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Handzhoufordprojectusermanual1/39OverviewofthismanualAboutthismanualThismanualcontainsinformationaboutfordHandzhoukawasakirobotsoftware.UsageThismanualdescribebaseapplicationsoftwarewhichhandleplcbasicIOcommunication(job,fault,interlock,HMI..).Thismanualalsodescribealltheroutinesusedforsealing,welding,handling,studwelding,fastwelding,brushing.WhoshouldreadthismanualThismanualisintendedfor:•Personnelinchargeofrobotprogramming•Personnelinchargeofinstallation•Personnelinchargeofcommissioning•PersonnelinchargeofmaintenanceUserqualificationAnoperatoronlyrequiresminimalinformationandinstructionforoperatingtheinstallationinordertobeabletoworkwithkawasakirobot.Aprogrammershouldbefamiliarwithkawasakiprogrammingandbesufficientlytrainedforthekawasakirobotprocedure.Inparticularheshouldbefamiliarwiththefollowingitems:•KawasakirobotprogramminglanguageAS•KawasakiblocteachinglanguageWhatisbaseapplicationDescriptionHandzhoufordprojectusermanual2/39Baseapplicationisasoftwaremodulethatispresentoneveryrobotswhichhandlesplccommunication,HMIandwhichgiveservicetootherapplication.Baseapplicationhandles:•robotprogramsafety(robotpositionatstart-up,robotstoponholdrequestfromplc..)•Jobs:inconjunctionwithplcbaseapplicationstarttherequestedjobnumber•Workauthorisation:inconjunctionwithplcworkauthorisationarehandled•Interlocks:PLCmanageinterlocksandthecaseeffectivegivearobotaprivilegeaccess.•Errorandalarmreporting:BaseapplicationreportserrorandalarmtoPLCforacentralisedviewing.•AdedicatedHumanMachineInterfaceisdisplayedontherobotteachpendanttohelpusersincaseoftroubleshooting.ThisHMIallowsinsomespecialcaseusertomakesomeconfiguration(e.g:gripper)TermsandconceptsUsageHandzhoufordprojectusermanual3/39BASERobotstart-upJobsWorkauthorisationInterlocksFaultsAlarmsAlarms,errorsHMIInformationsconfigurationPLCTEACHPENDANTInterfacetoprocessE.gsealing,Welding..FunctionsSafetyThischaptercontainsinformationrelativetopathorganisationandcontrolsusercanachieve.Productiontasksareachievethroughpathchosenbyaremotecontroller.Theremotecontroller(egPLC)sendinformation(IO)throughanindustrialnetwork(Profinet)therobotgetthisinformationsandselectthepath.Communicationlengthis128bits.Eachbithasasignificationandthesebitsarethesameoneveryrobotontheline(standarddefinitionofIOexchangeforPLC).Wedefineacycleasaprogramnumber(egacartype),duringthecycleprogramexecutioncanbesynchronisedwithPLC,suchawayofprogrammingavoidcollisionandallowPLCtotrackrobotjobonsomespecificpositions.Handzhoufordprojectusermanual4/39SpecificpositionsHOMEUsuallyacyclestartsfromaspecificposition(HOMEposition)andfinishatthesameposition.HOMEpositionisaglobalanduniqueposition,therobotinternalsoftwarechecksifeachaxispositionareinarangeof2degreesandsetthecaseoftheoutputrobotinHOME.AnewcycleisonlytakeninaccountiftherobotisatHOMEposition.Forrobotsafetyatprogramstart-upthispositionischeckedandiftherobotisanyelsewheretheuserisinvitedtodrivetherobotbyhandtohome.Kawasakiuserprogram.PROGRAMpg10()#230HOME;neededasstandardcommandCALLhometopeo10;mustprovideahometopounceprogramCALLpeojob(10);mustcallpeojobwithpgnumberIFzendcyclereqGOTOendcycle;neededbyapplication;