ABB SmarTac, Applications Manual

Page 1: ...Application manual SmarTac ...

Page 2: ...Trace back information Workspace R16 1 version a11 Checked in 2016 03 29 Skribenta version 4 6 284 ...

Page 3: ...Application manual SmarTac Document ID 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved ...

Page 4: ...r property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Additional copies of this manual may be obtained from ABB The original language for this publication is English Any ...

Page 5: ...4 1 Safety 34 4 2 Introduction 35 4 3 Exercise 1 program displacement 41 4 4 Exercise 2 using SmarTac to modify a displacement frame 41 4 4 1 Introduction 42 4 4 2 Exercise 2 one dimensional search 48 4 4 3 Programming tips 49 4 5 Exercise 3 using SmarTac for multi dimensional searching 49 4 5 1 Introduction 50 4 5 2 Exercise 3 two dimensional search 56 4 6 Exercise 4 using SmarTac to determine si...

Page 6: ... 81 6 RAPID reference 81 6 1 Instructions 81 6 1 1 Search_1D One dimensional search 88 6 1 2 Search_Groove Find groove width and location 95 6 1 3 Search_Part Search for feature presence 98 6 1 4 PDispAdd Add program displacements 99 6 2 Functions 99 6 2 1 PoseAdd Adds the translation portions of pose data 100 6 2 2 OFrameChange Create a new shifted object frame 102 6 3 The module OFrame 105 Index...

Page 7: ...r should be familiar with industrial robots and their terminology be familiar with the RAPID programming language be familiar with system parameters and how to configure them Reference documents Document ID References 3HAC050947 001 Technical reference manual RAPID overview 3HAC050917 001 Technical reference manual RAPID Instructions Functions and Data types 3HAC027097 001 Operating manual Getting...

Page 8: ...ration Decommissioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with exploded views or references to separate spare parts lists Circuit diagrams or references to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products Technical reference manual Lubrication in gearbo...

Page 9: ...ng manuals The operating manuals describe hands on handling of the products The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and trouble shooters The group of manuals includes among others Operating manual Emergency safety information Operating manual General safety information Operating manual Getting started IRC5 ...

Page 10: ...ools or special power supply units for the machining process The external voltage connected to the controller remains live even when the robot is disconnected from the mains Additional connections Therefore it is important that all safety regulations are followed when doing mechanical and electrical installation work Safety regulations Before beginning mechanical and or electrical installations en...

Page 11: ...he SmarTac board is supplied as an add on unit and installed in the robot cabinet RAPID system module A RAPID system module SmarTac sys provided by ABB supports powerful programming tools explained in User s guide on page 33 Searching with SmarTac SmarTac searching can be added to programs while programming a part or it can be added to a pre existing weld routine Application manual SmarTac 11 3HAC...

Page 12: ...potential an input is set in the robot controller When the input is detected robot location is stored and motion stops Search instructions The search instructions included in the SmarTac software are designed to return offset information In other words the result of a search is the distance between where the original search location was programmed and where the robot has now found the part Why use...

Page 13: ... that is loaded into all arc welding motion tasks when the option is purchased Process configuration parameters are used to connect real I O signals and to modify the default settings Compatibility Programs with SmarTac searches written with versions of SmarTac prior to revision 6 0 are not compatible with SmarTac 6 0 and higher Application manual SmarTac 13 3HAC024845 001 Revision A Copyright 200...

Page 14: ...e programmers that have attended an advanced programming class offered by ABB unless the programmer has a solid mathematical background Robot system operator For the robotic system operator the addition of searches is largely transparent and requires no further training 14 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 1 Introduction 1 3 2 User s q...

Page 15: ...tatic discharge ESD protection in order not to damage them Use the wrist strap located on the inside of the controller door WARNING All personnel working with the robot system must be very familiar with the safety regulations see Safety on page 33 Incorrect operation can damage the robot or injure someone Application manual SmarTac 15 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights re...

Page 16: ...e The SmarTac option can be purchased as stand alone without any hardware Required tools The following tools are required to install the SmarTac option Terminal block screwdriver Multi meter Wire cutters Wire strippers Installation See the documentation for your sensor for the correct hardware setup and diagnostics 16 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All...

