Chrysler Cusw Fanuc Robot Standard Rel 1.3

AS OF 1/12/2012 1 CUSW REL1.3

Printed copies are not source controlled

Chrysler’s Robotics Group Applications Standards For

Controlled Robots For Use On CUSW North America Projects

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TABLE OF CONTENTS

RELEASE REVISION AND COMMENTS PAGE ...................................................................................................... 5

PROCESS REQUIREMENTS TO ALLOW FOR ALIGNMENT OF ROBOT ............................................................ 7

ROBOTIC BY-PASS CONCEPT ............................................................................................................................... 7

TEACH PENDANT USER KEY ASSIGNMENT ........................................................................................................ 7

USE OF PULSED OUTPUTS .................................................................................................................................... 7

USE OF ROBOT PROGRAM SPACE CHECK ........................................................................................................ 7

COORDINATED MOTION OF HORIZONTAL AXIS ................................................................................................. 7

ROBOT DRESS REQUIREMENTS........................................................................................................................... 7

SEALER STYLE NUMBERS ..................................................................................................................................... 7

SEALER SYSTEM CALIBRATION TO ROBOT ANALOG OUTPUT ...................................................................... 8

SEALER SCHEDULES ............................................................................................................................................. 8

NETWORK ADDRESSES ......................................................................................................................................... 8

FANUC ROBOTICS ROBOT SIGNALS AND MACHINE AUTOMATIC .................................................................. 8

ROBOT D-NET OUTPUT BIT MAP (ROBOT TO PLC)............................................................................................ 9

ROBOT D-NET INPUT BIT MAP (PLC TO ROBOT) .............................................................................................. 13

ROBOT IO MAP ASSIGNMENTS ........................................................................................................................... 18

ROBOT BIT MAP .................................................................................................................................................... 19

ROBOT APPLICATION ERROR TIMING ............................................................................................................... 41

ROBOT APPLICATION ERRORS .......................................................................................................................... 42

PLC LOGIC REFERENCE ...................................................................................................................................... 48

ROBOT PROGRAM NAMING ................................................................................................................................. 49

ROBOT INTERFERENCE ZONES .......................................................................................................................... 50

INTERFERENCE ZONE EXAMPLE 1 ............................................................................................................................ 51 INTERFERENCE ZONE EXAMPLE 2 ............................................................................................................................ 52

INTERFERENCE ZONE EXAMPLE 3 .................................................................................................................... 53

PLC / ROBOT TIMING DIAGRAMS........................................................................................................................ 54

REGISTER USAGE ................................................................................................................................................. 57

NUMERICAL REGISTER USAGE .......................................................................................................................... 57

POSITION REGISTER USAGE ............................................................................................................................... 59

USER ALARMS ....................................................................................................................................................... 61

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REFERENCE POSITION USAGE ........................................................................................................................... 62

INTERCONNECTS .................................................................................................................................................. 63

MACROS ................................................................................................................................................................. 64

FLOW CHART EXAMPLES .................................................................................................................................... 66

MATERIAL HANDLING .............................................................................................................................................. 67 DISPENSE............................................................................................................................................................... 72 SPOT WELDING ...................................................................................................................................................... 73 STUD WELDING ...................................................................................................................................................... 75 TIP CHANGE (STYLE #3) ......................................................................................................................................... 76 PURGE (STYLE #4) ................................................................................................................................................. 77 TIP BURN IN (STYLE #5) .......................................................................................................................................... 78 SERVICE (STYLE #6) ............................................................................................................................................... 79 TIP DRESS GUN 1 (STYLE #7) ................................................................................................................................. 80 TIP DRESS GUN 2 (STYLE #8) ................................................................................................................................. 81 TOOL CHANGE (STYLE #9) ...................................................................................................................................... 82 SET APPLICATION IO (MACRO) ................................................................................................................................ 83 CHECK ATI ERRORS (MACRO) ................................................................................................................................ 84 CHECK TOOL (MACRO) ........................................................................................................................................... 85 DROP TOOL NEST 1 (MACRO) ................................................................................................................................. 86 ENTER ZONE 1 (MACRO) ......................................................................................................................................... 88 HOME IO (MACRO) ................................................................................................................................................. 88 MOVE HOME (MACRO) ............................................................................................................................................ 88 MOVE HOME FROM POUNCE (MACRO) .................................................................................................................... 88 PICK TOOL NEST 1 (MACRO) ................................................................................................................................... 89 PROCESS APPLICATION MACROS (SPOT, DISPENSE, STUD) ...................................................................................... 91 PURGE PED GUN (MACRO) ..................................................................................................................................... 94 RESET STEPPER (MACRO) ...................................................................................................................................... 94 TIP BURN IN (MACRO) ............................................................................................................................................. 95 TIP DRESS GUN 1 (MACRO) .................................................................................................................................... 97 TIP DRESS GUN 2 (MACRO) .................................................................................................................................... 98 TIP DRESS PED GUN (MACRO) ................................................................................................................................ 99 TOOL DROP PREPARATION (MACRO) ..................................................................................................................... 100 TOOL PICK PREPARATION (MACRO) ....................................................................................................................... 101

TEACH PENDANT LOGIC EXAMPLES ............................................................................................................... 102

MATERIAL HANDLING ............................................................................................................................................ 103 DISPENSE............................................................................................................................................................. 105 SPOT WELDING .................................................................................................................................................... 106 STUD WELDING .................................................................................................................................................... 107 TIP CHANGE (STYLE #3) ....................................................................................................................................... 108 PURGE (STYLE #4) ............................................................................................................................................... 108 TIP BURN IN (STYLE #5) ........................................................................................................................................ 109 SERVICE PROGRAM (STYLE #6)............................................................................................................................. 109 TIP DRESS GUN 1 (STYLE #7) ............................................................................................................................... 109 TIP DRESS GUN 2 (STYLE #8) ............................................................................................................................... 110 TOOL CHANGE (STYLE #9) .................................................................................................................................... 110 CHECK ATI ERRORS (MACRO) .............................................................................................................................. 111 CHECK TOOL (MACRO) ......................................................................................................................................... 112 DROP TOOL NEST 1 (MACRO) ............................................................................................................................... 113 PICK TOOL NEST 1 (MACRO) ................................................................................................................................. 114 ENTER ZONE 1 (MACRO) ....................................................................................................................................... 116 HOME IO (MACRO) ............................................................................................................................................... 116 PROCESS APPLICATION – PED SPOT (MACRO) ....................................................................................................... 117 PROCESS APPLICATION – PED DISPENSE (MACRO) ................................................................................................ 118 PROCESS APPLICATION – PED STUD (MACRO) ....................................................................................................... 119 PURGE PED GUN (MACRO) ................................................................................................................................... 119 RESET STEPPER (MACRO) .................................................................................................................................... 119 TIP BURN IN (MACRO) ........................................................................................................................................... 119

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TIP CHANGE PED GUN (MACRO) ........................................................................................................................... 119 TIP DRESS GUN 1 (MACRO) .................................................................................................................................. 120 TIP DRESS GUN 2 (MACRO) .................................................................................................................................. 120 TIP DRESS PED GUN (MACRO) .............................................................................................................................. 121 TOOL DROP PREPERATION (MACRO) ..................................................................................................................... 122 TOOL PICK PREPERATION (MACRO) ....................................................................................................................... 123

The flow charts and sample programs supplied in this document are intended as a basic example and may not include all information required to properly control a robot in all applications. It is the build vendor's responsibility to provide robot programming required for proper system operation. The examples set forth in this document shall be followed. Any deviations will require approval by Chrysler Robot Specialist.

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RELEASE REVISION AND COMMENTS PAGE

Release # Release Date Comments Rel. 1.0 12/14/10 - Initial Release

Rel. 1.1 2/4/11 Adjusted Rbt/PLC bitmap to eliminate water saver control. DO[99], DI[7], DI[97], DI[98]. Update the Node Allocation – Eliminated the Water Savers, moved to PLC control. Updated Rbt/PLC Node descriptors per the bitmap. Spared out 4 Water Saver Nodes-I/O. Updated Safety I/O Added WaterOff to the bitmap DO[100] Removed reference to WK and WD in robot program naming Spared out DO91, 92, 95, 96 and 100 – Use Group Output [MaintReqBits1-8]. (TipChangeReq, ServiceReq, RbtTPPurgeGun1, RbtTPPurgeGun2, TipDressReq) Added air pressure master node and outputs to PLC DO[91] and [92] Added StepMode output DO[103] Added SignatureChgInd output DO[111] Updated Watersaver App Errors Updated Nordson App Errors to match new configuration Updated Nordson BitMap to match new configuration REL. 1.2 Added sealer style comment. Added sealer calibration requirement Added sealer schedule programming requirement Swapped air pressure inputs to match tooling Removed repo input bit 4 DI[84] Added General Communication Fault DeviceNet Master App Error [2] Added Low Battery Indicator App Error [4] Removed App Error [127] Dispense 1 Minor Alarm Removed App Error [128] Dispense 1 Communication Fault to Robot Removed App Error [137] Dispense 2 Minor Alarm Removed App Error [138] Dispense 2 Communication Fault to Robot Nordson app errors modifications Added Interference Zone 3 reference Added DO[107] – TipBurnInComp Added AtPurgePos to position register Added Tip Wear Update to Spotweld program Added PartPresent 7-10 on bit map sheet.

REL1.3 Updated DI[121] Added RbtClrZone7 & 8 to DO[39], DO[40], Zone(7 & 8)ClrToEnter to DI[39], DI[40] and DO[908] PulseBatteryLow Updated Interconnects list Added IPG_Laser and HighYag Head I/O to nodes 17 and 18 Added LaserEnbld DO[87] and HYagEnbld DO[88] Added LaserEnable1 DI[6] and LaserGuideOn DI[7] Added LaserCut Head and Grinder to nodes 19 – 23 Changed the TipChange burn-in schedule from 58 to 62 per Welding CoC team P. 104. Updated the Nordson bitmaps per the requirements of the tech sealer document. Added DI[98:StartUpPurge] to PLC bitmap per tech requirements. Added DO[95:TipDressReq] to PLC bitmap Updated Interconnect Table Added track lube faults to the application error list Added note indicating responsibility to set IP addresses and Node addresses. Added I/O map for the Precitec unit. Added DI127 Tip Dress Bypass Added DI768-775 and DO768-775 for Mig Weld Reamer Added DI776-783 and DO776-783 for Laser cutting field I/O Update Tip Dress Macro add DI127 TipDressInBypass Added RTU Auto Lube I/O

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PROCESS REQUIREMENTS TO ALLOW FOR ALIGNMENT OF ROBOT It is an AAME requirement that all Body shop and Assembly robots be capable of running an alignment program. This program will bring the robot into a position which will allow positioning of all axes to check robot alignment. The robot alignment position and path to reach this position must be considered when locating and processing the robot in the cell. Consideration must also be given when dressing out robot cables, hoses, end effectors and junction boxes on the robot arm so these items do not impede the robots ability to move to the alignment position. Where possible, all axes should be aligned at the same time. In cases where cell layout would be affected or additional dress-out or safeties would be required to align all axes simultaneously, multiple alignment positions will be allowed. In addition to alignment program, all OEM‟S must verify that the robot is set to FANUC ROBOTICS factory values for alignment position prior to programming robot.

PROCESS CYCLE TIME REQUIREMENTS

It is an AAME requirement that all Body shop and Assembly robots be capable of meeting process cycle time without the presence of robot errors or warnings of any kind.

ROBOTIC BY-PASS CONCEPT The Robot By-pass Mode is selected through the HMI screen associated with the specific robot. When in By-pass Mode, the PLC logic should allow the following: In processes which allow a specific robot to be by-passed, (line capable of running without this specific robot with manual or automatic back-

up capabilities).

A. Allow the current part or job to transfer out of that station (if the robot is clear). B. Allow the line to continue to run while the robot is in by-pass and clear of all tooling. C. Send required back-up information to down stream robot(s) and/or FIS/AVI for downstream manual backup.

In processes which do not allow for the line to run with a specific robot in by-pass.

A. Allow the current part or job to transfer out of that station (if the robot is clear). B. Stop further machine cycles if left in by-pass mode. C. Allow for easy changes to the PLC logic to override item “B” in the event that the plant provides temporary manual back-up for

continued production. Note: Process Engineering, during the Design Phase of a project, will identify robots that can be by-passed while tooling continues to operate.

TEACH PENDANT USER KEY ASSIGNMENT The user definable keys on the robot teach pendants are to remain at FANUC ROBOTICS default settings unless a deviation is submitted by the Requestor and approved by a Chrysler Robotic Group representative.

USE OF PULSED OUTPUTS The use of pulsed outputs requires approval by a Chrysler Robot Specialist.

USE OF ROBOT PROGRAM SPACE CHECK The use of robot program space check requires approval by a Chrysler Robot Specialist.

COORDINATED MOTION OF HORIZONTAL AXIS All robots utilizing a horizontal slide axis shall be setup and programmed using coordinated motion with the other six axes of the robot arm.

ROBOT DRESS REQUIREMENTS FANUC robot dress packages for all spot welding and material handling robots will be supplied for installation. It is the responsibility of the build supplier (robot programmer) to adjust and validate all robot dress packages to meet the dress manufacturer‟s warranty. Robot programs must be considered when configuring the supplied dress package.

SEALER STYLE NUMBERS Sealer styles shall match the value of the robot program number. (i.e. If the sealer robot is executing program #30, the sealer style program shall utilize style #30).

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SEALER SYSTEM CALIBRATION TO ROBOT ANALOG OUTPUT

- It is the robot programmers responsibility to calibrate the Sealer System to the Robot System. Minimum and maximum speeds

related to the robot analog output signal to produce required bead sizes must be established and verified at time of programming.

SEALER SCHEDULES

- It is the robot programmers responsibility to populate all sealer schedules with values appropriate for the working programs. All

sealer schedules not utilized in a program shall be set to the maximum flow rate available from the sealer system.

NETWORK ADDRESSES

- It is the robot programmers responsibility to set all IP addresses and Node addresses associated with the robot system.

FANUC ROBOTICS ROBOT SIGNALS AND MACHINE AUTOMATIC The PLC logic should monitor the following robot DeviceNet outputs. The “Robot Ready” signal should be true to achieve machine automatic but is not required to maintain machine automatic. Proper fault messages should be generated for each associated condition. “Robot Ready” DeviceNet - This signal is true when the following conditions are met: CMDENBL SI[2]=ON (OK) (standard operator panel input 2, remote) CMDENBL SFSPD=ON (OK) (safety speed input signal) CMDENBL ENBL=ON (OK) CMDENBL $RMT_MASTER=0 (OK) (no remote device in control of motion) CMDENBL No active alarms (OK) CMDENBL Not in single step (OK) SYSRDY ENBL=ON (OK) SYSRDY GRP1 Servo ready (OK) SYSRDY GRP2 Servo ready (OK) (Spotweld only) GRP1 Motion enabled (OK) (Robot motion group) GRP2 Motion enabled (OK) (Servo motion group, spotweld only) Spot weld enabled (OK) (Weld status, welding applications only) Gun stroke enabled (OK) (Gun stroke status, welding applications only) The following signals are available through DeviceNet and should be displayed as faults or messages when their appropriate state hinders achievement of the tooling system automatic: Robot System Ready for AUTO RobotInAuto RbtReady IOSimulated 20HourRunModeAct Collision Guard Enabled TP Enabled Waiting for TP Input Robot E-Stop Enabled Weld Enabled (Spotweld only) STEP Mode

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ROBOT D-NET OUTPUT BIT MAP (ROBOT TO PLC)

SIGNAL NAME ROBOT OUTPUT DESCRIPTION

RobotInAuto 1 This robot output signal is used to inform the PLC that the robot Auto/Teach key switch is the auto position.