synchronisationprimitiveCALLwaitforsegment(16,"SpotCarChb10GEO","¹Ì¶¨º¸½Ó")CALLspotchb10geo;workprogramCALLendsegment(16);synchronisationprimitiveHOME;neededasstandardcommandendcycle:;neededendofcyclemanagement.ENDHandzhoufordprojectusermanual5/39PLCsynchonisationPEOX(E.GPounceX)Toavoidcycletimeissue(wespecifiedthatHOMEpositionisaglobalposition)weneedtohaveanotherspecificpositionneartherobotwork.Thispositionistobetaughtoutofcollisionandisspecifictothejobnumber(programsentbyPLCindicatingtasktobedone).UsermustprovidetwoprogramforsafelydrivetoandfromHOMEposition•HometopeoX•PeoXtoHomeWhereXisthejobnumber.UsercannotchangethesenamesbecausetheyareautomaticallycalledbybaseapplicationwhenPLCrequesttodrivebacktoHOME(abortthetask).Nb:forcodenumber10(PG10)thesepatharecalled•Hometopeo10•Peo10ToHomeServicepositionAservicepositionisneededforsomeprocess,itallowusertoenterinthecelltodosomemaintenanceoperations(cleaning,check..).Servicepositioncanbefreelyprogrammedusermustonlycallaroutinenamed“inservice“.Whenthisroutineiscalledplcallowusertoenterinthecellwhenallmaintenanceoperationsarefinishtheoperatorissueacyclestartandrobotmaincyclecanrestart.TipchangepositionAservicepositionisneededforsomeprocess,itallowusertoenterinthecelltodosomeoperations.Forexampleinweldingprocess,tipsneedtobechangedsowhentherobotisinservicepositionusercanenterinthecellandchangethem.Servicepositioncanbefreelyprogrammedusermustonlycallaroutinenamed“intipchg“.Whenthisroutineiscalledplcallowusertoenterinthecellwhentiparechangedtheoperatorissueacyclestartandrobotmaincyclecanrestart.Handzhoufordprojectusermanual6/39RobotmainprogramDescriptionRobotmaintaskisprogram“zmain”,thisprogramismonitoredbybackgroundtaskandselectedautomaticallywhentherobotisinautomaticmode(thistoavoidthatanunhallowedprogramruninautomaticmode).Themaintaskofthisprogramistocheckinitializesomeparameters,checkifrobotatstart-upisatHOMEpositionandthenselectthetasktobedoneaccordingtoPLCrequest.Handzhoufordprojectusermanual7/39RobotinHome ?InitialisationInTeachmodedrivetherobotbacktoHOMEPLCrequestHandlePLCrequestEXECUTEPATHGOBACKHOMESETWorkfinishPGnumberOKRobotinhomeSynchronisationprimitivesDescriptionInordertosynchroniserobotmovementandplctaskwedefinesomefunctionstoallowusertointeractwithPLC.Throughpre-definedIOrobotcommunicatewithPLC.Thereis3kindofsynchronisationobjects:•Areaorsegment•Interlocks•ServicepositionArea/segmentsynchronisationobjectWhenperformingjobtasktherobotneedtowaitforsomeeventtoarise(likecarinposition,tablerotationfinished,…)todothisuserneedatsomepositiontocallapredefinedroutineandaskplctogranthimtheaccess.Thisactionisperformedbycalling:•WaitforSegmentUsershouldcallthisfunctionafterafinepoint(accuracysetto0)andprovidesomeparameters:•areanumber:(integerfrom1to16)givenbyPLC•areadescriptioninenglish(string)•areadescriptioninchinese(string);synchronisationprimitiveCALLwaitforsegment(16,"SpotCarChb10GEO","¹Ì¶¨º¸½Ó")WhenrequestedoperationisfinishedandinordertostaysynchronisedwithPLCuserneedtoinformPLC.Todosousermustcall:•EndSegmentAndprovideoneargument:•areanumber;synchronisationprimitiveCALLendsegment(16)Example:Hereinthissampletherobottaskispickapart,weldthendropitonthecar.Toperformsuchataskwewillneedatleast3area:•Area1-PLCgrantaccesstopickthepart•Area2–PLCgrantaccesstoweldthepart•Area2–PLCgrantaccesstodropthepartHandzhoufordprojectusermanual8/39Thentherobotprogramshouldbelike.PROGRAMpg10()HOME;neededasstandardcommandCALLhometopeo10;mustprovideahometopounceprogramCALLpeojob(10);mustcallpeojobwithpgnumberIFzendcyclereqGOTOendcycle;neededbyapplication;synchronisationprimitiveCALLwaitforsegment(1,"Pickpart10","Pickpart10")CALLpickchb10;workprogramCALLendsegment(1);synchronisationprimitiveCALLwaitforsegment(2,"SpotPart10","SpotPart10")CALLspotchb10;workprogramCALLendsegment(2);synchronisationprimitiveCALLwaitforsegment(3,"Droppart10","Droppart10")CALLdropchb10;workprogramCALLendsegment(3);synchronisationprimitiveHOME;neededasstandardcommandendcycle:;neededendofcyclemanagement.ENDNB:Areasmustfirstbetaken(waitforsegment)andthenreleased(endsegment),acalltoendsegmentinacycleHandzhoufordprojectusermanual9/39Segment1Segment2Segment3withoutprecedingitbywaitforsegmentwillcauseanerror(“tryingtofreeasegmentneverused”).Multipleareascanbeusedinaprogramupto16.Areascanbereleasedintheuserconvenienceorder.Ex:releasingsegmentinuserdefineorder.PROGRAMpg10()HOME;neededasstandardcommandCALLhometopeo10;mustprovideahometopounceprogramCALLpeojob(10);mustcallpeojobwithpgnumberIFzendcyclereqGOTOendcycle;neededbyapplication;synchronisationprimitiveCALLwaitforsegment(16,"Anticipation","anticipation")CALLwaitforsegment(1,"Spotcarmodel10","Spotcar")CALLspotchb10;workprogramCALLendsegment(16);endofworkopenclampsCALLMoveback10;movebackprogramCALLendsegment(1);releasecarHOME;neededasstandardcommandendcycle:;neededendofcyclemanagement.ENDInthisprogramuserrequestplctoopenclampsonthelastweldingpoint,andthenwhentherobotisoutofcarcollisionrequestplctomovethecar.InterlocksynchronisationobjectInacellmultiplerobotcellsometimesrobotcanworkinthesameworkspace.Robotprogrammerneedtosynchronisetheexecutionofeachrobotpathtoavoidcollisions.Baseapplicationdefines16interlockzonetobefreelyprogrammedbyrobotprogrammer,thereforeforeachzoneoneinterlockmustbeprogrammedinaccordancewithPLC.Toavoidmasterslaveinterlockprogramminginrobotsoftware,eachinterlocklineissenttoplcandthenitisuptoplctodecidewhichrobothewillgranttheaccess.Toprogramaninterlockusershouldusetheroutinecalled:•EnterzoneUsershouldcallthisfunctionafterafinepoint(accuracysetto1)andprovidesomeparameters:•zonenumber:integerfrom1to16Whentherobotisoutofcollisionzonethenitistimetofreethezone.Todosousermustcall:Handzhoufordprojectusermanual10/39•ExitZoneUsershouldcallthisfunctionafterafinepoint(accuracysetto0)andprovidesomeparameters:•zonenumber:integerfrom1to16NB:Somecellscontains6robotsandsomerobotscanworkinthesameworkspacethanallothermeansthatthisrobotmayneed6interlocks.Aswesaidthatinterlocksarefreelyprogrammableinaccordancewithplc,wesetsomestringstodefinewhichzoneisconnectedtowhichrobot($ildescrp[1]..