Page 17: ...module Consequently it is compatible with any RAPID program assuming the I O configuration is non conflicting and no previous version of SmarTac is loaded Compatibility Programs with SmarTac searches that are written with versions of SmarTac prior to revision 6 0 are not compatible with SmarTac 6 0 and higher Application manual SmarTac 17 3HAC024845 001 Revision A Copyright 2004 2016 ABB All right...

Page 18: ...default references to SmarTac speed and signal configuration groupings included in the procSmarTacSig_X cfg and procSmarTacSpd cfg files for up to 4 motion tasks where the X represents task numbers 1 4 Override defaults The user may override the defaults by replacing the entries with new entries Below is the default file loaded by SmarTac PROC CFG_1 0 5 0 Smartac procSmarTacSet_1 cfg file created ...

Page 19: ...ample override Smartac proc cfg file created 2005 09 22 SMARTAC_SETTINGS name T_ROB1 uses_signals smtsigwire1 uses_speeds smtspeedstd Change default I O names To change the default I O names the user should supply a new I O settings by creating new assignments PROC CFG_1 0 5 0 Example override Smartac proc cfg file for new signal names created 2005 09 24 SMARTAC_SETTINGS Structure created by SmarT...

Page 20: ... with Fronius TouchSense Below is an example of a configuration that could be used to set up a SmarTac system with Fronius TouchSense In this case only the software package for SmarTac is used no SmarTac hardware should be used instead the touch sensing capability of the Fronius welder is used EIO CFG_1 0 5 0 EIO_SIGNAL Name doFr1SensorRef SignalType DO Unit ioFroniusSim1 UnitMap 4 Name diFr1PartD...

Page 21: ...SAB retailer on how to use the gas nozzle as sensor EIO CFG_1 0 5 0 EIO_SIGNAL Name doTouchSenseActive SignalType DO Unit B_AW_PROC_40 UnitMap 15 Name diTouchSenseContact SignalType DI Unit B_AW_PROC_40 UnitMap 50 PROC CFG_1 0 5 0 Example using ESAB AristoMig touch sense for wire or gas sensing nozzle SMARTAC_SIGNALS name smtsig1 detect_input diTouchSenseContact reference_set_output wire_select_ou...

Page 22: ...oftware The software is loaded automatically when the option SmarTac is purchased for RobotWare 22 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 2 Installation 2 3 3 Loading software ...

Page 23: ...eferenced to the fixture ground If less than 25 VDC is measured see Trouble shooting on page 75 4 Ground the gas cup to the weld fixture using a length of wire steel tool or similarly conductive object Verify that diSE_DET1 is on at this time If it is not see Trouble shooting on page 75 5 Write a simple test routine using the Search_1D instruction see User s guide on page 33 6 If the Search_1D ins...

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Page 25: ...for example containing salt solution will act as a load that will reduce the sensitivity and or reduce the sensing voltage below SmarTac working range Distilled water or a non conductive coolant such as ethylene glycol is recommended as gun coolant solution Tap water is unacceptable A positive lead break box secondary contact is required to isolate the power source when SmarTac sensing is taking p...

Page 26: ...his option may be purchased though ABB The use of searches ranges from very simplistic to very complex In some instances very complex searching techniques must be used to adequately determine weld seam locations In such instances assistance from an experienced ABB technician may be required 26 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 3 Applic...

Page 27: ...terminal Gas nozzle probe Work surface coating Electrically conducting cooling water or other low impedance bridges in the welding gun for example deposits from the welding process Open circuit impedance between the weld power source terminals xx1400001476 Convection cooled welding gun SmarTac used with a convection cooled air cooled welding gun will loose some sensitivity due to losses through th...

Page 28: ...n reduce the sensing voltage below SmarTac working range In Electric equivalent diagram on page 27 this loss is represented by resistor 1 Non conductive liquid such as ethylene glycol or distilled water is recommended as gun coolant Tap water is unacceptable 28 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 3 Application guide 3 3 1 Interaction wit...

Page 29: ... This function reduces the effect of weld equipment impedance It involves the use of a memory feature that latches SmarTac s reference at the time of searching The memory feature is controlled by an output from the robot Application manual SmarTac 29 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 3 Application guide 3 3 2 Detection reference ...

Page 30: ...am shows SmarTac s working range which is the area to the right of the vertical dashed line in the diagram This line is equivalent to a load of 1 5 k ohm Sensitivity Object contact resistance in ohms On the Y axis Equipment load on the measurement circuit in ohms On the X axis xx1400001477 30 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 3 Applica...