RobotFaulted 2 This robot output signal is used to inform the PLC that the robot is in a faulted state.

WaitForTPInput 3 This robot output signal is used to inform the PLC that a user response is required at the robot teach pendant.

InCycle 4 This robot output signal is used to inform the PLC that a robot program is executing. This includes Home I/O execution. “InCycle” remains high when the program is paused.

CollisionDetd 5 This robot output signal is used to inform the PLC that a collision was detected on the robot.

IOSimulated 6 This robot output signal is used to inform the PLC that a robot input is simulated.

WldEnabled 7 This robot output signal is used to inform the PLC that the weld mode is enabled at the weld controller.

RobotReady 8 This robot output signal is used to inform the PLC that all conditions for robot ready are satisfied.

ActiveStyleBit1 9 This robot output along with the next six bits, grouped as “Group Outputs”, are used to inform the PLC of the current style active. The group outputs are viewed as the binary bit weight viewed as a decimal value.

ActiveStyleBit2 10 Reference description: “ActiveStyleBit1”






PrgPaused 16 This robot system output signal “UO[4: Paused]” is used to inform the PLC that the robot program is in a paused condition. Signal is active in Auto and Teach modes.

PrgRunning 17 This robot system output signal “UO[3: Program Running]” is used to inform the PLC that the robot program is running. Signal is active in Auto and Teach modes.

RobotAtWork 18 This robot output signal is used to inform the PLC that the robot has left the pounce position and is in the work portion of the robot program.

WorkComplete 19 This robot output signal is used to inform the PLC that the robot has completed the work program. Resets after WorkCompleteAck received from the PLC.

20HourRunModeAct 20 This robot output signal is used to inform the PLC that the robot is in 20 hour run mode.

MaintReqBit1 21 This robot output signal along with the next 3 bits, grouped as “Group Outputs” are used to inform the PLC to execute the desired maintenance program 1-9. The group outputs are viewed as the binary bit weight viewed as a decimal value.

MaintReqBit2 22 Reference description: “MaintReqBit1”



RobotAtPounce 25 This robot output signal is used to inform the PLC that the robot is at the pounce position. (Output set by user program)

RobotAtService 26 This robot output signal is used to inform the PLC that the robot is at the service position.

RobotAtHome 27 This robot output signal is used to inform the PLC that the robot is at the home position.

RobotInTipDress 28 This robot output signal is used to inform the PLC that the robot is at the tip dress position.

TipDressComplt 29 This robot output signal is used to inform the PLC that the tip dress procedure has completed.

RdyForTipChg 30 This robot output signal is used to inform the PLC that the robot is in tip change position.

ClearToTransfer 31 This robot output signal is used to inform the PLC that the robot is clear of the transfer.

WldInPrgrsActiv1 32 This robot output signal is used to inform the PLC that the weld controller 1 is executing a weld sequence.

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RobotClrZone1 33 This robot output signal is used to inform the PLC that the robot is clear of interference zone 1.

RobotClrZone2 34 This robot output signal is used to inform the PLC that the robot is clear of interference zone 2







UserOutput1 41 This robot output signal is designated as user defined output 1.








ClrOfPickup1 49 This robot output signal is used to inform the PLC that the robot is clear of pickup 1 position.

AtPickup1 50 This robot output signal is used to inform the PLC that the robot is at the pickup 1 position.

ClrOfDropoff1 51 This robot output signal is used to inform the PLC that the robot is clear of dropoff 1 position.

AtDropoff1 52 This robot output signal is used to inform the PLC that the robot is at the dropoff 1 position.













Clr2UnclampEarly 65 This robot output signal is used to inform the PLC that the robot is clear to unclamp the tooling.

RbtAtUserPos1 66 This robot output signal is used to inform the PLC that the robot is at user position 1


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Spare 70 Spare

Req2EntrToolNest 71 This robot output signal is used as a request from the robot, entry to the tool nests to the PLC.

ClearOfToolNest 72 This robot output signal is used to inform the PLC that the robot is clear of the tool nest.

ServiceComp 73 This robot output signal is used to signal the PLC that service is complete.

MajorMinorFlt 74 This robot output signal is used to signal the PLC that the posted application error is a major fault

WaitingForPlcCmd 75 This robot output signal is used to inform the PLC that the robot is waiting for a PLC command. (Active while in a user program – WaitDI or WaitGI)

RemoveFault 76 This robot output signal is used to inform the PLC to remove the application error.

RobotPartPres1 77 This robot output signal is used to inform the PLC that part present 1 is activated.










LaserEnbld 87 This robot output signal is used to inform the PLC that the Laser is enabled.

HYagEnbld 88 This robot output signal is used to inform the PLC that the HighYag head is enabled.

PickOverride 89 This robot output signal is used to inform the PLC that the robot is in a pick over ride process.

CollisGuardEnbld 90 This robot output signal is used to inform the PLC if collision guard is enabled.

AIr OK 91 This robot output indicates the air pressure is OK

AirPressAcptRng 92 This robot output indicates the air pressure is within acceptable range.

WetDryMode 93 This robot output signal is used to inform the PLC if the robot is in Wet mode.

AbortPickReq 94 This robot output signal is used to inform the PLC that the robot is requesting the abort pick sequence.

TipDressReq 95 This robot output informs the PLC that the weld timer has issued a tip dress request.

Spare 96 Spare

ExtPurg1InProgrs 97 This robot output signal is used to inform the PLC that dispenser 1 purge sequence is in progress.

ExtPurg2InProgrs 98 This robot output signal is used to inform the PLC that dispenser 2 purge sequence is in progress.

WaterOn 99 This robot output signal is used to inform the PLC to turn the water saver on.

WaterOff 100 This robot output signal is used to inform the PLC to turn the water saver off.

TurnOnTipDresser 101 This robot output signal is used to inform the PLC to turn on the tip dresser motor(s).

StepperResetAck 102 This robot output signal is used to inform the PLC that the weld controller has reset stepper .

StepMode 103 This robot output signal is used to inform the PLC that the robot is in StepMode.

RobotAtPurgePos 104 This robot output indicates the robot is in position to purge.

RobotClrFixt1 105 This robot output signal is used to inform the PLC that the robot is clear of fixture 1 (based on automatic zone/window definition in the robot).

RobotClrFixt2 106 This robot output signal is used to inform the PLC that the robot is clear of fixture 2 (based on automatic zone/window definition in the robot).

TipBurnInComp 107 This robot output informs the PLC that the tip burn in is complete.

Spare 108 Spare

ReposTooling1 109 This robot output along with the next two bits, (ReposTooling2 – ReposTooling4) grouped as “Group Outputs”, are used to inform the PLC to reposition the tooling. The group outputs are viewed as the binary bit weight viewed as a decimal value.

ReposTooling2 110 Reference description: “ReposTooling1”

SignatureChgInd 111 This robot output indicates to the PLC that the DCS signature current and previous match and have been verified.

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RbtAtInspectPos 112 This robot output signal is used to inform the PLC that the robot is at the inspection position.

TeachPendantEnbd 113 This robot output signal is used to inform the PLC that the teach pendant switch is enabled.

StartExtApp1Proc 114 This robot output informs the PLC to start external application 1 process.

StartExtApp2Proc 115 This robot output informs the PLC to start external application 2 process.

ToolIDOnWrist1 116 This robot output signal along with the next two bits, (ToolIDOnWrist2 - ToolIDOnWrist4) grouped as “Group Outputs”, are used to inform the PLC which tool is on the robot wrist. The group outputs are viewed as the binary bit weight viewed as a decimal value.

ToolIDOnWrist2 117 Reference description: “ToolIDOnWrist2”

ToolIDOnWrist4 118 Reference description: “ToolIDOnWrist4”

ProcessFault 119 This robot output signal is used to inform the PLC that a process fault is present.

AppErrorActive 120 This robot output signal is used to inform the PLC that an application error is active. Reference: Robot input 8 as acknowledge to this bit.

AppErrorBit1 121 This robot output signal along with the next seven bits, (AppErrorBit2 - AppErrorBit128) grouped as “Group Outputs”, are used to inform the PLC of the current value of the application error that is posted. The group outputs are viewed as the binary bit weight viewed as a decimal value.

AppErrorBit2 122 Reference description: “AppErrorBit1”







Reference DCX Book of Implementation Guidelines for proper Tag and UDT Naming – Design standards for Control Logix AMS 0220 Section 9.3.2, 7.0 Tag – DeviceNet Tag Naming Guidelines, Starting on page 28.

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ROBOT D-NET INPUT BIT MAP (PLC TO ROBOT)

SIGNAL NAME ROBOT INPUT # DESCRIPTION

NoHold 1 This robot system input “UI[2:Hold]” is used to decelerate and stop the robot. This signal is held high for normal operation of the robot.

Resume 2 This robot system input “UI[6:Start]” is used to resume a paused style program.

FaultReset 3 This robot system input “UI[5:Fault Reset]” is used to reset robot and robot controlled peripheral device faults.

20HourRunMode 4 This robot input is used to put the robot into 20 hour run mode.

ReqToEnter 5 This robot input is used to pause the robot program after it has completed the current task and/or motion.

LaserEnable1 6 This robot input is used to signal the robot to activate the Laser system

LaserGuideOn 7 This robot input is used to signal the robot to activate the Laser Guide

AppErrorAck 8 This robot input is used as an acknowledgment from the PLC that the application error has been read.

STYLEBit1 9 This robot system input “UI[9:RSR1/PNS1/STYLE1]” along with the next six bits, grouped as “Group Inputs”, are used for style selection inputs from the PLC. The group inputs are viewed as the binary bit weight in a decimal fashion.

STYLEBit2 10 System input “UI[10:RSR2/PNS2/STYLE2]” Reference description: “Style1”






WeldGunForceChk 16 This robot input is used to initiate the weld gun force check from a style program at the wait for dropoff position.

InterferenceClr1 17 This robot input is used to signal the robot that interference is clear at area 1.

InterferenceClr2 18 This robot input is used to signal the robot that interference is clear at area 2.

AcceptVolume 19 This robot input is used to externally accept the sealer bead from the PLC if a volume fault was issued.

VolumeFltReset 20 This robot input is used to externally tell the robot from the PLC to reset a volume fault on the dispense unit.

PPOK_ClrToGrip 21 This robot input is used to signal the robot to grip the part. (Used for Clr to Grip part)

GripOK_ClrToExit 22 This robot input is used to signal the robot to exit the position. (Used for Clmp&Hold)

AbortExitPick 23 This robot input is used to signal the robot to Abort Exit Pick.

AbortExitDrop 24 This robot input is used to signal the robot to Abort Exit Drop.

RetFromPounce 25 This robot input is used to signal the robot to return from the pounce position back to the home position. When executed, the robot program will return to the home position and mainline program without issuing a “WorkComplete”.

ServiceCompltReq 26 This robot input is used to signal the robot to complete the service program and return to home position and mainline program from the service position.

ServiceRequest 27 This robot input is used to signal the robot to execute a maintenance routine when the robot is at the Waiting for Dropoff# position. (M/H robots only)

TipDressGunReq 28 This robot input is used to signal the robot to initiate the tip dress procedure from a style program.

ProdStart 29 This robot system input “UI[18:Prod Start]” is used to initiate a new style program. When this bit is high and a style number has been set, the robot will start executing the selected style program. [Go to pounce position of selected program]

Spare 30 This robot input is not used.

GoToWork 31 This robot input is used to signal the robot to leave “Pounce Position” and execute the work portion of the robot program.

WorkCompleteAck 32 This robot input is used to signal that “WorkComplete” was received by the PLC.

Zone1ClrToEnter 33 This robot input is used to inform the robot that interference zone 1 is clear to enter. Reference the AME zone logic standard for further information.



Zone4ClrToEnter 36 This robot input is used to inform the robot that interference zone 4 is clear to enter.

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Reference the AME zone logic standard for further information.





UserInput1 41 This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input.








GoToPickup1 49 This robot input is used to signal the robot to continue its program to the pickup 1 position.

ExitPickup1 50 This robot input is used to signal the robot to continue its program from the pickup 1 position.

GoToDropoff1 51 This robot input is used to signal the robot to continue its program to the dropoff 1 position.

ExitDropoff1 52 This robot input is used to signal the robot to continue its program from the dropoff 1 position.













Part1InFixture 65 This robot input is used to signal the robot that part 1 is present in the tooling fixture.



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App1ClrToEnter 71 This robot input is used to signal the robot that the process application 1 fixture/area is clear for the robot to enter.

App2ClrToEnter 72 This robot input is used to signal the robot that the process application 2 fixture/area is clear for the robot to enter.

ToolInNest1 73 This robot input is used to inform the robot there is a tool present in nest 1.




PickTool1 77 This robot input along with the next three bits, (PickTool2 – PickTool8) grouped as “Group Inputs”, are used to signal the robot to pick up a specific tool. The group inputs are viewed as the binary bit weight in a decimal fashion.

PickTool2 78 Reference description: “PickTool1”



Clr2EntToolNest 81 This robot input is used to signal the robot that the tool nest(s) is clear to enter.

ToolingRepod1 82 This robot input along with the next two bits, (ToolingRepod2 – ToolingRepod4) grouped as “Group Inputs”, are used to signal the robot that the tooling/fixture/dumps are repositioned. The group inputs are viewed as the binary bit weight in a decimal fashion.

ToolingRepod2 83 Reference description: “ToolingRepod1”

Spare 84 This robot input is not currently used.

PalletPosBit1 85 This robot input along with the next seven bits, (PalletPosBit2 – PalletPosBit128) grouped as “Group Inputs”, are used to signal the robot to move to a specific pallet position.

PalletPosBit2 86 Reference description: “PalletPosBit1”







WetDryMode 93 This robot input is used to signal the robot to go into Wet mode.

AbortReq 94 This robot input is used to signal the robot to run an Abort routine.

PurgeGun1Req 95 This robot input is used to signal the robot to execute a purge sequence for dispenser 1.

PurgeGun2Req 96 This robot input is used to signal the robot to execute a purge sequence for dispenser 2.

WaterFlowOK 97 This robot input is used to signal the robot that water flow is OK.

StartUpPurge 98 This robot input is used during the sealer purge process to instruct the robot to execute a longer purge time due to the enabling of the sealer unit from conservation mode.

TipDressDumpExtd 99 This robot input is used to signal the robot that the tip dresser dump is extended.

TipDrsDumpRetrct 100 This robot input is used to signal the robot that the tip dresser dump is retracted.

TipDrsMotorOn 101 This robot input is used to signal the robot that the tip dresser motor is running.

ExtStepperReset1 102 This robot input is used to signal the robot to reset weld controller stepper 1.

ExtStepperReset2 103 This robot input is used to signal the robot to reset weld controller stepper 2.

TipBurnInReq 104 This robot input is used to call the tip burn in program from the work program while the robot is at home position and from the wait for dropoff position. (Requires input looping)

TipChgReq 105 This robot input is used to call the tip change program from the work program while the robot is at home position and from the wait for dropoff position. (Requires input looping)

InspectRequired 106 This robot input is used to signal the robot to execute the inspection process.

InspectComplete 107 This robot input is used to signal the robot to return from inspection position.

ClrToExitUsrPos1 108 This robot input is used to signal the robot that it is clear to exit user position 1.