$ildescrp[16]).PROGRAMpgdescription()#21;Addadescriptiontoapgprogramme;ThesepgprogrammecanbecalledbyPrgmanualselect;$pgname[X]="description"X=PGCODEACCORDINGTOPLC;$pgname[1]="Fordprogrammodel1";$pgname[200]="Tipdressgun1;Interlockdescriptionenglish$pgname[10]="Fordprogrammodel10"$ildescrp[1]="8x020-R02"$ildescrp[2]="8x020-R02"$ildescrp[3]="8x020-R02"$ildescrp[4]="8x020-R03"$ildescrp[5]="8x020-R04"$ildescrp[6]="8x020-R05"$ildescrp[7]="8x020-R08"$ildescrp[8]="*********"$ildescrp[9]="8x020-R12"$ildescrp[10]="8x020-R32"$ildescrp[11]="8x020-R42"$ildescrp[12]="8x020-R52"$ildescrp[13]="8x020-R62"$ildescrp[14]="8x020-R72"$ildescrp[15]="8x020-R82"$ildescrp[16]="8x020-R92".ENDBlockteachingprogramInthisprogramtheusertakeinterlock5whichiswithrobotR1andfreeitlater.PleasenoticetheACCU0beforeeachcall.JOINTSPEED9ACCU0TIMER0TOOL1WORK0CLAMP1(OFF,0,1,1)OX=WX=CL1=0.000,10.0,10.0,0.0,0.0,0.0,0.0#[-8.7104,-8.6297,-18.952,92.273,-81.548,-22.625,245.02];CALLenterzone(5);r1_enterzoneJOINTSPEED9ACCU4TIMER0TOOL1WORK0CLAMP1(OFF,0,1,1)OX=WX=CL1=0.000,10.0,10.0,0.0,0.0,0.0,0.0#[-7.3042,14.211,-17.398,91.139,-83.013,-20.949,245.02];JOINTSPEED9ACCU4TIMER0TOOL1WORK0CLAMP1(OFF,0,1,1)OX=WX=CL1=0.000,10.0,10.0,0.0,0.0,0.0,0.0#[-7.3827,12.704,-13.079,90.625,-82.871,-16.599,259.3];Handzhoufordprojectusermanual11/39…...........................JOINTSPEED9ACCU0TIMER0TOOL1WORK0CLAMP1(OFF,0,1,1)OX=WX=CL1=0.000,10.0,10.0,0.0,0.0,0.0,0.0#[-9.5646,18.259,-16.781,85.214,-106.13,-16.167,222.32];CALLexitzone(5);r1_exitzoneJOINTSPEED9ACCU0TIMER0TOOL1WORK0CLAMP1(OFF,0,1,1)OX=WX=CL1=0.000,10.0,10.0,0.0,0.0,0.0,0.0#[-9.7441,17.679,-12.65,86.46,-106.26,-11.863,29.999];InthepresentscenariothefirstrobotwhorequestthezonewillbegrantedaccessbyPLC.IncaseofsimultaneousaccessPLCwillonlygivetheprivilegetoonerobotavoidinginthatcaseanycollision.Handzhoufordprojectusermanual12/39R1R2PLCR1CALLenterzone(1)R2CALLenterzone(2)R2CALLexitzone(2)R1CALLexitzone(1)InterlockzoneControlledbyPLCHumanmachineinterfaceDescriptionAdedicatedinterfaceispresentonthependantoftherobot.Thisinterfaceiscomposedof6differentpanels.Panel1,2and6areforbaseapplication3,4,5areforprocess.PaneldescriptionPanel1Thispanelisageneralpanelthat•DisplayspecificpositionHOME,SERVICEPOS,POUNCE,TipChange•DisplayspecificInputDryrun,Taskrunning,Pgfault,Processfault•Displayalarms•Displayrobotnumber•DisplaylastCycletime•displayprogramnamerunning•Displaysegment/Areaused•Displayinterlockused•Makeabackuponusbkey•NavigatethroughpanelsHandzhoufordprojectusermanual13/39Panel2Thispanelisusedtodisplay•Inputandoutputusedforsegment(statusandrequest)•InputandoutputusedInterlocks(statusandrequest)Thispanelalsoallowusertodrivetherobotinfullautomatic(normallynotallowed)speedformaintenancepurposeinamodecalled“checkmode”.Thismodeallowusertofreelyselectaprogramforexample“loaddetermination”.WhentherobotinthismodePLCcannotrequestanyprogramfromrobot.Handzhoufordprojectusermanual14/39Panel6Thispanelisdedicatedtodisplayroboterrorthatneedvalidationfromtheoperator.Thispanelisautomaticallydisplayedwhenrobotisinerror,usercanstillnavigatethroughallpanelsbutneedtoacknowledgetheerror.Handzhoufordprojectusermanual15/39Panel3,4,5Thesepanelsareusedbyprocessapplication,todisplayspecificinformations.Thepictureaboveshowascreenofweldingapplicationwithobaratimer.Handzhoufordprojectusermanual16/39ProcessSpotweldingapplicationThismanualwillnotcoverallspotapplication.Kawasakiprovideblocteachinginstructionsforteachingspotpoint.