Page 31: ... the load from the welding equipment increases The higher the sensing voltage the more accurate the search will be Typical voltage A typical voltage seen on a real system is about 37 VDC Application manual SmarTac 31 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 3 Application guide 3 3 4 Sensing voltage ...

Page 32: ...E_SENSORX Output used to set the sensing reference voltage doSE_REFX Output used to switch the search detection signal between channel 11 and 12 Channel 11 is connected to the gas cup and channel 12 to the wire The signal will be defined as a simulated signal if optional wire searching hardware has not been installed doWIRE_SELX xx1400001478 Figure 3 1 I O time line 32 Application manual SmarTac 3...

Page 33: ...uld always be closed when the control cabinet is turned on Only qualified technicians should ever attempt trouble shooting The SmarTac sensing voltage applied at the torch when searching is supplied by a 38 VDC low current source This sensing current is harmless CAUTION All users must read the safety instructions in the product manual for the controller and the robot before operating the robotic s...

Page 34: ...s increase cycle time and programming complexity In this manual the simplest cases will be handled first In many cases these techniques will be enough In some situations where the part fit up and or fixture is poor you will need to understand all the tricks described in the manual 2 What is a frame A good understanding of work objects and displacement frames is the key to successful programming wi...

Page 35: ...n add in these instructions into one of your Most Common pick lists PDispAdd PDispOff PDispSet Search_1D Search_Groove Search_Part Tape a piece of paper to a table or similar surface within the robot s reach On the paper draw a rectangle 4 View the modules select the new module ST_TEST and select the new routine disp_ex1 5 Jog the robot so that the torch is pointing at the rectangle on the paper T...

Page 36: ...400001481 Jog the robot down to the rectangle so that the tip is just above one of the rectangle corners 8 Create a MoveL at this position using tWeldGun and no work object selected Do the same for the rest of the corners returning to the first corner so that you have a short program that traces out the rectangle xx1400001482 9 Insert the instruction PDispOff 10 Continues on next page 36 Applicati...

Page 37: ...e movement path Each of the robtargets in the MoveL instructions is related to the world frame In this case however the work object has not been specified so wobj0 is used by default This work object is the same as the world frame xx1400001484 Continues on next page Application manual SmarTac 37 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 4 User s guide 4 3 Exercise 1 pro...

Page 38: ...t has two frames the user frame uframe and the object frame oframe Also note that the values are all zero for the locations and ones and zeros for the orientations That is why the work object has no affect on our program It is the same as the World frame xx1400001486 Tap Cancel to close the work object window Then select View Data Types 15 Select pose data types 16 Continues on next page 38 Applic...

Page 39: ...frame And as discussed earlier the object frame and user frame in wobj0 are the same as the world frame So the rectangle moved 15 mm relative to the world as well This is what program displacement frames do A change in the displacement frame changes the location of the robtargets Displacement frames can be turned on and off using PDispSet and PDispOff Similarly changes in the work object will move...

Page 40: ...ors could occur Quaternions must be normalized so it is not possible to choose numbers randomly Advanced Look at the robtarget data using the same technique for looking at pose data Note that the robtarget data does not change when the rectangle is moved using the displacement frame 40 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 4 User s guide 4...

Page 41: ... is a one dimensional search A one dimensional search finds an offset in one direction What is Search_1D Search_1D is an instruction that is included in the SmarTac system module Of the three search instructions included in the module this is the most common It is useful in a variety of situations and will be present in most of the exercises and examples from this point on The instruction Search_1...

Page 42: ...EST 1 Select disp_ex1 and open the File menu 2 Select Create Copy xx1400001492 Change the default routine name disp_ex1Copy to disp_ex2 then look at the in structions in the new routine xx1400001493 3 Remove the paper with the rectangle drawn on it 4 Continues on next page 42 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 4 User s guide 4 4 2 Exerc...

Page 43: ...ggle the Program Window to instruction mode If you have a Most Common pick list with SmarTac instructions select it 10 Move the cursor to the first line MoveJ Using the Copy and Paste buttons copy the MoveJ and paste the copy below 11 We will add more movements and a search instruction between the two MoveJ in structions The search will collect information about the location of the plate and store...