AS OF 1/12/2012 16 CUSW REL1.3





ExtApp1StartReq 113 This robot input is used to signal the robot to tell dispense controller 1 to initiate a remote start.

ExtApp1Complete 114 This robot input is used to signal the robot that external application 1 is complete.

ExtApp2StartReq 115 This robot input is used to signal the robot to tell dispense controller 2 to initiate a remote start.

ExtApp2Complete 116 This robot input is used to signal the robot that external application 2 is complete.

Reseal 117 This robot input is used to execute a Reseal process.

RejectPart 118 This robot input is used to execute a Reject Part process

NoSafeSpeed1 119 This robot input is used to drop the robot into a slow speed during part inspection.

ReweldStud 120 This robot input is used to command the robot to issue a Reweld Stud command. (Fault Ack and Start1 or Start2 to ST/W.

AcceptStud/Part 121 This robot input is used to command the robot to issue a Accept Stud command. (Fault Ack to ST/W and Weld Complete to robot) Accept Part (MH application)

RejectStud 122 This robot input is used to command the robot to issue a Reject Stud command. (Fault Ack to ST/W and Weld Complete and JumpLbl to Dropoff to the robot.

ChangedHead 123 This robot input is used to instruct the robot that the ST/W head has been changed.

StudSlide1InPos 124 This robot input indicates to the robot, that studwelder 1 is in the weld position.

StudSlide2InPos 125 This robot input indicates to the robot, that studwelder 2 is in the weld position.

PickOverrideReq 126 This robot input indicates to the robot to execute the pick override section of the program

TipDressBypass 127 This robot input indicates to the robot that the tip dresser is in bypass.

NoSafeSpeed2 128 This robot input is used to drop the robot into a slow speed during part inspection.

Reference DCX Book of Implementation Guidelines for proper Tag and UDT Naming – Design standards for Control Logix AMS 0220 Section 9.3.2, 7.0 Tag – DeviceNet Tag Naming Guidelines, Starting on page 28.

AS OF 1/12/2012 17 CUSW REL1.3


ROBOT OUTPUTS

ROBOT INPUTS SAFETY PLC COMMUNICATIONS

SAFETY PLC COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS SIGNAL NAME

NODE ADDRESS

ROBOT ADDRESS SIGNAL NAME

1 CSO 1 ESPB

1 CSI 1 EES

1 CSO 2 RB MTR OFF

1 CSI 2 EGS

1 CSO 3 AUTO

1 CSI 3 SW24V

1 CSO 4 AXP1 MON

1 CSI 4 TC24V

1 CSO 5 TC24V MON

1 CSI 5 spare

1 CSO 6 spare

1 CSI 6 spare

1 CSO 7 DM MON

1 CSI 7 spare

1 CSO 8 CSBP

1 CSI 8 spare

1 CSO 9 spare

1 CSI 9 spare

1 CSO 10 Joint 1 Zone Disabled

1 CSI 10 Joint 1 Zone Disable

1 CSO 11 Joint 2 Zone Disabled

1 CSI 11 Joint 2 Zone Disable

1 CSO 12 spare

1 CSI 12 spare

1 CSO 13 spare

1 CSI 13 spare

1 CSO 14 spare

1 CSI 14 spare

1 CSO 15 spare

1 CSI 15 spare

1 CSO 16 spare

1 CSI 16 spare

RTU Auto Lube I/O

RTU Auto Lube I/O Robot Input # Name

Robot Output # Name

1 PinionCRMon

1 PinionLubeOn 2 BearingCRMon

2 BearingLubeOn

3 Pinion24VOkMon

3 4 Bearing24VOkMon

4

5 Pinion24VOk

5 6 Bearing24VOk

6

7

7 8

8

AS OF 1/12/2012 18 CUSW REL1.3


ROBOT IO MAP ASSIGNMENTS

ROBOT COMMUNICATION OUTPUT

ASSIGNMENTS INPUT

ASSIGNMENTS NODE NUMBER PLC COMMUNICATIONS DO [1 - 128] DI [1 - 128] 1

SPARES DO [129 - 192] DI [129 - 192]

PRECITEC DO [193 - 352] DI [193 - 352] 10

SPOT WELD SCR#1 DO [193 - 224] DI [193 - 224] 11




NELSON STUD WELDER DO [321 - 384] DI [321 - 384] 16

DISPENSE #1 DO [385 - 448] DI [385 - 448] 25

DISPENSE #2 DO [449 - 512] DI [449 - 512] 26

MH EOAT MODULE #1 INPUT DI [513 - 528] 31





MH EOAT MODULE #1 OUTPUT DO [513 - 544] 39

MH EOAT MODULE MISC OUTPUT DO [545 - 576] 36

SPARE DO [577 - 585]

MH EOAT VAC MODULE #1 DO [593 - 600] DI [593 - 600] 37

MH EOAT VAC MODULE #2 DO [601 - 608] DI [601 - 608] 38

USER DEFINABLE IO #1 DO [609 - 616] DI [609 - 616] 43

USER DEFINABLE IO #2 DO [617 - 624] DI [617 - 624] 44

SPARE DO [625 - 631] DI [625 - 631]

ATI TOOLCHANGER DO [632 - 639] DI [632 - 695] 54

ATI TOOLCHANGER (Robot Internal) DO [640 - 654]

SPARES DO [640 - 695]

FORM & PIERCE MOOG DO [696 - 727] DI [696 - 727] 48

FORM & PIERCE CLINCH NUT-FEEDER DO [728 - 743] DI [728 - 743] 49

FORM & PIERCE CLINCH NUT-TOOL DO [744 - 759] DI [744 - 759] 50

FORM & PIERCE PUMP DO [760 - 767] DI [760 - 767] 51

Mig Weld Reamer DO (768- 775) DI (768 - 775) 46

SPARES DO [776 - 784] DI [776 - 784]

TOOLCHANGER COVER / NEST #1 55




IPG_LASERWELD_GENERATOR (ASME) DO [785 - 800] DI [785 - 800] 17

HIGHYAG_HEAD (ASME) DO [817 - 848] DI [817 - 848] 18

LaserCut Head DO [849 - 856] DO [849 - 856] 19

GrinderMod1 DO [857 - 864] DO [857 - 864] 20

GrinderMod2 DO [865 - 872] DO [865 - 872] 21

GrinderAnalogMod1 AL 1-1 AL 2-2 AL 1-1 AL 2-2 22

GrinderAnalogMod2 AL 1-1 AL 2-2 AL 1-1 AL 2-2 23

Laser Cut Field I/O DO (776- 783) DI (776 - 783) 24

ISRA OR OTHER VISION DO [913 - 944] DI [913 - 1024] 60

APP ERROR SPARES DO [945 - 1024]

AS OF 1/12/2012 19 CUSW REL1.3


ROBOT BIT MAP

ROBOT OUTPUTS ROBOT INPUTS

PLC COMMUNICATIONS PLC COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS

GROUP ASSIGNMENT SIGNAL NAME

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


1 DO 1 Y 0.0 RobotInAuto 1 DI 1 X 0.0 NOHold

1 DO 2 Y 0.1 RobotFaulted 1 DI 2 X 0.1 Resume

1 DO 3 Y 0.2 WaitForTPInput 1 DI 3 X 0.2 FaultReset

1 DO 4 Y 0.3 InCycle 1 DI 4 X 0.3 20HourRunMode

1 DO 5 Y 0.4 CollisionDetd 1 DI 5 X 0.4 ReqToEnter

1 DO 6 Y 0.5 IOSimulated 1 DI 6 X 0.5 LaserEnable1

1 DO 7 Y 0.6 WldEnabled 1 DI 7 X 0.6 LaserGuideOn

1 DO 8 Y 0.7 RobotReady 1 DI 8 X 0.7 AppErrorAck

1 DO 9 Y 1.0 GO[1] ActiveStyBit1 1 DI 9 X 1.0 GI[1] STYLEBit1







1 DO 16 Y 1.7 PrgPaused 1 DI 16 X 1.7 WeldGunForceChk

1 DO 17 Y 2.0 PrgRunning 1 DI 17 X 2.0 InterferenceClr1

1 DO 18 Y 2.1 RobotAtWork 1 DI 18 X 2.1 InterferenceClr2

1 DO 19 Y 2.2 WorkComplete 1 DI 19 X 2.2 AcceptVolume

1 DO 20 Y 2.3 20HourRunModeAct 1 DI 20 X 2.3 VolumeFltReset

1 DO 21 Y 2.4 GO[5] MaintReqBit1 1 DI 21 X 2.4 PPOK_ClrToGrip

1 DO 22 Y 2.5 GO[5] MaintReqBit2 1 DI 22 X 2.5 GripOK_ClrToExit

1 DO 23 Y 2.6 GO[5] MaintReqBit4 1 DI 23 X 2.6 AbortExitPick

1 DO 24 Y 2.7 GO[5] MaintReqBit8 1 DI 24 X 2.7 AbortExitDrop

1 DO 25 Y 3.0 RobotAtPounce 1 DI 25 X 3.0 RetFromPounce

1 DO 26 Y 3.1 RobotAtService 1 DI 26 X 3.1 ServiceCompltReq

1 DO 27 Y 3.2 RobotAtHome 1 DI 27 X 3.2 ServiceRequest

1 DO 28 Y 3.3 RobotInTipDress 1 DI 28 X 3.3 TipDressGunReq

1 DO 29 Y 3.4 TipDressComplt 1 DI 29 X 3.4 ProdStart

1 DO 30 Y 3.5 RdyForTipChg 1 DI 30 X 3.5 Spare

1 DO 31 Y 3.6 CleartoTransfer 1 DI 31 X 3.6 GoToWork

1 DO 32 Y 3.7 WldInPrgrsActiv1 1 DI 32 X 3.7 WorkCompleteAck

1 DO 33 Y 4.0 RbtClrZone1 1 DI 33 X 4.0 Zone1ClrToEnter








1 DO 41 Y 5.0 UserOutput1 1 DI 41 X 5.0 UserInput1








1 DO 49 Y 6.0 ClrOfPickup1 1 DI 49 X 6.0 GoToPickup1

1 DO 50 Y 6.1 AtPickup1 1 DI 50 X 6.1 ExitPickup1

1 DO 51 Y 6.2 ClrOfDropoff1 1 DI 51 X 6.2 GoToDropoff1

1 DO 52 Y 6.3 AtDropoff1 1 DI 52 X 6.3 ExitDropoff1













1 DO 65 Y 8.0 Clr2UnclampEarly 1 DI 65 X 8.0 Part1InFixture

1 DO 66 Y 8.1 RbtAtUserPos1 1 DI 66 X 8.1 Part2InFixture




1 DO 70 Y 8.5 Spare 1 DI 70 X 8.5 Part6InFixture

1 DO 71 Y 8.6 Req2EntrToolNest 1 DI 71 X 8.6 App1ClrToEnter

AS OF 1/12/2012 20 CUSW REL1.3



PLC COMMUNICATIONS PLC COMMUNICATIONS 1 DO 72 Y 8.7 ClearOfToolNest 1 DI 72 X 8.7 App2ClrToEnter