Thismanualwillcovertheadaptationmadebyabbtobeabletousespotweldinginconjunctionwithobaraandboschtimer.ATimer(boschorobara)communicateswiththerobotthroughprofinet,ourapplicationhandles(inaplcbackgroundtask“kladder”)allinputandoutputcomingfromthetimerandthensettheninordertomakekawasakispotapplicationworkwiththesetimers.Thisapplicationprovidefullfunctionalityforspotweldingas:•Sendtimerprogrammenumberinadvance•Countthenumberofweld•Handletipdressingrequest•Handletipchangerequest•Handleforobaratimertipchange(countnumberofspot,numberofdress,tipendoflife)•Handlespotfault(retryabort…)•Handlenoweldindryrun•Handlewaterserver•Handlepulledtip•Handleclearidentificationoferrorforboschtimer•TipdressmotorrotationHandzhoufordprojectusermanual17/39KladderKawasakispotapplicationInputoutputObara/BoschTimerInputOutput•AutomaticTipchangerSeveralprogramsareatuserdispositionandoneprocessHMI.ProgramlistNamedescriptionPG256Thisprogramisautomaticallycalledbykawasakisoftwarewhenthegunisclosed.ItcontainsspotweldingactionincaseoferrorreportStartDresserStartthetipdressmotorStopDresserStopthetipdressmotorClearTipDressCleartimertipdressrequestClearTipChangeCleartimertipchangerequestManChgTipManualchangetip.RequestfromusertochangethetipandthenallowprogramtocontinueDescriptionofaweldingpointJOINTSPEED9ACCU0TIMER0TOOL1WORK0CLAMP1(ON,3,1,1)OX=WX=CL1=0.000,10.0,10.0,0.0,0.0,0.0,0.0#[27.621,1.641,-14.289,83.793,66.986,-164.42,2.7527];UB-81201-04-LACCU0:Accuracyofthepointshouldbe0CLAMP1(ON,3,1,1)•Clamp1forgun1•ONmeansclosethegunandapplyforcesetbyprogram•3programnumber2.7527:ThicknessofthepartUB-81201-04-L:commentmeaningpointNB:formoredetailspleaserefertokawasakimanualHandzhoufordprojectusermanual18/39ObaratimerHMIBoschtimerHMIHandzhoufordprojectusermanual19/39HandlingapplicationDescriptionHandlingapplicationisasetofroutineandtwopanelinrobotHMI.Handlingapplicationallowuserto•configureagripper•simulatesomeinputsofagripper•open/closeagripper•displaythestatusofagripperInourterminologytoperformanactionwedefinetwoactioncloseandopen.Theseactionsareactivatedbyoneortwooutputsthatcanbe•clamp•suctionvalve•locatingpin•…andtheresultingstateisgivenbyoneortwoinputs.Weusuallyalsowanttoperformtheseactionsinacertainorder.Sometimestocloseagripperusermustfirstcloseonesetofclampwaituntiltheseclampsareclosethenclosesomeother.Agripperisdefinedasfollowed:•1or2outputspersequence•Upto6associatedstates(1or2inputsperstate(open/closed))•Upto6sequenceA,B,C,D,E,F•Upto6partpresenceUserroutinesCloseSeq:closeagroupofsequenceofagripperandwaitforagroupofinput.CloseSeq(.Gripper,.Seqno,.nowait,.Timeout)•Gripper:grippernumber•Seqno:Sequencenumber(pré-definedsequenceareSeqA,SeqB,SeqC,SeqD,SeqE,SeqF)•Nowait:▪Falseclosesequenceandwait▪Trueclosesequenceanddon'twait•Timeout:timebeforetriggerafaultmessageinthecasesequenceisnotclosedEx:CloseSeq(1,SeqA+SeqB+SeqE,FALSE,2)ClosesequenceA,B,E,checkassociatedinputs.Ifoneofthesequenceisnotclosewithin2secondsafaultHandzhoufordprojectusermanual20/39messagewillbetriggeredandthegripperHMIwillbedisplayedonthependantscreen.OpenSeq:Openagroupofsequenceofagripperandwaitforagroupofinput.OpenSeq(.Gripper,.Seqno,.nowait,.Timeout)•Gripper:grippernumber•Seqno