Page 44: ...ch_1D peEX1 v200 tWeldGun 13 The routine should look like this xx1400001497 Jog the robot to the SearchPoint and modify the position of the second robtarget in the Search_1D instruction The gas cup should make contact with the plate without deflecting the torch 14 Continues on next page 44 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 4 User s gui...

Page 45: ...e program pointer to the Search_1D instruction 16 Press the enabling device and press the forward button The robot should move to the StartPoint then search towards the SearchPoint until the plate is detected 17 Continues on next page Application manual SmarTac 45 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 4 User s guide 4 4 2 Exercise 2 one dimensional search Continued ...

Page 46: ... plate and then trace out the plate 19 Move the plate about 10 mm away from the SearchPoint and try running the routine see Exercise 2 displacement on page 46 20 If the plate was moved in the direction of the search without any rotation the torch should still trace out the plate correctly xx1400001500 Figure 4 1 Exercise 2 displacement Questions 1 Look at the data in peEX1 How does it change after...

Page 47: ...th the error recovery options to see what they do See Instructions on page 81 for details on error handing Application manual SmarTac 47 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 4 User s guide 4 4 2 Exercise 2 one dimensional search Continued ...

Page 48: ... at an angle to the feature surface 3 For a newly programmed search try executing the search using the forward button When the robot stops motion with the torch touching the part move the cursor to the SearchPoint and modify the position of the robtarget This ensures that a search on a perfect part will return a displacement that is very close to zero 48 Application manual SmarTac 3HAC024845 001 R...

Page 49: ... surface was Limitations for single and multi dimensional searching In example 2 you may have noticed that if the plate was rotated when moved the displacement frame would not compensate for the rotation This is the limitation of single and multi dimensional searching These search techniques are relatively easy to master and despite the limitation provide accurate search information about the weld...

Page 50: ...plate then move the program pointer to this MoveL 7 Press the enabling device and press the step forward button once Align the plate to the torch tip Step though the rest of the points to get the plate back to where it was when we first wrote the routine 8 Move the cursor to the top of the routine Press the enabling device and step forward until the search is complete and the robot stops at the Mo...

Page 51: ...fine tWeldGun MoveL v200 fine tWeldGun MoveL v200 fine tWeldGun MoveL v200 fine tWeldGun PDispOff MoveL v200 fine tWeldGun ENDPROC Modify the robtargets in the new Search_1D to search the end of the plate The new search will be referred to as search 2 xx1400001501 14 Highlight the second Search_1D instruction and tap Enter 15 Tap OptArg to look at the optional arguments 16 Continues on next page A...

Page 52: ...se xx1400001502 17 Tap OK 18 Select the new argument to open the new window xx1400001503 19 Continues on next page 52 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 4 User s guide 4 5 2 Exercise 3 two dimensional search Continued ...

Page 53: ...in any direction and re execute the routine The torch should trace out the plate 22 Questions 1 Why is it necessary that the PrePDisp is set to peEX1 in this example What happens when a different displacement frame other than peEX1 is used in the first Search_1D 2 What happens when this optional argument in the second Search_1D is not present 3 Two and three dimensional searches should almost alwa...

Page 54: ...isp_ex3_3D MoveJ v200 fine tWeldGun MoveL v200 fine tWeldGun Search_1D peEX1 v200 tWeldGun MoveL v200 fine tWeldGun MoveL v200 fine tWeldGun Search_1D peEX1 v200 tWeldGun PrePDisp peEX1 MoveL v200 fine tWeldGun MoveL v200 fine tWeldGun MoveL v200 fine tWeldGun Search_1D peEX1 v200 tWeldGun PrePDisp peEX1 MoveL v200 fine tWeldGun MoveJ v200 fine tWeldGun PDispSet peEX1 MoveL v200 fine tWeldGun Move...

Page 55: ...ion xx1400001504 6 In Example 1 what happens if you search the same edge twice using PrePDisp to add the second search result to the first Application manual SmarTac 55 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 4 User s guide 4 5 2 Exercise 3 two dimensional search Continued ...

Page 56: ...ranslation and rotation Imagine that the robtargets P2 and P3 in the illustration describe the ArcL On and ArcL Off of a weld If each robtarget is represented by a different program displacement then the weld seam can be moved rotational as well xx1400001506 To do this for a real weld seam the robtargets P2 and P3 will have to be searched separately and the displacement data stored in two differen...