1 DO 73 Y 9.0 ServiceComp 1 DI 73 X 9.0 ToolInNest1

1 DO 74 Y 9.1 MajorMinorFlt 1 DI 74 X 9.1 ToolInNest2

1 DO 75 Y 9.2 WaitingForPlcCmd 1 DI 75 X 9.2 ToolInNest3

1 DO 76 Y 9.3 RemoveFault 1 DI 76 X 9.3 ToolInNest4

1 DO 77 Y 9.4 RobotPartPres1 1 DI 77 X 9.4 GI[4] PickTool1




1 DO 81 Y 10.0 RobotPartPres5 1 DI 81 X 10.0 Clr2EntToolNest

1 DO 82 Y 10.1 RobotPartPres6 1 DI 82 X 10.1 GI[5] ToolingRepod1

1 DO 83 Y 10.2 RobotPartPres7 1 DI 83 X 10.2 GI[5] ToolingRepod2

1 DO 84 Y 10.3 RobotPartPres8 1 DI 84 X 10.3 Spare

1 DO 85 Y 10.4 RobotPartPres9 1 DI 85 X 10.4 GI[6] PalletPosBit1

1 DO 86 Y 10.5 RobotPartPres10 1 DI 86 X 10.5 GI[6] PalletPosBit2

1 DO 87 Y 10.6 LaserEnbld 1 DI 87 X 10.6 GI[6] PalletPosBit4

1 DO 88 Y 10.7 HYagEnbld 1 DI 88 X 10.7 GI[6] PalletPosBit8

1 DO 89 Y 11.0 PickOverride 1 DI 89 X 11.0 GI[6] PalletPosBit16

1 DO 90 Y 11.1 CollisGuardEnbld 1 DI 90 X 11.1 GI[6] PalletPosBit32

1 DO 91 Y 11.2 AirOK 1 DI 91 X 11.2 GI[6] PalletPosBit64

1 DO 92 Y 11.3 AirPressAcptRng 1 DI 92 X 11.3 GI[6] PalletPosBit128

1 DO 93 Y 11.4 WetDryMode 1 DI 93 X 11.4 WetDryMode

1 DO 94 Y 11.5 AbortPickReq 1 DI 94 X 11.5 AbortReq

1 DO 95 Y 11.6 TipDressReq 1 DI 95 X 11.6 PurgeGun1Req

1 DO 96 Y 11.7 Spare 1 DI 96 X 11.7 PurgeGun2Req

1 DO 97 Y 12.0 ExtPurg1InProgrs 1 DI 97 X 12.0 WaterFlowOK

1 DO 98 Y 12.1 ExtPurg2InProgrs 1 DI 98 X 12.1 StartUpPurge

1 DO 99 Y 12.2 WaterOn 1 DI 99 X 12.2 TipDressDumpExtd

1 DO 100 Y 12.3 WaterOff 1 DI 100 X 12.3 TipDrsDumpRetrct

1 DO 101 Y 12.4 TurnOnTipDresser 1 DI 101 X 12.4 TipDrsMotorOn

1 DO 102 Y 12.5 StepperRstAck 1 DI 102 X 12.5 ExtStepperReset1

1 DO 103 Y 12.6 StepMode 1 DI 103 X 12.6 ExtStepperReset2

1 DO 104 Y 12.7 RobotAtPurgePos 1 DI 104 X 12.7 TipBurnInReq

1 DO 105 Y 13.0 RobotClrFixt1 1 DI 105 X 13.0 TipChgReq

1 DO 106 Y 13.1 RobotClrFixt2 1 DI 106 X 13.1 InspectRequired

1 DO 107 Y 13.2 TipBurnInComp 1 DI 107 X 13.2 InspectComplete

1 DO 108 Y 13.3 Spare 1 DI 108 X 13.3 ClrToExitUsrPos1

1 DO 109 Y 13.4 GO[2] ReposTooling1 1 DI 109 X 13.4 ClrToExitUsrPos2

1 DO 110 Y 13.5 GO[2] ReposTooling2 1 DI 110 X 13.5 ClrToExitUsrPos3

1 DO 111 Y 13.6 SignatureChgInd 1 DI 111 X 13.6 ClrToExitUsrPos4

1 DO 112 Y 13.7 RbtAtInspectPos 1 DI 112 X 13.7 ClrToExitUsrPos5

1 DO 113 Y 14.0 TeachPendantEnbd 1 DI 113 X 14.0 ExtApp1StartReq

1 DO 114 Y 14.1 StartExtApp1Proc 1 DI 114 X 14.1 ExtApp1Complete

1 DO 115 Y 14.2 StartExtApp1Proc 1 DI 115 X 14.2 ExtApp2StartReq

1 DO 116 Y 14.3 GO[3] ToolIDOnWrist1 1 DI 116 X 14.3 ExtApp2Complete

1 DO 117 Y 14.4 GO[3] ToolIDOnWrist2 1 DI 117 X 14.4 Reseal

1 DO 118 Y 14.5 GO[3] ToolIDOnWrist4 1 DI 118 X 14.5 RejectPart

1 DO 119 Y 14.6 ProcessFault 1 DI 119 X 14.6 NoSafeSpeed1

1 DO 120 Y 14.7 AppErrorActive 1 DI 120 X 14.7 ReweldStud

1 DO 121 Y 15.0 GO[4] AppErorrBit1 1 DI 121 X 15.0 AcceptStud/Part

1 DO 122 Y 15.1 GO[4] AppErrorBit2 1 DI 122 X 15.1 RejectStud

1 DO 123 Y 15.2 GO[4] AppErrorBit4 1 DI 123 X 15.2 ChangedHead

1 DO 124 Y 15.3 GO[4] AppErrorBit8 1 DI 124 X 15.3 StudSlide1InPos

1 DO 125 Y 15.4 GO[4] AppErrorBit16 1 DI 125 X 15.4 StudSlide2InPos

1 DO 126 Y 15.5 GO[4] AppErrorBit32 1 DI 126 X 15.5 PickOverrideReq

1 DO 127 Y 15.6 GO[4] AppErrorBit64 1 DI 127 X 15.6 TipDressBypass

1 DO 128 Y 15.7 GO[4] AppErrorBit128 1 DI 128 X 15.7 NoSafeSpeed2

AS OF 1/12/2012 21 CUSW REL1.3



PLC COMMUNICATIONS Precitec PLC COMMUNICATIONS Precitec

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


1 DO 129 Part OK 1 DI 129 Part No Bit 0

1 DO 130 Part Not OK 1 DI 130 Part No Bit 1 1 DO 131 Inspection Incomplete 1 DI 131 Part No Bit 2 1 DO 132 Line Stop 1 DI 132 Part No Bit 3 1 DO 133 Not OK Left Side 1 DI 133 Part No Bit 4 1 DO 134 Not OK Right Side 1 DI 134 Part No Bit 5 1 DO 135 Reserved 1 DI 135 Part No Bit 6 1 DO 136 Reserved 1 DI 136 Part No Bit 7 1 DO 137 Seam Fault Generic Term A 1 DI 137 Part No Bit 8 1 DO 138 Seam Fault Generic Term B 1 DI 138 Part No Bit 9 1 DO 139 Seam Fault Generic Term C 1 DI 139 Part No Bit 10 1 DO 140 Reserved 1 DI 140 Part No Bit 11 1 DO 141 Reserved 1 DI 141 Part No Bit 12 1 DO 142 Reserved 1 DI 142 Part No Bit 13 1 DO 143 Reserved 1 DI 143 Part No Bit 14 1 DO 144 Reserved 1 DI 144 Part No Bit 15 1 DO 145 System Ready 1 DI 145 Part No Bit 16 1 DO 146 Spare 1 DI 146 Part No Bit 16 1 DO 147 Spare 1 DI 147 Part No Bit 18 1 DO 148 Spare 1 DI 148 Part No Bit 19 1 DO 149 Spare 1 DI 149 Part No Bit 20 1 DO 150 Spare 1 DI 150 Part No Bit 21 1 DO 151 Spare 1 DI 151 Part No Bit 22 1 DO 152 Spare 1 DI 152 Part No Bit 23 1 DO 153 Spare 1 DI 153 Part No Bit 24 1 DO 154 Spare 1 DI 154 Part No Bit 25 1 DO 155 Spare 1 DI 155 Part No Bit 26 1 DO 156 Spare 1 DI 156 Part No Bit 27 1 DO 157 Spare 1 DI 157 Part No Bit 28 1 DO 158 Spare 1 DI 158 Part No Bit 29 1 DO 159 Spare 1 DI 159 Part No Bit 30 1 DO 160 Spare 1 DI 160 Part No Bit 31 1 DO 161 Spare 1 DI 161 Part Type Bit 0

1 DO 162 Spare 1 DI 162 Part Type Bit 1 1 DO 163 Spare 1 DI 163 Part Type Bit 2 1 DO 164 Spare 1 DI 164 Part Type Bit 3 1 DO 165 Spare 1 DI 165 Part Type Bit 4 1 DO 166 Spare 1 DI 166 Part Type Bit 5 1 DO 167 Spare 1 DI 167 Part Type Bit 6 1 DO 168 Spare 1 DI 168 Part Type Bit 7 DO 169 Spare DI 169 Spare

DO 170 Spare DI 170 Spare























AS OF 1/12/2012 22 CUSW REL1.3



PRECITEC COMMUNICATIONS PRECITEC COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


10 DO 193 Y 0.0 Seam Sequence number Bit 0 10 DI 193 X 0.0 System fault: no laserlines

10 DO 194 Seam Sequence number Bit 1 10 DI 194 System fault: no flasht

10 DO 195 Seam Sequence number Bit 2 10 DI 195 System fault: camera problem

10 DO 196 Seam Sequence number Bit 3 10 DI 196 System fault: reserved

10 DO 197 Seam Sequence number Bit 4 10 DI 197 System fault: internal software problem

10 DO 198 Seam Sequence number Bit 5 10 DI 198 System fault: autofocus-axis



10 DO 201 Seam number Bit 0 10 DI 201 System fault: wrong position of sensor head

10 DO 202 Seam number Bit 1

10 DI 202 System fault: seam start/seam end not detected

10 DO 203 Seam number Bit 2 10 DI 203 System fault: reserved


10 DO 205 Seam number Bit 4

10 DI 205 System fault: Air conditioner / cabinet temperature

10 DO 206 Seam number Bit 5 10 DI 206 System fault: inkjet has fault

10 DO 207 Seam number Bit 6 10 DI 207 System fault: inkjet has warning


10 DO 209 Inspection part active 10 DI 209 Part OK (OK=1)

10 DO 210 Take-over Seam Seq. No 10 DI 210 Part NOK (NOK = 1)

10 DO 211 Inspection seam active 10 DI 211 Inspection incomplete

10 DO 212 Linelaser on 10 DI 212 Linestop (Stop = 1)

10 DO 213 No images 10 DI 213 NOK left side

10 DO 214 Air nozzle on 10 DI 214 NOK right side

10 DO 215 Select inkjet 10 DI 215 reserved

10 DO 216 reserved 10 DI 216 reserved

10 DO 217 Error code left 10 DI 217 Seam fault generic term A

10 DO 218 Error code right 10 DI 218 Seam fault generic term B

10 DO 219 reserved 10 DI 219 Seam fault generic term C






10 DO 225 Quit system fault 10 DI 225 System ready (collective signal)

10 DO 226 reserved 10 DI 226 Sensor ready

10 DO 227 reserved 10 DI 227 Inkjet ready














10 DO 241 Calibration active 10 DI 241 Calibration request

10 DO 242 reserved 10 DI 242 Calibration finished

10 DO 243 reserved 10 DI 243 Calibration OK

10 DO 244 reserved 10 DI 244 Calibration NOK




















AS OF 1/12/2012 23 CUSW REL1.3











10 DO 273 Part-No Bit 0 (Year Bit 0) 10 DI 273 Part-No Bit 0 (Year Bit 0)




10 DO 277 Part-No Bit 4 (Day Bit 0) 10 DI 277 Part-No Bit 4 (Day Bit 0)












10 DO 289 Part-No Bit 16 (Current no Bit 0) 10 DI 289 Part-No Bit 16 (Current no Bit 0)










10 DO 299 Part-No Bit 26 (Current no Bit 10)

10 DI 299 Part-No Bit 26 (Current no Bit 10)











10 DO 305 Part-No Bit 32 10 DI 305 Part-No Bit 32
















10 DO 321 Part-Type Bit 0 10 Part-Type Bit 0








10 DO 329 reserved 10 reserved











AS OF 1/12/2012 24 CUSW REL1.3















Note: Configuration of the Precitec must done manually by the robot programmer. The robot must be set up with the custo as

a material handling robot and spotwelding and studwelding cannot be configured.

AS OF 1/12/2012 25 CUSW REL1.3



SPOT WELD SCR#1 COMMUNICATIONS SPOT WELD SCR#1 COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


11 DO 193 Y 0.0 W1EnableWld 11 DI 193 X 0.0 W1WeldEnabled

11 DO 194 W1FaultRst 11 DI 194 W1NoFault

11 DO 195 W1WldFltAck 11 DI 195 W1NoAlert

11 DO 196 GO[11] W1PrgBit1 11 DI 196 W1WeldFltAvail

11 DO 197 GO[11] W1PrgBit2 11 DI 197 GI[11] W1WeldFltBit1





11 DO 202 W1InitiateWld 11 DI 202 W1WeldComplete

11 DO 203 W1PressTest 11 DI 203 W1WeldInProgres

11 DO 204 W1InitRet 11 DI 204 W1SteppersReset

11 DO 205 W1RstStepper 11 DI 205 W1NearEndOfStep

11 DO 206 W1IsoContSvrEnb 11 DI 206 W1EndOfStepper

11 DO 207 W1ControlStop 11 DI 207 W1ReadyToWeld

11 DO 208 W1Tipsdressed 11 DI 208 W1DressTipsReq

11 DO 209 GO[12] W1WldIDBit1 11 DI 209 W1RetractOut#1


11 DO 211 GO[12] W1WldIDBit4 11 DI 211 W1FltMSGCode

11 DO 212 GO[12] W1WldIDBit8 11 DI 212 W1AlrtMSGCode

11 DO 213 GO[12] W1WldIDBit16 11 DI 213 Spare










11 DO 223 Spare 11 DI 223 Spare




NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


































AS OF 1/12/2012 26 CUSW REL1.3




NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS




































NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


































AS OF 1/12/2012 27 CUSW REL1.3



NELSON STUD WELDER COMMUNICATIONS NELSON STUD WELDER COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


16 DO 321 Y 0.0 StartWeld1 16 DI 321 X 0.0 NOError1

16 DO 322 StartWeld2 16 DI 322 WeldComp1

16 DO 323 StartWeld3 16 DI 323 WeldGunRetrctd1

16 DO 324 StartWeld4 16 DI 324 StudTouchingWrk1

16 DO 325 StartWeld5 16 DI 325 SuspectWeld1

16 DO 326 FeedStud1 16 DI 326 NOError2

16 DO 327 FeedStud2 16 DI 327 WeldComp2

16 DO 328 FeedStud3 16 DI 328 WeldGunRetrctd2

16 DO 329 FeedStud4 16 DI 329 StudTouchingWrk2

16 DO 330 FeedStud5 16 DI 330 SuspectWeld2

16 DO 331 GO[21] SelectProgBit1 16 DI 331 NOError3

16 DO 332 GO[21] SelectProgBit2 16 DI 332 WeldComp3

16 DO 333 GO[21] SelectProgBit4 16 DI 333 WeldGunRetrctd3

16 DO 334 GO[21] SelectProgBit8 16 DI 334 StudTouchingWrk3

16 DO 335 GO[21] SelectProgBit16 16 DI 335 SuspectWeld3

16 DO 336 GO[21] SelectProgBit32 16 DI 336 NOError4

16 DO 337 GO[21] SelectProgBit64 16 DI 337 WeldComp4

16 DO 338 GO[21] SelectProgBit128 16 DI 338 WeldGunRetrctd4

16 DO 339 Restart 16 DI 339 StudTouchingWrk4

16 DO 340 SetWeldComp 16 DI 340 SuspectWeld4

16 DO 341 GO[22] SelectOperMode0 16 DI 341 NOError5

16 DO 342 GO[22] SelectOperMode1 16 DI 342 WeldComp5

16 DO 343 ResetFault 16 DI 343 WeldGunRetrctd5

16 DO 344 Std1Output24 16 DI 344 StudTouchingWrk5

16 DO 345 Std1Output25 16 DI 345 SuspectWeld5

16 DO 346 Std1Output26 16 DI 346 MaintCountReachd

16 DO 347 Std1Output27 16 DI 347 FeederLow

16 DO 348 Std1Output28 16 DI 348 UnitOnline

16 DO 349 Std1Output29 16 DI 349 AllGunsReady

16 DO 350 Std1Output30 16 DI 350 SimModeActive

16 DO 351 Std1Output31 16 DI 351 Std1Input31


16 DO 353 Std1Output33 16 DI 353 GI[22] ErrorCodeBit1
















16 DO 369 AdvWeldGun1 16 DI 369 Std1Input49
















AS OF 1/12/2012 28 CUSW REL1.3



NORDSON DISPENSE (PS2) #1 COMMUNICATIONS NORDSON DISPENSE (PS2) #1 COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


25 DO 385 Y 0.0 GO[31] Disp1StyBit1 25 DI 385 X 0.0 Dsp1DispenRdy

25 DO 386 GO[31] Disp1StyBit2 25 DI 386 Dsp1DispenInPrc

25 DO 387 GO[31] Disp1StyBit3 25 DI 387 Dsp1VolumeOK

25 DO 388 GO[31] Disp1StyBit4 25 DI 388 Reserved





25 DO 393 Disp1RbtinPrc 25 DI 393 Dsp1LowVolFlt

25 DO 394 Disp1StyStrobe 25 DI 394 Dsp1HighVolFlt

25 DO 395 Disp1GunON 25 DI 395 Dsp1LowPressFlt

25 DO 396 Reserved 25 DI 396 Dsp1HighPressFlt

25 DO 397 Disp1ManPurgeEnbl 25 DI 397 Dsp1ColDetd

25 DO 398 Reserved 25 DI 398 Reserved



25 DO 401 Disp1Complete 25 DI 401 Reserved
















25 DO 417 GO[32] Dsp1MatFlwCmdB1 25 DI 417 Reserved































25 DO 448 Disp1FaultRst 25 DI 448 Reserved

AS OF 1/12/2012 29 CUSW REL1.3



NORDSON DISPENSE (PS2) #2 COMMUNICATIONS NORDSON DISPENSE (PS2) #2 COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


26 DO 449 Y 0.0 GO[36] Disp2StyBit1 26 DI 449 X 0.0 Dsp2DispenRdy

26 DO 450 GO[36] Disp2StyBit2 26 DI 450 Dsp2DispenInPrc

26 DO 451 GO[36] Disp2StyBit3 26 DI 451 Dsp2VolumeOK






26 DO 457 Disp2RbtinPrc 26 DI 457 Dsp2LowVolFlt

26 DO 458 Disp2StyStrobe 26 DI 458 Dsp2HighVolFlt

26 DO 459 Disp2GunON 26 DI 459 Dsp2LowPressFlt

26 DO 460 Reserved 26 DI 460 Dsp2HighPressFlt

26 DO 461 Disp2ManPurgeEnbl 26 DI 461 Dsp2ColDetd




26 DO 465 Disp2Complete 26 DI 465 Reserved















































26 DO 512 Disp2FaultRst 26 DI 512 Reserved

AS OF 1/12/2012 30 CUSW REL1.3



MH EOAT MODULE #1 OUTPUT COMMUNICATIONS (SMC) MH EOAT MODULE #1 INPUT COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS

ROBOT INTERNAL

ASSIGNMENT SIGNAL NAME NODE

ADDRESS ROBOT

ADDRESS PMC

ADDRESS GROUP

ASSIGNMENT SIGNAL NAME

39 DO 513 K0.0 DO 10001 VLV1Extend 31 DI 513 X 0.0 Part1Present

39 DO 514 K0.1 DO 10002 VLV1Retract 31 DI 514 Part2Present

39 DO 515 K0.2 DO 10003 VLV2Extend 31 DI 515 Part3Present


39 DO 517 K0.4 DO 10005 VLV3Extend 31 DI 517 MHDev1Retracted

39 DO 518 K0.5 DO 10006 VLV3Retract 31 DI 518 MHDev1Extended











39 DO 529 K2.0 DO 10017 VLV9Extend

39 DO 530 K2.1 DO 10018 VLV9Retract ROBOT INPUTS

39 DO 531 K2.2 DO 10019 VLV10Extend MH EOAT MODULE #2 INPUT COMMUNICATIONS

39 DO 532 K2.3 DO 10020 VLV10Retract NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


39 DO 533 K2.4 DO 10021 VLV11Extend 32 DI 529 X 0.0 Part5Present


39 DO 535 K2.6 DO 10023 VLV12Extend 32 DI 531 Part7Present










32 DI 541 MHDev11Retracted

32 DI 542 MHDev11Extended



AS OF 1/12/2012 31 CUSW REL1.3


ROBOT OUTPUTS

MH EOAT MODULE MISC OUTPUT COMMUNICATIONS ROBOT INPUTS

(AB) COMBO EOAT VAC/CLAMPS/MISC MH EOAT MODULE #3 INPUT COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


36 DO 545 Y 0.0 User Define Output1 33 DI 545 X 0.0 Part9Present

36 DO 546 User Define Output2 33 DI 546 Part10Present



36 DO 549 User Define Output5 33 DI 549 MHDev13Retracted

36 DO 550 User Define Output6 33 DI 550 MHDev13Extended











36 DO 561 User Define Output17

36 DO 562 User Define Output18 ROBOT INPUTS

36 DO 563 User Define Output19 MH EOAT MODULE #4 INPUT COMMUNICATIONS

36 DO 564 User Define Output20

NODE

ADDRESS ROBOT

ADDRESS PMC

ADDRESS GROUP


36 DO 565 User Define Output21 34 DI 561 X 0.0 MHDev19Retracted













ROBOT OUTPUTS 34 DI 574 MHDev25Extended

OUTPUT COMMUNICATIONS 34 DI 575 MHDev26Retracted

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS



DO 577 Spare

DO 578 Spare ROBOT INPUTS

DO 579 Spare MH EOAT MODULE #5 INPUT COMMUNICATIONS

DO 580 Spare NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


DO 581 Spare 35 DI 577 X 0.0 MHDev27Retracted

DO 582 Spare 35 DI 578 MHDev27Extended

DO 583 Spare 35 DI 579 MHDev28Retracted

DO 584 Spare 35 DI 580 MHDev28Extended

DO 585 Spare 35 DI 581 MHDev29Retracted


ROBOT OUTPUTS 35 DI 583 MHDev30Retracted

SPOT TP LOGIC COMMUNICATIONS 35 DI 584 MHDev30Extended

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS



RbtInternal DO 586 Y0073.1 W1RstWtrSvr 35 DI 586 MHDev31Extended

RbtInternal DO 587 Y0073.2 W1WtrOff 35 DI 587 MHDev32Retracted

RbtInternal DO 588 Y0073.3 W2RstWtrSvr 35 DI 588 MHDev32Extended

RbtInternal DO 589 Y0073.4 W2WtrOff 35 DI 589 MHDev33Retracted

RbtInternal DO 590 Y0073.5 W1RstStepper 35 DI 590 MHDev33Extended

RbtInternal DO 591 Y0073.6 W2RstStepper 35 DI 591 MHDev34Retracted


AS OF 1/12/2012 32 CUSW REL1.3


ROBOT OUTPUTS

MH EOAT COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


RbtInternal DO 592 MH_MAJORFLT


MH EOAT VAC MODULE #1 OUTPUT COMMUNICATIONS MH EOAT VAC MODULE #1 INPUT COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


37 DO 593 Y 0.0 doVacCH1On 37 DI 593 X 0.0 VacuumCH1PP

37 DO 594 doBlwOffCh1On 37 DI 594 VacuumCH2PP

37 DO 595 doVacCH2On 37 DI 595 VacuumCH3PP


37 DO 597 doVacCH3On 37 DI 597

37 DO 598 doBlwOffCh3On 37 DI 598




MH EOAT VAC MODULE #2 OUTPUT COMMUNICATIONS MH EOAT VAC MODULE #2 INPUT COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


38 DO 601 Y 0.0 doVacCH5On 38 DI 601 X 0.0 VacuumCH5PP


38 DO 603 doVacCH6On 38 DI 603 VacuumCH7PP







USER DEFINABLE IO #1 COMMUNICATIONS (AB) USER DEFINABLE IO #1 COMMUNICATIONS (AB)

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


43 DO 609 Y 0.0 UserDefineddo609 43 DI 609 X 0.0 UserDefineddi609

43 DO 610 UserDefineddo610 43 DI 610 UserDefineddi610








USER DEFINABLE IO #2 COMMUNICATIONS (AB) USER DEFINABLE IO #2 COMMUNICATIONS (AB)

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


44 DO 617 Y 0.0 UserDefineddo617 44 DI 617 X 0.0 UserDefineddi617








AS OF 1/12/2012 33 CUSW REL1.3



COMMUNICATIONS SMC PRESURE SWITCH COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


DO 625 Y 0.0 Spare 39 DI 625 X 0.0 Air OK

DO 626 Spare 39 DI 626 Air Acceptable range

DO 627 Spare 39 DI 627 Spare






ATI TOOLCHANGER COMMUNICATIONS ATI TOOLCHANGER COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


54 DO 632 Y 0.0 LatchOrLock 54 DI 632 X 0.0 ToolLocked

54 DO 633 UnlatchOrUnlock 54 DI 633 ToolUnLocked

54 DO 634 Spare 54 DI 634 DNetPowerOK

54 DO 635 ClearErrs 54 DI 635 AuxPowerOK

54 DO 636 ManualModeActd 54 DI 636 ReadyToLock1

54 DO 637 OutOfNest 54 DI 637 ReadyToLock2

54 DO 638 Spare 54 DI 638 ReadyToLockV1

54 DO 639 Spare 54 DI 639 ReadyToLockV2

54 DI 640 ToolStndIntlkV1

ROBOT OUTPUTS 54 DI 641 ToolStndIntlkV2

ATI TOOLCHANGER (ROBOT USER DEFINED) COMM. 54 DI 642 ToolStndRelayV1

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


54 DI 643 ToolStndRelayV2

N/A DO 640 ToolNotPresent 54 DI 644 ToolPresent

N/A DO 641 InvalidToolRqst 54 DI 645 ReservedTooldi13

N/A DO 642 UnexpctdTlPrsnt 54 DI 646 ReservedTooldi14

N/A DO 643 NestNotEmpty 54 DI 647 ReservedTooldi15

N/A DO 644 NestIsEmpty 54 DI 648 RTLMismatch

N/A DO 645 GeneralFaults 54 DI 649 TSIVMismatch

N/A DO 646 Reference Position 11 UnCoupleToolPos1 54 DI 650 LatchOverLoad

N/A DO 647 Reference Position 12 UnCoupleToolPos2 54 DI 651 UnlatchOverLoad

N/A DO 648 Reference Position 13 UnCoupleToolPos3 54 DI 652 SpareOverload

N/A DO 649 Reference Position 14 UnCoupleToolPos4 54 DI 653 RTLrtlvMismatch

N/A DO 650 Reference Position 15 UnCoupleToolPos5 54 DI 654 TSIVtsrvMismatch

N/A DO 651 Reference Position 16 UnCoupleToolPos6 54 DI 655 UnsafeUnlatch

N/A DO 652 Reference Position 17 UnCoupleToolPos7 54 DI 656 LckUnlckSensFlt

N/A DO 653 Reference Position 18 UnCoupleToolPos8 54 DI 657 LatchNotComplt

N/A DO 654 RbtOKtoUnCouple 54 DI 658 UnlatchNotComplt

54 DI 659 TSIVFault

54 DI 660 RTLFault

ROBOT OUTPUTS 54 DI 661 CommError

ROBOT INTERNAL COMMUNICATIONS 54 DI 662 ReservedTooldi30

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


54 DI 663 ReservedTooldi31

DO 655 Spare 54 DI 664 GI[41] ToolIDswtch1bit1












DO 667 Spare 54 DI 676 GI[44] ToolIDSwtch4bit1








DO 675 Spare 54 DI 684 UnlatchEnabled

AS OF 1/12/2012 34 CUSW REL1.3


DO 676 Spare 54 DI 685 ReservedTooldi53











DO 687 Spare

DO 688 Spare

DO 689 Spare

DO 690 Spare

DO 691 Spare

DO 692 Spare

DO 693 Spare

DO 694 Spare

DO 695 Spare


FORM & PIERCE MOOG COMMUNICATIONS FORM & PIERCE MOOG COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


48 DO 696 Y 0.0 doDrvAReset 48 DI 696 X 0.0 diDrvA_Ok

48 DO 697 48 DI 697 diDrvA_On

48 DO 698 doDrvAMode1Sel 48 DI 698

48 DO 699 doDrvAMode2Sel 48 DI 699 diDrvAHomeComp

48 DO 700 doStyleDrvALub 48 DI 700 diDrvAForce_Lub

48 DO 701 doDrvAAutomode 48 DI 701 diDrvAReturned

48 DO 702 48 DI 702 diDrvAAtPos

48 DO 703 doDrvBReset 48 DI 703

48 DO 704 48 DI 704 diDrvAMode1Ackn

48 DO 705 doDrvBMode1Sel 48 DI 705 diDrvAMode2Ackn

48 DO 706 doDrvBMode2Sel 48 DI 706

48 DO 707 doStyleDrvBLub 48 DI 707 diSr400On

48 DO 708 doDrvBAutomode 48 DI 708 diSrFuseOk

48 DO 709 48 DI 709

48 DO 710 48 DI 710

48 DO 711 48 DI 711

48 DO 712 doDrvATorqEnble 48 DI 712 diDrvB_Ok

48 DO 713 48 DI 713 diDrvB_On

48 DO 714 doDrvAExtPos1 48 DI 714

48 DO 715 doDrvARetPos2 48 DI 715 diDrvBHomeComp

48 DO 716 doDrvAPosSel 48 DI 716 diDrvBForce_Lub

48 DO 717 48 DI 717 diDrvBReturned

48 DO 718 48 DI 718 diDrvBAtPos

48 DO 719 48 DI 719

48 DO 720 doDrvBTorqEnble 48 DI 720 diDrvBMode1Ackn

48 DO 721 48 DI 721 diDrvBMode2Ackn

48 DO 722 doDrvBExtPos1 48 DI 722

48 DO 723 doDrvBRetPos2 48 DI 723

48 DO 724 doDrvBPosSel 48 DI 724

48 DO 725 48 DI 725

48 DO 726 48 DI 726

48 DO 727 48 DI 727


FORM & PIERCE CLINCH NUT-FEEDER COMMUNICATIONS FORM & PIERCE CLINCH NUT-FEEDER COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


49 DO 728 doExtendPusher 49 DI 728 diPusherExtended

49 DO 729 doReturnPusher 49 DI 729 diPusherReturned

49 DO 730 doExtendPlunger 49 DI 730 diPlungerRetrned

49 DO 731 doReturnPlunger 49 DI 731 diPlungerExtnded

49 DO 732 49 DI 732 diClinchAirOk

49 DO 733 49 DI 733

49 DO 734 49 DI 734 diFdNutPresent

49 DO 735 49 DI 735

49 DO 736 49 DI 736

49 DO 737 49 DI 737

49 DO 738 49 DI 738

49 DO 739 49 DI 739

49 DO 740 49 DI 740

49 DO 741 49 DI 741

49 DO 742 49 DI 742

49 DO 743 49 DI 743

AS OF 1/12/2012 35 CUSW REL1.3



FORM & PIERCE CLINCH NUT-TOOL COMMUNICATIONS FORM & PIERCE CLINCH NUT-TOOL COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


50 DO 744 doWkSupRetract 50 DI 744 diRbtNutPresent

50 DO 745 50 DI 745 diWorkSptRet

50 DO 746 50 DI 746

50 DO 747 50 DI 747

50 DO 748 50 DI 748

50 DO 749 50 DI 749

50 DO 750 50 DI 750

50 DO 751 50 DI 751

50 DO 752 50 DI 752

50 DO 753 50 DI 753

50 DO 754 50 DI 754

50 DO 755 50 DI 755

50 DO 756 50 DI 756

50 DO 757 50 DI 757

50 DO 758 50 DI 758

50 DO 759 50 DI 759


FORM & PIERCE PUMP COMMUNICATIONS FORM & PIERCE PUMP COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


51 DO 760 doChrgAccumultor 51 DI 760 diRobotAirOk

51 DO 761 51 DI 761

51 DO 762 doExtIntensCyl 51 DI 762 diWkAtPressure

51 DO 763 doRetIntensCyl 51 DI 763

51 DO 764 51 DI 764 diIntensCylRetd

51 DO 765 51 DI 765

51 DO 766 51 DI 766

51 DO 767 51 DI 767


Mig weld Reamers Mig weld Reamers

46 DO 768 Start 46 DI 768 Complete

46 DO 769 Spray 46 DI 769 Error








Laser Cut Field I/O

Laser Cut Field I/O

24 DO 776

Release Assist Gas

24

DI 776 Collision Sens OK

24 DO 777 Spare 24 DI 777 Collision Sens OK

24 DO 778 Spare 24 DI 778 Purge Air On

24 DO 779 Spare 24 DI 779 Purge Air Acpt Range

24 DO 780 Spare 24 DI 780 Pre Pounce Assist Gas

24 DO 781 Spare 24 DI 781 Pre-Pounce Assist gas Acpt

24 DO 782 Spare 24 DI 782 Pre-Cut Assist Gas on

24 DO 783 Spare 24 DI 783 Pre-Cut Assist Gas Acpt


AS OF 1/12/2012 36 CUSW REL1.3


NOT USED


TOOLCHANGER COVER / NEST #1 COMMUNICATIONS TOOLCHANGER COVER / NEST #1 COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


