after tip dressing
2.3.1 Robot routine for short circuit weld after First Tip Dress
This routine has to be executed after every tip change. The SPATZ+ weld timer service programs 141-
145 for gun1 to gun 5 are used. This service programs are predefined weld programs with squeeze time,
current time (KSR) and hold time. Short circuit resistance or trigger angle monitoring with limit supervi-
sion is activated to check the result of the tip dress.
The robot routine should have the following steps:
1. Execute First Tip Dress routine
2. Do a weld with Spot No. 141 for gun 1, 142 for gun 2 ….
3. If tip dress result is ok (short circuit resistance within the preprogrammed limits), there will be no er-
ror message of the weld timer. Continue to step 4.
If the tip dress result is not ok, there will be an error message of the weld timer.
Message: Check tip dress result. Have a look to both cap surfaces.
Go back to step 1.
4. Move robot to home position

2.3.2 Robot routine for short circuit weld after Tip Dress
This routine has to be executed after every tip dress. The SPATZ+ weld timer service programs 151-155
for gun1 to gun 5 are used. This service programs are predefined weld programs with squeeze time, cur-
rent time (KSR) and hold time. Short circuit resistance or trigger angle monitoring with limit supervision is
activated to check the result of the tip dress.
The robot routine should have the following steps:
1. Execute Tip Dress routine
2. Do a weld with Spot No. 151 for gun 1, 152 for gun 2 ….
3. If tip dress result is ok, there will be no error message of the weld timer. Continue to next step.
If the tip dress result is not ok, there will be an error message of the weld timer.
Message: Check tip dress result. Have a look to both cap surfaces.
Go back to step 1.
4. Move robot to home position

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