Page 57: ...n PrePDisp peEX1 MoveL v200 fine tWeldGun MoveL v200 fine tWeldGun PDispSet peEX2 Corner 1 MoveL P1 v200 fine tWeldGun PDispSet peEX3 Corner 2 MoveL P2 v20 fine tWeldGun PDispOff MoveL v200 fine tWeldGun ENDPROC Three displacement frames will be used peEX1 peEX2 and peEX3 You will need to create these if they do not exist in the system Be careful that the correct pre dis placement is called for ea...

Page 58: ...ute the routine each time Does the robot torch follow edge each time 6 If it does not there check the program again to be sure all the correct displacement frames are in the right places Questions 1 How is the usage of PrePDisp different from that in Exercise 3 two dimensional search on page 50 2 Look at the values in each of the program displacements peEX1 peEX2 and peEX3 What are the values for ...

Page 59: ...determine how the whole part has moved in translation and rotation The best way to do this is to use a work object to describe where the part is in relation to the world frame Based on search information the object frame of a work object can be moved in translation and rotation If the weld sequence in written in this work object the points in the sequence will move with changes to the work object ...

Page 60: ...ement frame relative to that work object The SmarTac module contains two mathematical functions that can be used in conjunction with the Search_1D instruction to make this searching technique easier 60 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 4 User s guide 4 7 1 Introduction Continued ...

Page 61: ...of two or three displacement frames The function returns pose data In use it looks like this peSUM PoseAdd peFIRST peSECOND Using PoseAdd is similar to using the optional argument PrePDisp in Search_1D OFrameChange OFrameChange uses seven arguments a reference work object three reference points and three displacement frames The function returns wobjdata In use it looks like this obNEW OFrameChange...

Page 62: ...rcise 4 There will be four searches for this technique so the plate will have to be clamped so that most of the plate is off the table xx1400001510 Continues on next page 62 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 4 User s guide 4 7 3 Exercise 5 object frame manipulation ...

Page 63: ...rogram module OFrame Tip The module is included on the disk included in the delivery It is also shown in The module OFrame on page 102 1 Continues on next page Application manual SmarTac 63 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 4 User s guide 4 7 3 Exercise 5 object frame manipulation Continued ...

Page 64: ...cements are active 5 Jog the robot so that the torch is situated about 150 mm above the plate surface and pointing down at the plate 6 Move the cursor to the first MoveJ and modify the position You may have to change your settings in the Jog Window to reflect the work object change xx1400001513 7 Jog the robot so that the torch TCP is just touching the p1 mark and modify the second MoveL MoveL p1 ...

Page 65: ...Remember that the search direction should be perpendicular to the edge of the part 15 Modify all the rest of the moves and searches as shown in Reference sketch on page 63 16 Test run the SearchSample procedure 17 Move the program pointer to the routine called WeldSample WeldSample does not have any ArcL instructions so RobotWare Arc does not need to be present to load this module It has only Move...

Page 66: ...s the combination of what two searches 6 pe3 is the combination of what two searches 7 For the best accuracy there should be two searches for each reference point located close to each reference point In this exercise we use only four searches to approximate this How far do you have to rotate the plate before you notice the inaccuracy 8 Why does this occur 9 Would this be a concern for most real w...

Page 67: ...this Search_Part bPresent p1 p2 v200 tWeldGun The robot moves on a path from p1 through p2 If contact is made with the part feature the Boolean bPresent is set to TRUE If no contact is made it is set to FALSE See Search_Part Search for feature presence on page 95 Example In this example a weld procedure is selected based on the presence of a particular part feature PROC Which_Part MoveJ v200 z10 t...

Page 68: ... that you can take the plate away later 2 Run the routine to be sure it works OK 3 Questions 1 With the plate in place what is the value of the Boolean after searching 2 With the plate removed what is the value of the Boolean after searching Advanced 1 What happens when you move the plate so that it is touching the gas cup at the start of the search 68 Application manual SmarTac 3HAC024845 001 Rev...

Page 69: ...stalled this is possible The SmarTac instructions are designed to handle this Search_1D and Search_Part each have an optional argument Wire that will switch the signal to the wire if selected The instruction Search_Groove assumes that wire searching capabilities are present Application manual SmarTac 69 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 4 User s guide 4 9 1 Intr...