55 DO Y 0.0 Close Cover #1 55 DI X 0.0 Cover #1 Closed

55 DO Open Cover #1 55 DI Cover #1 Open

55 DO 55 DI Tool in nest #1 switch 1


55 DO 55 DI

55 DO 55 DI

55 DO 55 DI

55 DO 55 DI



NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS






56 DO 56 DI

56 DO 56 DI

56 DO 56 DI

56 DO 56 DI



NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS






57 DO 57 DI

57 DO 57 DI

57 DO 57 DI

57 DO 57 DI



NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS






58 DO 58 DI

58 DO 58 DI

58 DO 58 DI

58 DO 58 DI

AS OF 1/12/2012 37 CUSW REL1.3



IPG_Laserweld_Generator IPG_Laserweld_Generator

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


17 DO 785 doLasrRequest 17 DI 785 X 0.0 diLasrReady

17 DO 786 doLasrProgStart 17 DI 786 diLasrEmissionOn

17 DO 787 doLasrEnbPCCtrl 17 DI 787 diLasrIntrCtrlOn

17 DO 788 doLasrReset 17 DI 788 diLasrError

17 DO 789 doGuideLaserCtrl 17 DI 789 diGuideLaserOn

17 DO 790 doLasrAnalogCtrl 17 DI 790 diLasrAnalogCtrl

17 DO 791 doLasrProgStop 17 DI 791 diLasrAssigned

17 DO 792 doLasrProgLSB 17 DI 792 diLasrOn

17 DO 793 doLasrProg1 17 DI 793 diLasrProgActive

17 DO 794 doLasrProg2 17 DI 794 diLasrProgEnd

17 DO 795 doLasrProg3 17 DI 795 diLasrProgIntrpt

17 DO 796 doLasrProg4 17 DI 796 diLasrSyncOutput

17 DO 797 doLasrProg5 17 DI 797 diLasrWarning

17 DO 798 doLasrProgMSB 17 DI 798 diLasrChillWarn

17 DO 799 doLasrSyncInput 17 DI 799 diLasrChillError

17 DO 800 doLasrReserve 17 DI 800 diLasrChillReady


















HighYag HighYag

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


18 DO 817 doHYagTriggerA 18 DI 817 diHYagScanAvail

18 DO 818 doHYagProcError 18 DI 818 diHYagScanRdy

18 DO 819 doHYagLaserError 18 DI 819 diHYagScanMonitr

18 DO 820 doHYagRestScannr 18 DI 820 diHYagGenError

18 DO 821 doHYagPSelPart 18 DI 821 diHYagStructErr

18 DO 822 doHYagPSelRbtTrx 18 DI 822 diHYagScanAtWork

18 DO 823 doHYagPSelTrxPt 18 DI 823 diHYagSlideHoldr

18 DO 824 doHYagPSelSeam 18 DI 824 diHYagSlideWarn

18 DO 825 doHYagPSelRbtVel 18 DI 825 diHYagSlideError

18 DO 826 doHYagModeBit0 18 DI 826 diHYagPosError

18 DO 827 doHYagModeBit1 18 DI 827 diHYagTempError

18 DO 828 doHYagModeBit2 18 DI 828 diHYagC-JetError

18 DO 829 doHYagC-JetOnOff 18 DI 829 diHYagEnetActive

18 DO 830 doHYagReserve 18 DI 830 Spare

18 DO 831 doHYagNumBit0 18 DI 831 Spare


















AS OF 1/12/2012 38 CUSW REL1.3



LaserCut Head LaserCut Head

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


19 DO 849 GO(46] HeightSelBit1 19 DI 849 InPosition

19 DO 850 GO[46] HeightSelBit2 19 DI 850 RetdPos

19 DO 851 GO[46] HeightSelBit3 19 DI 851 TipTouch

19 DO 852 Tch/CtrOfTrvl 19 DI 852 Crsh/FltActive

19 DO 853 MotInhbt/Hold 19 DI 853 GI[46] StatCode1

19 DO 854 TipSelBit 19 DI 854 GI[46] StatCode2

19 DO 855 AnalogInEnbl 19 DI 855 GI[46] StatCode3

19 DO 856 Reset 19 DI 856 GI[46] StatCode4


GrinderMod1 GrinderMod1

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


20 DO 857 ACT/RET SetActiveRetract 20 DI 857 GI[47] ForceFedbackBit0

20 DO 858 GO[47] ComdFourceLevBit0 20 DI 858 GI[47] ForceFedbackBit1



20 DO 861 GO[47] ComdFourceLevBit3 20 DI 861 PlusLimit

20 DO 862 GO[48] ToolNumBit0 20 DI 862 MinusLimit

20 DO 863 GO[48] ToolNumBit1 20 DI 863 Spare

20 DO 864 GO(48] ToolNumBit2 20 DI 864 Spare


GrinderMod2 GrinderMod2

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE

ADDRESS ROBOT

ADDRESS PMC

ADDRESS GROUP



21 DO 866 GO[49] UserInputBit0 21 DI 866 Spare





21 DO 871 SpindleEnable 21 DI 871 CRF Fault



GRINDING ANALOG MODULE #1 GRINDING ANALOG MODULE #1

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE

ADDRESS ROBOT

ADDRESS PMC

ADDRESS GROUP


22 AO 1, 1-16 CommandForce 22 AI 1, 1-16 ActualForce

22 AO 2, 1-16 Spare 22 AI 2, 1-16 CarriagePos

22 AO 3, 1-16 Spare 22 AI 3, 1-16 Spare

22 AO 4, 1-16 AMPThermister 22 AI 4, 1-16 Spare

Spare Spare

Spare Spare

Spare Spare

Spare Spare

ROBOT OUTPUTS ROBOT INPUTS GRINDING ANALOG MODULE #2 GRINDING ANALOG MODULE #2

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


23 AO 5, 1-16 VelCommand 23 AI 5, 1-16 VelMon

23 AO 6, 1-16 Spare 23 AI 6, 1-16 CurrentRef

23 AO 7, 1-16 Spare 23 AI 7, 1-16 Spare

23 AO 8, 1-16 Spare 23 AI 8, 1-16 CurrentMon

Spare Spare

Spare Spare

Spare Spare

Spare Spare










AS OF 1/12/2012 39 CUSW REL1.3








DO 904

Spare DI 904 Spare









ROBOT OUTPUTS ROBOT INPUTS ISRA VISION COMMUNICATIONS ISRA VISION COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


60 DO 913 Y 0.0 GO[38] doISRA_CmdB1 60 DI 913 X 0.0 GI[31] diISRA_StatBit1

60 DO 914 GO[38] doISRA_CmdB2 60 DI 914 GI[31] diISRA_StatBit2



60 DO 917 doISRA_Strt_M 60 DI 917 diISRA_Ready

60 DO 918 doISRA_reservd 60 DI 918 diISRA_Snap_ip

60 DO 919 GO[40] doISRA_Rst_E 60 DI 919 diISRA_Data_ip

60 DO 920 doISRA_ID_Valid 60 DI 920 diISRA_ID_OK

60 DO 921 GO[39] doISRA_TpIDB1 60 DI 921 GI[38] diISRA_reservd

60 DO 922 GO[39] doISRA_TpIDB2 60 DI 922 GI[38] diISRA_ErrPLC

60 DO 923 GO[39] doISRA_TpIDB4 60 DI 923 GI[38] diISRA_ErrRbt

60 DO 924 GO[39] doISRA_TpIDB8 60 DI 924 GI[38] diISRA_OutTol

60 DO 925 GO[39] doISRA_TpIDB16 60 DI 925 GI[38] diISRA_Disabl

60 DO 926 GO[39] doISRA_TpIDB32 60 DI 926 GI[38] diISRA_ErrImage

60 DO 927 GO[39] doISRA_TpIDB64 60 DI 927 GI[38] diISRA_reservd1

60 DO 928 GO[39] doISRA_TpIDB128 60 DI 928 GI[38] diISRA_ErrDet

60 DO 929 GO[41] doISRA_SubStyle 60 DI 929 GI[32] diISRA_XB1








60 DO 937 GO[42] doISRA_Color 60 DI 937 GI[32] diISRA_XB256








60 DI 945 GI[33] diISRA_YB1

ROBOT OUTPUTS 60 DI 946 GI[33] diISRA_YB2

APP. ERROR CODE (ROBOT USER DEFINED) COMM. 60 DI 947 GI[33] diISRA_YB4

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


60 DI 948 GI[33] diISRA_YB8

N/A DO 945 N/A AppErrSpare01 60 DI 949 GI[33] diISRA_YB16












N/A DO 957 N/A AppErrSpare13 60 DI 961 GI[34] diISRA_ZB1







AS OF 1/12/2012 40 CUSW REL1.3











N/A DO 973 N/A AppErrSpare29 60 DI 977 GI[35] diISRA_RXB1
















N/A DO 989 N/A AppErrSpare45 60 DI 993 GI[36] diISRA_RYB1
















N/A DO 1005 N/A AppErrSpare61 60 DI 1009 GI[37] diISRA_RZB1
















N/A DO 1021 N/A AppErrSpare77




ROBOT OUTPUTS ROBOT INPUTS ROBOT INTERNAL COMMUNICATIONS ROBOT INTERNAL COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


NODE ADDRESS

ROBOT ADDRESS

PMC ADDRESS


RbtInternal DO 901 WaterValve1ON RbtInternal DI 901 WaterFlowOK1

RbtInternal DO 902 WaterValve1OFF RbtInternal DI 902

RbtInternal DO 903 RbtInternal DI 903 WaterFlowOK2

RbtInternal DO 904 WaterValve2ON RbtInternal DI 904

RbtInternal DO 905 WaterValve2OFF RbtInternal DI 905

RbtInternal DO 906 RbtInternal DI 906

RbtInternal DO 907 VacuumCH_ON RbtInternal DI 907 VacuumCH_ON

RbtInternal DO 908 PulseBatteryLow RbtInternal DI 908

RbtInternal DO 909 XFORMTEMPOk1 RbtInternal DI 909 XFORMTEMPOk1




AS OF 1/12/2012 41 CUSW REL1.3


ROBOT APPLICATION ERROR TIMING

LO

OP

Un

til

AL

L A

ppli

cati

on E

rro

rs (

if a

ppli

cab

le)

is m

on

ito

red

L

OO

P U

nti

l A

LL

Ap

pli

cati

on E

rro

rs (

if a

ppli

cab

le)

is m

on

ito

red

Application Error Bits (Group Output)

a

a = 500 msec

ROBOT INPUTS FROM PLC ROBOT OUTPUTS TO PLC Not Robot I/O

GO[4] = FIS ID

DO[121 – 128]

b b

Application Error Active

DO[120]

Application Error Acknowledge (PLC Signal)

Error Ack goes LOW when Error Active goes LOW

Error Active goes LOW when Error Ack goes HIGH

ADDING APPLICATION ERROR BITS TO PLC

REMOVING APPLICATION ERROR BITS FROM PLC


a

Application Error Active


Error Ack goes LOW when Error Active goes LOW


Application Error Remove


DI[8]

GO[4] = FIS ID

DO[121 – 128]

DO[120]

DI[8]

DO[76]

DO[120]



Error Ack goes LOW when Error Active goes LOW DI[8]


Application Error

Active

GO[4] = FIS ID

DO[121 – 128]

SYNCHRONIZE PLC / IDENTIFY TOP OF PMC LOGIC

LOW State

AS OF 1/12/2012 42 CUSW REL1.3


ROBOT APPLICATION ERRORS

INPUT/S GROUP INPUT

DESCRIPTION ERROR

SEVERITY PLC

CODE IO STATE

INTERNAL ROBOT HANDSHAKE TO PLC N/A N/A Clear all faults command ID N/A 0 N/A

SPARE 1

General Communication DeviceNet Master Major 2

3

Low Battery Indicator Minor 4

CLINCH NUT No Nut In Anvil 5

Feeder Air Not On 6

Clinch Nut Still in Anvil 7

Clinch Nut Not Present at Feeder 8

Nut Feeder Plunger Not In Position 9

Clinch Nut Part Present Fault 10

Nut Feeder Pusher Not In Position 11

NET-FORM-PIERCE Work Support Pressure Fault 12

Moog Mode Fault 13

Moog Drive A OK Fault 14

Moog Drive B OK Fault 15

Moog Drive A ON Fault 16

Moog Drive B ON Fault 17

Moog Drive A Position Fault 18

Moog Drive B Position Fault 19

Moog Drive A Force Fault 20

Moog Drive B Force Fault 21

QMC/FMS AAC Error Major 22

AAC Required Major 23

ATC Error Major 24

ATC Required Major 25

ATC Expired Major 26

Vision Comm Heartbeat Lost Major 27

Vision System App Fault Major 28

29

30

31

32

AS OF 1/12/2012 43 CUSW REL1.3


INPUT/S GROUP INPUT

DESCRIPTION ERROR

SEVERITY PLC

CODE IO STATE

SPOTWELDING DI 197 -201 DI 229 -233

GI[11] GI[13]

I/O Error Major/Minor 33 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

I/O Alarm Major/Minor 34 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Incomplete Weld Major/Minor 35 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Stepper Approaching Max Major/Minor 36 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

End Of Stepper Major/Minor 37 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Sure Weld Trend Limit Major/Minor 38 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

High/Low Current Limit Major/Minor 39 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Firing Error Major/Minor 40 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Cylinder Fault Major/Minor 41 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Cylinder Alarm Major/Minor 42 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Power Factor Error Major/Minor 43 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Compensation Error Major/Minor 44 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Insufficient Line Voltage Major/Minor 45 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Extend Weld Major/Minor 46 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Isolation Contactor Error Major/Minor 47 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Welding Buss Voltage Major/Minor 48 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Weld Data Not Programmed Major/Minor 49 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Analog Pressure Error Major/Minor 50 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

C-Factor Limit Major/Minor 51 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Secondary Current Major/Minor 52 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Welding Transformer Major/Minor 53 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Over Temperature Major/Minor 54 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Shorted SCR Major/Minor 55 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Internal Timer Error Major/Minor 56 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Inverter Fault Major/Minor 57 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Timer Not Ready Major/Minor 58 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]

Reserved Major/Minor 59 N/A

DI 197 -201 DI 229 -233

GI[11] GI[13]


DI 197 -201 DI 229 -233

GI[11] GI[13]


AS OF 1/12/2012 44 CUSW REL1.3


INPUT/S GROUP INPUT

DESCRIPTION ERROR

SEVERITY PLC

CODE IO STATE

DI 197 -201 DI 229 -233

GI[11] GI[13]


DI 197 -201 DI 229 -233

GI[11] GI[13]