:Sequencenumber(pré-definedsequenceareSeqA,SeqB,SeqC,SeqD,SeqE,SeqF)•Nowait:▪Falseclosesequenceandwait▪Trueclosesequenceanddon'twait•Timeout:timebeforetriggerafaultmessageinthecasesequenceisnotopenEx:OpenSeq(1,SeqA+SeqB+SeqE,FALSE,2)OpensequenceA,B,E,checkassociatedinputs.Ifoneofthesequenceisnotopenwithin2secondsafaultmessagewillbetriggeredandthegripperHMIwillbedisplayedonthependantscreen.OpenToolChanger:OpenthetoolchangerCloseToolChanger:ClosethetoolchangerChkBeforePick:Performallnecessarycheckbeforepickagripper.ForthemomentjustchecktoolID.ChkAfterDrop:Performallnecessarycheckafterdropagripper.ForthemomentjustchecktoolID.DropGripper:Dropthegripperonatoolstand.Deactivatebussupervisionandopentoolchanger.DropGripper(.Gripper)•Gripper:grippernumberPickGripper:Pickthegripperonatoolstand.Activatebussupervisionandclosetoolchanger.PickGripper(.Gripper,.Timeout)•Gripper:grippernumber•Timeout:Timeoutforbusdetection.CheckPpOn/CheckPpOFF:checkthestateofpartpresenceCheckPpOn(.Gripper,.ppart,.Timeout)CheckPpOff(.Gripper,.ppart,.Timeout)•Gripper:grippernumberHandzhoufordprojectusermanual21/39•.ppart:pre-definedPP1,PP2,PP3,PP4,PP5,PP6•Timeout:Timeoutforbusdetection.HumaninterfaceHandlingapplicationiscomposedoftwopanels:•Panel1:grippergeneralstatus•Panel2:gripperassociatedsequencestateanddefinitionPanel1Inthispaneltheoperatorcan:•Displaythestatusofeachsequenceusedbyagripper•Setasignalnumberforapartpresence•Setanameforapartpresence•Simulateapartpresence•ChangethegrippernumberHandzhoufordprojectusermanual22/39Panel2Inthispaneltheoperatorcan:•Setasignalnumber•Setasignalname•Setaname•Simulateaninput•Navigatethroughsequence•Open/Closeasequence•DisplaythestateofasequenceHandzhoufordprojectusermanual23/39SealingapplicationDescriptionSealingapplicationisasetofroutinesandonepanelinrobotHMI.Thisapplicationcoversealingwithoneortwogun.Gracosystemisusedtoprovideseal.Sealingstartandsealingstopisachieveusingclampfunctions(clamp1seal1,clamp2seal2).Robotisconfiguredhasasealingrobot.Sealingapplicationhandleinbackgroundtaskthenecessaryoperationsforapplyingglue.Sealingapplicationalsochecktheamountofsealappliedduringthepathandwiththehelpofanhandshakewithgracosystemwarmuserifthevolumeofsealisnotinthewantedtolerance.UserroutinesSealingInit:InitialisationofthegracosystemSealingInit(.Gun)•Gun:sealingsystemnumberSealingEnd:Checkgracosystemandvolumeofseal,reportanyerrorduringthepath.SealingEnd(.Gun)•Gun:sealingsystemnumberSetFlow:Setapre-pressurebeforestartsealingandsetalsotheamountofsealdroppedduringsealing.SetFlow(.Flow,.FlowPerc)•Flow:amountofseal•FlowPerc:(pre-pressure)percentageofmaximumflowSamplepathCALLSealingInit(1)CALLSetFlow(12.5,50)LINEARSPEED3ACCU2TIMER0TOOL1WORK0CLAMP1(OFF,0,0,O)2(OFF,0,0,0)OX=WX=#[-60.623,53.431,-21.712,156.7,-76.667,-174.33];LINEARSPEED3ACCU2TIMER0TOOL1WORK0CLAMP1(OFF,0,0,O)2(OFF,0,0,0)OX=WX=#[-60.654,55.055,-20.967,156.81,-77.472,-174.69];sealingstarts100mmafterthispointHandzhoufordprojectusermanual24/39LINEARSPEED3ACCU2TIMER0TOOL1WORK0CLAMP1(ON,100,1,0)2(OFF,0,0,0)OX=WX=#[-60.191,54.595,-22.326,156.42,-78.339,-174.95];LINEARSPEED3ACCU2TIMER0TOOL1WORK0CLAMP1(ON,0,1,0)2(OFF,0,0,0)OX=WX=#[-56.191,54.595,-32.326,156