Page 70: ...t the wire will touch the part instead of the gas cup 2 Questions 1 Did the system work correctly 2 What problems could arise from searching with the side of the wire 3 What problems could arise when searching with the tip of the wire in the direction of the wire See the following figure xx1400001516 70 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserve...

Page 71: ...y this need Note See Search_Groove Find groove width and location on page 88 Requirements for Search_Groove Search_Groove performs a series of searches when executed It requires two robtargets One is programmed outside the groove and the other in the center of the groove It requires a displacement frame that will be returned as the seam offset It requires a number that will be returned as the actu...

Page 72: ...m nominal width The program displacement is stored in peOffset The actual width of the groove is stored in nWidth The StartPoint is p1 and the CentrePoint is p2 The Initial Start Point is 15 mm above the StartPoint by default Searching for groove width and groove location xx1400001520 72 Application manual SmarTac 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 4 User s guide...

Page 73: ... first robtarget StartPoint be programmed 2 Where should the second robtarget CentrePoint be programmed 3 What effect does changing the nominal groove width NomWidth have on the search pattern 4 What effect does it have on the results displacement actual width 5 Which moves are effected by changes in the speeddata Advanced Action Add the optional arguments InitSchL and NomDepth 1 Set the InitSchL ...

Page 74: ...uctions on page 81 There is also an instruction called PDispAdd which is used with the same effect as the function PoseAdd Work objects Work objects are described in Operating manual IRC5 with FlexPendant Especially for users with coordinated work objects on positioning equipment a firm understanding of work object user and object frames is critical to writing good weld routines 74 Application man...

Page 75: ...nt see the product manual for the controller 3 If power is supplied to the board check that terminals 4 and 7 are at 0VDC If these are not set low set doSE_REF and doSE_SENSOR to zero Check that terminals 4 and 7 are at 0VDC If they are not at zero check that the physical outputs set doSE_REF and doSE_SENSOR are at zero at the I O board If it is not check the system parameters If ok check the Smar...

Page 76: ...tion Electrical Reference in the SmarTac hardware manual Also check the system parameters If nothing can be found wrong with the wiring or the system parameters replace the SmarTac board 3 Turn on doSE_REF When the part is not in contact with the torch sensing surface the following green LEDs on the SmarTac board should indicate the following D22 Search Refon D23 Search Sensor Validon If not check...

Page 77: ...ould be open when doSE_SENSOR is turned on If the output to switch the contactor is working correctly but the contactor is not working repair or replace the secondary contactor or positive lead break box If the output to the contactor is not present inspect the SmarTac wiring per the prints in section Electrical Reference in the SmarTac hardware manual 3 Check the continuity of the torch between t...

Page 78: ...nt A reading lower than 25 VDC indicates that there is a significant loss that will make search results inaccurate see Inaccurate results on page 79 If no voltage is present check that the SmarTac board is activating properly see SmarTac board activation error on page 76 If the board is activating correctly check the wiring from the torch to the SmarTac board Also check that the ground leads on th...

Page 79: ...sing surface and the part Ideally there should be about 38 VDC present A reading lower than 25 VDC indicates that there is a significant loss that will make search results inaccurate Low voltage can result from contaminated coolant defective torches and grounded welding wire See False positive torch contact on page 77 for more details 3 The TCP is moving Check to see that the torch is securely mou...

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Page 81: ...f Data type switch If selected the welding positive lead secondary contact break box remains open at the end of the search Additionally the SmarTac board remains activated after the search ends If this switch is selected directly before a welding instruction welding current will not reach the torch Wire Data type switch If selected the output doWIRE_SEL will be set high when the SmarTac activation...

Page 82: ...l be flagged if the magnitude of the search result Result is larger than the value entered for the Limit in mm SearchName Data type string If selected the search will be assigned this identifying name The name will accompany any error messages that are written to the event log TLoad Data type loaddata The TLoad argument describes the total load used in the movement The total load is the tool load ...

Page 83: ...is used for searching however on some systems the wire can be used for searching When the switch Wire is selected the digital output doWIRE_SEL is set high This switches the SmarTac signal from the gas cup to the wire xx1400001490 The StartPoint and SearchPoint are programmed The two points determine the direction of the search The SearchPoint is programmed so the torch is touching the part featur...

Page 84: ...ouching the part feature at the beginning of a normal search When RETURN is selected a default search result is used which will include any preoffset included in the search instruction A message will be logged in the event log Fault 2 If an error occurs during the search process a menu will appear with the following prompts Search failed Tries to search again with start point moved 50 RETRY Contin...