WATER SAVER DI 785 N/A W1OKtoWeld Major 64 N/C

DI 787 N/A 65 N/O

DI 817 N/A 66 N/C

DI 819 N/A 67 N/O

WELD SERVOGUN / ARC SPOT-068 N/A ServoGun Faulted 68

ARC-006 N/A Wire Fault 69

ARC-008 N/A Power Supply Fault 70

ARC-010 N/A Wire stick detected 71

ARC-013 N/A Arc Start failed 72

ARC-017 N/A Arc Start was Disabled 73

ARC-018 N/A Lost arc detect 74

ARC-030 N/A Wire stick is still detected 75

ARC-033 N/A Override must be 100% to weld 76

INTERNAL ROBOT N/A Transformer over temperature Major 77

TOOL CHANGER DO 640 N/A ToolNotPresent 78 N/O

DO 641 N/A Invalid Tool Requested 79 N/O

DI 648 N/A RTLMismatch 80 N/O

DI 649 N/A TSIVMismatch 81 N/O

DI 650 N/A LatchOverLoad 82 N/O

DI 651 N/A UnlatchOverLoad 83 N/O

DI 652 N/A SpareOverload 84 N/O

DI 653 N/A RTLrtlvMismatch 85 N/O

DI 654 N/A TSIVtsrvMismatch 86 N/O

DI 655 N/A UnsafeUnlatch 87 N/O

DI 656 N/A LckUnlckSensFlt 88 N/O

DI 657 N/A LatchNotComplt 89 N/O

DI 658 N/A UnlatchNotComplt 90 N/O

DI 659 N/A TSIVFault 91 N/O

DI 660 N/A RTLFault 92 N/O

DI 661 N/A Comm Error 93 N/O

DI 684 N/A Unlatch Enabled 94 N/C

DI 634 N/A DNetPowerNotPresent 95 N/O

DI 635 N/A AuxPowerNotPresent 96 N/O

DO 642 N/A Unexpected Tool Present 97 N/O

DO 643 N/A Nest not empty 98 N/O

DO 644 N/A Nest is empty 99 N/O

STUD WELDING DI 321 N/A NOError1 Major 100 N/C

DI 326 N/A NOError2 Major 101 N/C




DI 347 N/A Std1StudsLow Minor 105 N/O

DI 348 N/A Std1ReadyForAuto Major 106 N/O

DI 349 N/A Std1ReadyToWeld Major 107 N/C

AS OF 1/12/2012 45 CUSW REL1.3


SPARE 108

109

110

111

112

113

114

115

116

117

118

119

NORDSON DISPENSING #1 120

121

DI 393 N/A Nozzle 1 Low Volume Fault Major 122 N/O

DI 394 N/A Nozzle 1 High Volume Fault Major 123 N/O

DI397 N/A Nozzle 1 Collision Detected Major 124 N/O

Di395 N/A Dispense 1 Low Pressure Fault Major 125 N/O

DI396 N/A Dispense 1 High Pressure Fault Major 126 N/O

127

128

129

NORDSON DISPENSING #2 130

131

DI 457 N/A Nozzle 2 Low Volume Fault Major 132 N/O

DI 458 N/A Nozzle 2 High Volume Fault Major 133 N/O

DI461 N/A Nozzle 2 Collision Detected Major 134 N/O

DI459 N/A Dispense 2 Low Pressure Fault Major 135 N/O

DI460 N/A Dispense 2 High Pressure Fault Major 136 N/O

137

138

139

140

PERCEPTRON VISION Perceptron Communication Fault Major 141 N/O

Perceptron Status Fault Major 142 N/O

Perceptron Bad Measurement Major 143 N/O

General Search Error Major 144 N/O

145

DYNALOG MEASUREMENT Dynalog Major Fault Major 146 N/O

Dynalog Minor Fault Major 147 N/O

SPARE 148

149

150

AS OF 1/12/2012 46 CUSW REL1.3


ISRA VISION DI 917 N/A diISRA_Ready Major 150

DI 918 N/A diISRA_Meas_ip Major 151

DI 919 N/A diISRA_Data_ip Major 152

DI 920 N/A diISRA_ID_OK Major 153

DI 922 N/A diISRA_ErrPLC Major 154

DI 923 N/A diISRA_ErrRbt Major 155

DI 924 N/A diISRA_OutTol Major 156

DI 925 N/A diISRA_Disabl Major 157

DI 926 N/A diISRA_ErrImage Major 158

DI 928 N/A diISRA_ErrDet Major 159

MATERIAL HANDLING/VISION Rack not open fault Major 160 N/O

Part search fault Major 161 N/O

TRACK LUBE Track Bearing Lube Fault Minor 162

Track Pinion Lube Fault Minor 163

MATERIAL HANDLING N/A N/A VacuumCH1PP Fault Major/Minor 164 EVENT DRIVEN

N/A N/A VacuumCH2PP Fault Major/Minor 165 EVENT DRIVEN











N/A N/A Part Present 1 Fault Major/Minor 176 EVENT DRIVEN












N/A N/A MH Device 1 Retract Fault Major/Minor 188 EVENT DRIVEN















AS OF 1/12/2012 47 CUSW REL1.3





















N/A N/A MH Device 1 Extend Fault Major/Minor 222 EVENT DRIVEN


































Note: If a Material Handling Fault is disabled using the DF&C function, the appropriate application error bit will be posted as a MINOR fault indicating that the MAJOR fault is disabled. The Process Fault bit will remain low.

AS OF 1/12/2012 48 CUSW REL1.3


PLC LOGIC REFERENCE The 12PF program will utilize Allen-Bradley GuardLogix Processors with DeviceNet for PLC to Robot and Robot to PLC communications. Please reference the latest 12PF Library, distributed by DCX Controls Coordinators, for the robot related modules.

AS OF 1/12/2012 49 CUSW REL1.3


ROBOT PROGRAM NAMING

Robot program names shall follow the convention described by the table below:

Table 1. Program Names

Style # Program Name (8

char. max) Comment

(16 char. max) Program Description

Programs

1 STYLE001 Maint Style 1 (Maintenance Program) - User Specified

2 STYLE002 WeldGunForceChck User Specified - Weld Gun Force Check

3 STYLE003 Tip Change (Maintenance Program) - Executes motion and/or macro calls required to change the tips on the weld gun

4 STYLE004 Purge (Maintenance Program) - Executes motion and/or macro calls required to purge the dispense gun

5 STYLE005 Tip Burn In (Maintenance Program) - Executes motion and/or macro calls required to burn in the tips on the weld gun

6 STYLE006 Service Program (Maintenance Program) - Executes motion and/or macro calls required to move the robot to the service position

7 STYLE007 TipDress 1st Gun / Tip1BurnIN

(Maintenance Program) - Executes motion and/or macro calls required to dress the tips on the 1st gun

8 STYLE008 TipDress 2nd Gun / Tip2BurnIN

(Maintenance Program) - Executes motion and/or macro calls required to dress the tips on the 2nd gun

9 STYLE009 Tool Change (Maintenance Program) - Executes motion and/or macro calls required to change the tool on the robot

10 - 19 STYLE010 - STYLE019

User Specified User Specified

20 - 29 STYLE020 - STYLE029


30 - 39 STYLE030 - STYLE039


40 - 49 STYLE040 - STYLE049


50 - 63 STYLE050 - STYLE063

User Specified User Specified - Future expansion

AS OF 1/12/2012 50 CUSW REL1.3


ROBOT INTERFERENCE ZONES

Zone Identification Summary/Definitions: Station / Work Area based zones. Zones 1, 2& 3: Station Zones are defined as the area where two or more robots are executing work on or exchanging (transferring) a work piece at a physical station. Examples of stations are turntables, work fixtures, holding bucks and transfers or shuttles. Work Area Zones are defined as the area where two or more robots are executing work on or exchanging (transferring) a work piece without the use of a physical station. Examples of this would be robot to robot hand off by the use of Geo-fector EOAT (End Of Arm Tooling). Station and Work Area Zones are applied using an non-alternating pattern. For example a robot would pick-up a part in Zone 1 then transfer it to Zone 2. The next robot would pick-up the part from Zone 1 then transfers it to Zone 2. This non-alternating pattern would continue with Zone 3 only being required for a robot that needs three Station or Work Area zones.

Transition Zones/Hand-off zones Zones 4 & 5: Transition Zones are when two or more robots, working side by side, are needed to move (transition) from one process area to another process area when a physical interference between the robots is present during the transition. For example welding robots moving from a geo weld position to a re-spot weld position would require some Transition zone protection. Hand-off Zones are used for robot to robot hand-off. Hand-off is when one robot loads the work piece from it EOAT directly onto the other robot‟s EOAT without the use of a station. Hand-off Zones are applied using an non-alternating pattern. For example a robot would pick-up a part in Zone 4 then transfers it to Zone 5. The next robot would pick-up the part from Zone 4 then transfers it to Zone 5 etc.

Process Interference Zones / Duty Zones Zones 6 thru 8: Process Interference Zones are defined as the zones around the work piece that the robots application is working around. For example two or more robots might need to cross each others path in order to complete its process on the work piece. In this case these Process Zones would be used to allow the robots to safely “chase” each other around the work piece. Duty Zones are defined as other Duties that the process or application requires but are in excess of the previous zone definitions. For example, gantry robots having a part transfer at a higher elevation then Zones 1-3 could use these zones like a Work Area Zone. Examples: Interference Zone Example 1: This example shows Zone 1 and 2 as Station Zones. Zones 4 & 5 are Transition Zones and Zones 6 – 8 as Process Interference Zones. Interference Zone Example 2: This example shows Zone 1 and 2 as Work Area Zones. Zone 4 is a hand-off Zone and Zones 6 & 7 are Process Interference Zones

AS OF 1/12/2012 51 CUSW REL1.3


Interference Zone Example 1

AS OF 1/12/2012 52 CUSW REL1.3



AS OF 1/12/2012 53 CUSW REL1.3



The definitions described and show above, are to be followed as described and are not subject to interpretation. If the above definitions can not be applied to a specific application then approval from a Chrysler Robotics Engineer or Launch Technician will be required to redefine how Interference Zones are to be used. Reference Pictures Only See Standard Robot Logic Reference for Details.

AS OF 1/12/2012 54 CUSW REL1.3


PLC / ROBOT TIMING DIAGRAMS

Robot Inputs

*Hold

Resume

Fault Reset (2)

Style1-Style64

Option1-Option4

Prod Start (3) (3)

Robot Outputs

RobotInAuto

RobotFaulted-ProcessFault

Robot Ready

ActiveStyle1-ActiveStyle64

Prg Paused

Prg Running

In Cycle

Option1Active-Option4Active

RobotAtHome

1) Robot is in a starting mode of faulted inbetween cycle 2) Fault Reset can be dropped after seeing Robot Ready go high 3) Style and option bits need to be set before Prod Start is set, Prod Start can be dropped when Prg Running goes high

New Cycle Start

Production Cycle

Production Cycle

AS OF 1/12/2012 55 CUSW REL1.3


Robot Inputs

*Hold

Resume (5)

Fault Reset

Style1-Style64

Option1-Option4

Prod Start

Robot Outputs

RobotInAuto


(4)

Robot Ready


Prg Paused

Prg Running

In Cycle


RobotAtHome

4) Fault occurs and robot sets RobotFaulted and/or Process Fault

5) Resume signal does not require Style Number or Option Bits

Pro

du

ctio

n C

ycle

Pro

du

ctio

n C

ycle

Pro

du

ctio

n C

ycle

Pro

du

ctio

n C

ycle

Stop and Resume from Fault

AS OF 1/12/2012 56 CUSW REL1.3


Robot Inputs

*Hold (6)

Resume

Fault Reset

Style1-Style64

Option1-Option4

Prod Start

Robot Outputs

RobotInAuto


Robot Ready


Prg Paused

Prg Running

In Cycle


RobotAtHome

6) When *Hold signal is lost, robot pauses program without faults

Stop and Resume from Hold

Pro

du

ctio

n C

ycle

Pro

du

ctio

n C

ycle

Pro

du

ctio

n C

ycle

Pro

du

ctio

n C

ycle

AS OF 1/12/2012 57 CUSW REL1.3


REGISTER USAGE Register names shall be a maximum of 16 characters in length and the name shall reflect the purpose of the register or counter.

NUMERICAL REGISTER USAGE Numerical Registers are used for storage of Real or Integer values. The table below shows the registers that are reserved.

Table 2. Numerical Registers

Register Number Register Comment Register Description Preset Value

1 Current Tool ID Current Tool ID

2 Desired Tool ID Desired Tool ID

3 Devnet Status DeviceNet Device Status Check Result

4 DevnetConnRetry DeviceNet Connection Retries 3

5 Current Home Pos Home Position to Return to During Service Macro

6 CurrentFixtureID Current Fixture ID

7 DesiredFixtureID Desired Fixture ID

8 Line Number Line Number

9 Spare

10 SrvGunReserved

Reserved for ServoGun Tip Wear and Autotuning

11 SrvGunReserved

12 SrvGunReserved

13 SrvGunReserved

14 CompletedBurnIns Completed Number Burn Ins

15 RequiredBurnIns Required Number Burn Ins - set by user 3

16 ATISequenceStep Current Step of ATI Sequence

17 ATIRecovery ATI Recovery Method

18 Spare

19 Gun1BurnInSched Gun 1 Weld Schedule for Burn In

20 Gun2BurnInSched Gun 2 Weld Schedule for Burn In

21 Gun1 Spot Count Gun 1 Spot Weld Count

22 Gun1 Tip Dress Gun 1 Tip Dress

23 Gun2 Spot Count Gun 2 Spot Weld Count

24 Gun2 Tip Dress Gun 2 Tip Dress

25 TipWR Cycle CNT Tip Wear Cycle Count

26 TipWR Cycle MAX Tip Wear Max Cycles

27-39 Spare

40 NumWeldRetries Number of Weld Retries 1

41 ColGuardDefault Sensitivity Default Register for Collision Guard 100

42 ColGuardSensitiv Increased Sensitivity Register for Collision Guard 150

43-100 Spare

101 ToolModelNum Temporary Storage of Tool Model Number

102 1sRobot/StatNum Temporary Storage of 1's Digit of Robot/Station Number

103 10sRobot/StatNum Temporary Storage of 10's Digit of Robot/Station Number

104-129 Spare

130 ISRA Mode Vision Mode

131 ISRA Type Vision Vehicle Type

132 ISRA Subtype Vision Vehicle Sub

133 ISRA Color Vision Vehicle Color

134 ISRA PR Vision Ofset Index

135 ISRA Error Vision Error

136 ISRA Temp Vision Temp

AS OF 1/12/2012 58 CUSW REL1.3


Register Number Register Comment Register Description Preset Value

137 ISRA Set Nominal ISRA Set Nominal

138 ISRA Vis Pos X ISRA Vis Pos X

139 ISRA Vis Pos Ext ISRA Vis Pos Ext

140 Rack Position Rack Position

141

142 ISRA Menu ANS ISRA Menu ANS

143

144

145 Scratch1 Scratch1



148

149 Part Rapid X Part Rapid X

150 Part Delta X(mm) Part Delta X(mm)

151 0th Part X 0th Part X

152 Calc'd Part X Calc'd Part X

153 Calc'd Part No Calc'd Part No

154 Search 1 Part X POS Search 1 Part X POS

155 Search 2 Part X POS Search 2 Part X POS

156 Search X POS DIF Search X POS DIF

157 Found Part X Found Part X

158 Found Part No Found Part No

159 Part No DIF Part No DIF

160 ForcChkBadMeas

161 ForcChkFailed

162 ForcChk1ShakFail

163 ForcChk2ShakFail

164 ForcChkFShakFail

165 ForcChkPartsRack

There are a total of 200 numerical registers. The user is free to use any other numerical register. The following is an example of using a numerical register in a teach pendant program. 10: R[1] = 34 ; 11: GO[3] = R[1] ; => Meaning Robot Group Output GO[3] = 34 value

AS OF 1/12/2012 59 CUSW REL1.3


POSITION REGISTER USAGE The table below shows the position register list to be used on the WD project. Moving to these positions is handled using the appropriate macro listed in the macro section of this document.