Page 85: ... 5 013 Offset 13 34 The magnitude of the offset 10 The preset limit Continue with program execution OK Sends the error to calling routine RAISE When OK is selected the search result is accepted regardless of magnitude A message will be logged in the event log More examples Single dimension search in any direction MoveJ vmax fine tWeldGun Search_1D peOffset p1 p2 v200 tWeldGun PDispSet peOffset Arc...

Page 86: ...h the gas cup If an error occurs while searching and the operator elects to continue with default results the name First will appear along with the error description in the event log See Error handling on page 84 Search_1D pose1 p1 p2 v200 tWeldGun SearchName First Syntax Search_1D NotOff Wire Result expression INOUT of pose SearchStop expression INOUT of robtarget StartPoint expression IN of robt...

Page 87: ...ta types Data type robtarget Technical reference manual RAPID Instructions Functions and Data types MoveL Technical reference manual RAPID Instructions Functions and Data types Definition of loaddata Application manual SmarTac 87 3HAC024845 001 Revision A Copyright 2004 2016 ABB All rights reserved 6 RAPID reference 6 1 1 Search_1D One dimensional search Continued ...

Page 88: ...marTac board activation and deactivation is automatically handled Basic examples xx1400001522 xx1400001521 Search_Groove peOffset nWidth p1 p2 10 v200 tWeldGun The groove search is used to find the location and width of the groove to be welded The groove has a 10 mm nominal width The program displacement is stored in peOffset The actual width of the groove is stored in nWidth The StartPoint is p1 ...

Page 89: ...ype robtarget The start point of the search sequence This point should be programmed outside the groove touching the part surface with the wire s tip See the initial start point in Basic examples on page 88 CentrePoint Data type robtarget The point where the groove should be This robtarget should be programmed so that the wire s tip is above the center of the groove level with the adjacent part su...

Page 90: ...ement The total load is the tool load together with the payload that the tool is carrying If the TLoad argument is used then the loaddata in the current tooldata is not considered If the TLoad argument is set to load0 then the TLoad argument is not considered and the loaddata in the current tooldata is used instead For a complete description of the TLoad argument see MoveL in Technical reference m...

Page 91: ...instruction welding current will not reach the torch and an Arc Ignition Error will occur Error handling Menu message Fault Activation of the SmarTac failed Fault 1 Search failed Fault 2 GasCup or Wire touching part Fault 3 Groove not found Fault 4 Groove search failed Fault 5 Fault 1 If an error occurs when activating the SmarTac board a menu will appear with the following prompts Activation of t...

Page 92: ...h default search result RETURN Sends error to calling routine RAISE When RETRY is selected the start point of the search is shifted farther from the part feature This may give a good search result in cases where the part feature is unusually close and the torch is touching the part feature at the beginning of a normal search When RETURN is selected a default search result is used which will includ...

Page 93: ...apt fine tWeldGun ArcL Off vmax sm1 wd1 wvAdapt fine tWeldGun PDispOff Groove search with optional returned robtarget The robtarget p3 is updated with the actual groove centerline Search_Groove SearchStop p3 pose1 nWidth p1 p2 10 v200 tWeldGun Groove search that is named If an error occurs while searching and the operator elects to continue with default results the name First will appear along wit...

Page 94: ...sional search on page 81 Search_1D Search_Part Search for feature presence on page 95 Search_Part Technical reference manual RAPID Instructions Functions and Data types Data type pose Technical reference manual RAPID Instructions Functions and Data types Data type wobjdata Technical reference manual RAPID Instructions Functions and Data types Data type robtarget 94 Application manual SmarTac 3HAC0...

Page 95: ...arch Additionally the SmarTac board remains activated after the search ends If this switch is selected directly before a welding instruction welding current will not reach the torch Wire Data type switch If selected the output doWIRE_SEL will be set high when the SmarTac activation occurs The SmarTac sensor will be switched from the gas cup to the wire when selected bDetect Data type bool The Bool...

Page 96: ...selected in Speed The SmarTac board is activated and motion starts towards the SearchPoint The robot will continue past the search point for a total search distance described by twice the distance between StartPoint and SearchPoint If a feature is detected the required Boolean is set to TRUE otherwise it is set to FALSE In either case program execution continues Limitations If the switch NotOff is...

Page 97: ...art2 p3 p4 v200 tWeldGun WObj obPart Syntax Search_Part NotOff Wire bDetect expression INOUT of bool StartPoint expression IN of robtarget SearchPoint expression IN of robtarget Speed expression IN of speeddata Tool persistent PERS of tooldata WObj persistent PERS of wobjdata TLoad persistent PERS of loaddata Related information Described in Search_1D One dimensional search on page 81 Search_1D Te...

Page 98: ...ution When executed Result is added to the current displacement frame and the new program displacement frame is activated Syntax PDispAdd Result expression IN of pose Related information Described in Search_1D One dimensional search on page 81 Search_1D PoseAdd Adds the translation portions of pose data on page 99 PoseAdd Technical reference manual RAPID Instructions Functions and Data types Data ...

Page 99: ...e Data type pose The displacement frame Arguments PoseAdd Pose1 Pose2 Pose3 Pose1 Data type pose Pose data to be added Pose2 Data type pose Pose data to be added Pose3 Data type pose Pose data to be added Syntax PoseAdd Pose1 expression IN of pose Pose2 expression IN of pose Pose3 expression IN of pose Related information Described in PDispAdd Add program displacements on page 98 PDispAdd Technica...

Page 100: ...object frame of the reference work object obREF The new work object obNEW has this new object frame and the original user frame information from obREF Return value Data type wobjdata The new work object Arguments OFrameChange WObj RefP1 RefP2 RefP3 DispP1 DispP2 DispP3 WObj Data type robtarget Reference work object RefP1 Data type robtarget Reference point number one Defined in WObj RefP2 Data typ...

Page 101: ...expression IN of wobjdata RefP1 expression IN of robtarget RefP2 expression IN of robtarget RefP3 expression IN of robtarget DispP1 expression IN of pose DispP2 expression IN of pose DispP3 expression IN of pose Related information Described in PDispAdd Add program displacements on page 98 PDispAdd PoseAdd Adds the translation portions of pose data on page 99 PoseAdd Technical reference manual RAP...

Page 102: ...PERS pose pe2a 0 0 0 1 0 0 0 PERS pose pe3a 0 0 0 1 0 0 0 PERS pose pe1 0 0 0 1 0 0 0 PERS pose pe2 0 0 0 1 0 0 0 PERS pose pe3 0 0 0 1 0 0 0 PROC NewPoints PDispOff MoveJ RelTool p1 0 0 100 v200 fine tWeldGun WObj obREF MoveL RelTool p1 0 0 50 v200 fine tWeldGun WObj obNEW MoveL p1 v200 fine tWeldGun WObj obNEW Stop MoveL RelTool p2 0 0 50 v200 fine tWeldGun WObj obNEW MoveL p2 v200 fine tWeldGun...

Page 103: ...0 fine tWeldGun WObj obREF pe1 PoseAdd pe1a pe1b pe2 PoseAdd pe1a pe2a pe3 PoseAdd pe1b pe3a obNEW OFrameChange obREF p1 p2 p3 pe1 pe2 pe3 ENDPROC PROC RefPoints PDispOff MoveJ v200 fine tWeldGun WObj obREF MoveL RelTool p1 0 0 50 v200 fine tWeldGun WObj obREF MoveL p1 v200 fine tWeldGun WObj obREF Stop MoveL RelTool p2 0 0 50 v200 fine tWeldGun WObj obREF MoveL p2 v200 fine tWeldGun WObj obREF St...

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Page 105: ...isites operator 14 prerequisites programmer 14 prerequisites system 13 procSmarTacSet_X cfg 18 procSmarTacSig_X cfg 18 procSmarTacSpd cfg 18 S safety 10 Search_1D 81 Search_Groove 88 Search_Part 95 searching with welding wire 26 sensing circuitry 29 sensing voltage 31 sensitivity 27 SmarTac sys 34 software loading 22 start up test 23 system module 34 V voltage typical 31 W water cooled gun 28 Appl...

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Page 108: ... 344 400 ABB AS Robotics Discrete Automation and Motion Nordlysvegen 7 N 4340 BRYNE Norway Box 265 N 4349 BRYNE Norway Telephone 47 51489000 ABB Engineering Shanghai Ltd No 4528 Kangxin Hingway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 www abb com robotics 3HAC024845 001 Rev A en ...