Table 3. Position Registers

Position Register Number Position Register Comment Position Register Description

1 Home1 Home1

2 Home2 Home2

3 PouncePosition Pounce Position

4 M/HWaitPosition M/H Wait for Dropoff Position

5 ServicePosition Service Position

6 PurgePositionG1 Purge PositionG1

7 PurgePositionG2 Purge PositionG2

8 Spare

9 Spare

10 Spare

11 Spare

12 Spare

13 Spare

14 Spare

15 Spare

16 Spare

17 Spare

18 Spare

19 Spare

20

ReservedServoGun Reserved for Servo Gun Autotuning and Tip Wear Operations

21

22

23

24

25

26

27 ReservedSpotTeach Reserved for Servo Gun

28 Spare

29 Spare

30 Spare

31 Pick 1 Position PickUp Position #1

32 Drop 1 Position DropOff Position #1







39 Spare

40 Base Frame Base Frame

41 PF Low Lt Frame PF Low Lt Frame

42 PF Low Rt Frame PF Low Rt Frame

43 PF Up Lt Frame PF Up Lt Frame

44 PF Up Rt Frame PF Up Rt Frame

45 ?? Low Lt Frame ?? Low Lt Frame

46 ?? Low Rt Frame ?? Low Rt Frame

47 ?? Up Lt Frame ?? Up Lt Frame

48 ?? Up Rt Frame ?? Up Rt Frame

AS OF 1/12/2012 60 CUSW REL1.3


Position Register Number Position Register Comment Position Register Description

49 Current Position Current Position

50 Offs Base Frame Offs Base Frame

51 Above Pick Above Pick

52 Spare

53 Spare

54 ISRA Vis Pos ISRA Vis Pos

55 PF Nom Vis Pos PF Nom Vis Pos

56 ?? Nom Vis Pos ?? Nom Vis Pos

57 Rack Nom Vis Pos Rack Nom Vis Pos

58 ISRA CAM1 CALPOS ISRA CAM1 CALPOS

59 ISRA CAM2 CALPOS ISRA CAM2 CALPOS

60 - 89 Spares

90 TCP Target Position

98 Payload ID Position Starting Position to Start Payload ID

99 ZERO Position Robot Zero Mastering Position

100 Spare

101 Nest 1 Drop Position where the tool changer decouples tool 1.




105 Spare

106 Nest 1 Pick Position where the tool changer couples tool 1.




110 Spare

111 Tool Offset 1 Offset used for approach and retreat positions of the robot during the drop sequence.








119-200 Spares

Note 1: The robot must be able to move between the different Home positions in a single move without causing damage to the robot, dressout, or tooling. Note 2: Only use multiple home positions when performing a Change-out robot program (tool changer application). If no tool change application, the preferred method is only one home position, unless if a cycle time issue comes up.

AS OF 1/12/2012 61 CUSW REL1.3


USER ALARMS User Alarms are used to post an alarm and fault the robot from within a teach pendant program or macro. The table below shows the user alarms that are used for the PF project.

Table 4. User Alarms

User Alarm Number User Alarm Comment User Alarm Description

1 ToolNotPresent No tool present

2 Invalid Tool Requested Invalid tool requested for pick

3 Unexpected Tool Present Unexpected tool present for drop

4 Tool Nest not Empty Tool nest is not empty, can not drop tool

5 Tool Nest is Empty No tool in nest, can not pick tool

6 DNetPower Not On Apply DNet power

7 Aux Power Not On Apply aux power

8 ReadyToLock1 Not On Tool not positioned properly

9 ReadyToLock2 Not On Tool not positioned properly

10 ToolStndIntlk1 Not On TSI limit switch fault

11 ToolStndIntlk2 Not On TSI limit switch fault

12 RTL Sensor State Mismatch RTL sensor states don't match

13 TSIV Sensor State Mismatch TSIV sensor states don't match

14 Latch Overload/Short Circuit Short circuit or overload on latch solenoid output

15 Unlatch Overload/ShortCircuit Short circuit or overload on unlatch solenoid output

16 Spare Overload/Short Circuit Short circuit or overload on spare solenoid output

17 RTLV / RTL Mismatch Mismatch condition between RTLV and RTL inputs

18 TSRV / TSIV Mismatch Mismatch condition between TSIV and TSRV inputs

19 UnsafeUnlatch Unlatch command received resulting in an unsafe tool release and therefore was not processed.

20 LckUnlckSensFlt-Both High Locked and Unlock inputs high at same time

21 LatchNotComplt-Latch Timeout Timeout on locked input after latch command

22 UnltchNtComplt-UnlatchTimeout Timeout on unlocked input after unlatch command

23 TSIVFault-Switch Failed High Failure of TSIV limit switch(es) in high position

24 RTLFault-Switch Failed High Failure of RTL sensor(s) in high position

25 CommError-Master to Tool Communication error between master and tool modules

26 LckOrUnlckSensIncorrectState Lock or Unlock Sensor in Incorrect State - Possible Failed Sensor

27 - 79 Spare

80 ISRA: Reset Errors Timeout ISRA: Reset Errors Timeout

81 ISRA: Change Auto/Ready Prep ISRA: Change Auto/Ready Prep

82 ISRA: Change Auto Handshake ISRA: Change Auto Handshake

83 ISRA: Ready Prep Timeout ISRA: Ready Prep Timeout

84 ISRA: Meas Data OK Timeout ISRA: Meas Data OK Timeout

85 ISRA: Result Transfer ON ISRA: Result Transfer ON

86 ISRA: Result Transfer OFF ISRA: Result Transfer OFF

87 ISRA: Meas Still Running ISRA: Meas Still Running

88 ISRA: Wrong Op Mode Entered ISRA: Wrong Op Mode Entered

89

90 ISRA: Err Setting Meas Data ISRA: Err Setting Meas Data

91 ISRA: Err Starting Meas ISRA: Err Starting Meas

92 ISRA: Features/Tol Error ISRA: Features/Tol Error

93 ISRA: Measurement Error ISRA: Measurement Error

94

95 ISRA: Rack NOT OK ISRA: Rack NOT OK

There are a total of 50 user alarms. The user is free to use any other user alarm. The following is an example of using a user alarm in a teach pendant program. 10: UALM[1] ; 11: UALM[4] ;

AS OF 1/12/2012 62 CUSW REL1.3


REFERENCE POSITION USAGE

Reference Positions are global positions that can set an output automatically when the robot encoder values indicate that the robot is at the position. This automatic checking is done where the robot is jogged to a position or moved via a macro or program. The table below shows the reference positions to be used on the PF project.

Table 5. Reference Positions

Reference Position Number Position Name At Position Digital Output

1 Home1 27

2 Home2 User Specified

3 - 10 Spare User Specified

11 RobotAtUserPos1 66





23 UnCouple Tool Position 1 646








Note 1: The robot must be able to move between the different Home positions in a single move without causing damage to the robot, dressout, or tooling. Note 2: Only use multiple home positions when performing a Change-out robot program (tool changer application). If no tool change application, the preferred method is only one home position, unless if a cycle time issue comes up. Note 3: Housekeeping macros (HOME_IO) are run when the robot is in range of a reference position set as a valid home position. Reference Position #1 must be set as a valid home position to execute HOME_IO after normal program execution. HOME_IO execution follows normal program execution when a robot is moved from a non home position to a valid home position.

AS OF 1/12/2012 63 CUSW REL1.3


INTERCONNECTS The I/O Interconnect feature allows the robot to output the states of digital inputs to notify external devices of the state of those inputs. The interconnect tables displays the inputs that are mapped to outputs. For example, per the configuration in the table below if DI[95] was to turn on, the robot would then turn on DO[416]. If DI[95] then turns off, DO[416] also turns off. I/O is interconnected based on the configuration of the robot. For example, a material handling robot would have Input 513 interconnected to Output 77. It would not have Input 204 interconnected to Output 102 because these I/O points are used for spot welding robots. The table below shows the interconnects that are used for the PF project.

Table 6. Interconnects

INTERCONNECTS

Table # Application Type Input Description Output Description 3 Reserved DI-DO DI

DO

7 Reserved DI-DO DI

DO 39 MH DI-DO DI625 Air OK DO91 AirOK

40 MH DI-DO DI626 Air Aceptable Range DO92 AirPressAcptRng

41 MH DI-DO DI513 Part1Present DO77 RobotPartPres1










55 Tool Changing DI-DO DI664 ToolIDSwtch1Bit1 DO116 ToolIDOnWrist1



INTERCONNECTS

Table # Type Input Description Output Description 13 Spot Welding SI-DO SI12 OVERTEMP_SWG1 DO909 XFORMTEMPOk1

14 Spot Welding SI-DO SI13 OVERTEMP_SWG2 DO910 XFORMTEMPOk2

AS OF 1/12/2012 64 CUSW REL1.3


MACROS Macro programs can be run standalone, but are intended to be used as subroutines which are called from the main style program. Defining a program as a macro program is done by setting the program type to “Macro” in the program header. When these programs are called from a main style program, the program pointer jumps to the subroutine. Similarly, when the subroutine is complete, the program pointer jumps back to the next line in the main style program. Macro programs can be set to either prohibit or allow robot motion statements. When motion statements are prohibited, the macro program can be manually executed while a robot fault is active. Therefore, it is recommended that macro programs that only execute I/O signals be set to prohibit motion statements (i.e. open/close gripper macro programs). Prohibiting motion statements in a macro program is done by setting all available motion groups to “*” in the program header. Allowing motion statements in a macro program is done by setting the appropriate motion groups to “1”. The user is free to place additional macros into the macro table provided they do not take up a position reserved by the macro table listed below. FANUC Spottool+ standard macros such as tip wear compensation are not called out in the macro table. These macros are automatically loaded on the robot at time of software load.

Table 7. Macros

Macro Table Position

Macro Name (8 Char. Max)

Macro Comment (16 Char. Max) Macro Description

Macros

1 HOME_IO Setup Outputs Handles I/O for start of next cycle (housekeeping)

MF 1

APP_IO SetApplicationIO Setup all application specific inputs and outputs

ATI_CHCK Check ATI Errors Handles ATI errors experienced during the tool pick and tool drop processes

CHK_TOOL Check Tool Checks for the correct tool on the wrist

ENTRZON1 Enter Zone 1 Handles IO for zone entering









MOV_HOME Move to Home Executes motion to move the robot home from the current position

MVHMPNCE MoveHomeFromPnce Executes motion to move the robot home from the pounce position

NST1DROP Drop Tool Nest 1 Executes motion and/or macro calls required to drop tool 1 in nest 1




AS OF 1/12/2012 65 CUSW REL1.3


Macro Table Position

Macro Name (8 Char. Max)

Macro Comment (16 Char. Max) Macro Description

NST1PICK Pick Tool Nest 1 Executes motion and/or macro calls required to pick tool 1 from nest 1




PED_DISP Ped Dispense Executes motion and/or macro calls required to perform dispensing with a pedestal mounted gun

PED_SPOT Ped Spot Weld Executes motion and/or macro calls required to perform spot welding with a pedestal mounted weld gun

PED_STUD Ped Stud Weld Executes motion and/or macro calls required to perform stud welding with a pedestal mounted gun

PREPDROP Tool Drop Prep Executes motion and/or macro calls required to prepare to drop the tool on the wrist in its nest

PREPPICK Tool Pick Prep Executes motion and/or macro calls required to prepare to pick a tool from its nest

PRGPDGN1 Purge Ped Gun 1 Executes motion and/or macro calls required to perform a purge on pedestal mounted dispense gun 1

RST_STPR Reset Stepper Handles IO for resetting the spot weld stepper motor

TPBURNIN Tip Burn In Executes motion and/or macro calls required to perform a tip burn in on a servo weld gun

TPCHNGPD TipChangePedGun Executes motion and/or macro calls required to perform a tip change on a pedestal mounted weld gun

TPDRSPD TipDressPedGun Executes motion and/or macro calls required to perform a tip dress with a pedestal mount weld gun

TPDRSGN1 DressCarriedGun1 Executes motion and/or macro calls required to perform a tip dress on carried weld gun 1

TPDRSGN2 DressCarriedGun2 Executes motion and/or macro calls required to perform a tip dress on carried weld gun 2

10 - 11 Reserved for SpotTool+

18 Reserved for SpotTool+



AS OF 1/12/2012 66 CUSW REL1.3


FLOW CHART EXAMPLES Contained in the following pages are flow charts of the processes required for the PF program. The information contained in each section is for REFERENCE ONLY.

Flow Chart Legend

Connector: Off Page

Connector: On Page

Move: Servo movement called

in logic

Decision: Logic decision

Process: Logic statement

Data: Data/Input from an

external device is required to

process this step‟s logic

AS OF 1/12/2012 67 CUSW REL1.3


Material Handling

Start

Set Robot Payload, Tool

Frame, and User Frame

Acknowledge Style GO[1]

Setup Application Specific

I/O (Macro)

Verify Part not

Present (Macro)

A

Move to Pounce

Set at Pounce DO[25]

Set Desired Tool ID R[2]

Tool Changer Applications Only

Open the Gripper

and Verify Open

(Macro)

Check Tool (Macro)

Set additional

gripper states (if

necessary) (Macro)

No Tool

Changer

Go to Work or

Return Home

From

Pounce?

Move Home from

Pounce

(call Macro)

Return Home

DI[25]

Go To Work DI[31]

Wait for go to

Pickup 1 DI[49]

Reset Clear of Pickup 1

DO[49]

Reset Clear to Transfer

DO[31]

Zone Check (if

necessary) (Macro)

Set Robot at Work DO[18]

Reset Robot at Pounce

DO[25]

Move Over

Pickup 1

A

B

Verify Tool is

Correct (Macro)

Set MH Gripper (if

necessary) (Macro)

Verify Part not

Present (Macro)

End

Reset Collision Guard

Sensitivity to Default R[41]

Reset DO[89]

Reset DO[94]

AS OF 1/12/2012 68 CUSW REL1.3


Material Handling (cont’d)

B

Move to Pickup 1

Check for Part

Present (Macro)

Open the Gripper

and Verify Open

(Macro)

Set Reposition Tooling GO[2]

Wait for Tooling

Repositioned

GI[5]

Set At Pickup 1 DO[50]

Close the gripper and verify

closed (Macro)

Select Robot Payload with

Part

Reset Reposition Tooling

GO[2]

Wait for Tooling

Repositioned

GI[5]

Move Clear of

Fixture Part

Presence

C

Note: This robot

movement must be

of “FINE” type

Note: Reposition Tooling

bits only required when

Robot to Robot/Fixture

handshaking is needed

Note: Receiving robot or

fixture will always set the

Reposition Tooling bit to

the delivering robot or

fixture

Note: Validate open

before moving

Note: Set reposition

tooling handshake may

be required either before

or after gripper is closed

Set Collision Guard

Sensitivity R[42]

Note: Collision Guard

sensitivity increased prior

to moving into tooling to

help prevent damage if a

collision occurs

Wait for Exit

Pickup 1 DI[50]

Check for Part

Present (if

necessary) (Macro)

Note: Lessons learned,

PLC is looking for a part

in the robot gripper and

has not been droppedReset Collision Guard


Note: Material Handling

functions may require

process recovery. Refer

to the MH process

recovery section.

AS OF 1/12/2012 69 CUSW REL1.3



Reset at Pickup 1 DO[50]

D

C

Zone Check (if

necessary) (Macro)

Wait for go to

Dropoff 1 DI[51]

Move

Move Over

Dropoff 1

Verify Tool is

Correct (Macro)

Set Clear of Interference

Zone (if necessary) DO[33]

Set Clear of Pickup 1 DO[49]

Set Clear to Transfer DO[31]

Reset Clear of Dropoff 1

DO[51]


DO[31]

Process Applications(as required)

Dispense

Inspection

Spot Weld

Stud Weld

Move Clear of

Pickup 1

Set at Dropoff 1 DO[52]

Move to Dropoff

1

Set Collision Guard

Sensitivity R[42]

AS OF 1/12/2012 70 CUSW REL1.3



D

Wait for

Reposition

Tooling GI[5]

Set Tooling Repositioned

GO[2]

Open the Gripper (Macro)

Select Payload without

Part(s), Tool Frame and User

Frame

Move Clear of

Robot Part

Present

Wait for Exit

Dropoff 1 DI[52]

(if necessary)

Reset Tooling Repositioned

GO[2]

Reset at Dropoff 1 DO[52]

Verify Parts Not

Present

(Macro)

Move Clear of

Dropoff 1

E

Set Work Complete DO[19]

Wait for Work

Complete Ack.

DI[32]

Reset Work Complete DO[19]

End

E

Note: Assumes robot

drops part to fixture

Note: This robot

movement must be

of “FINE” type.

Note: Receiving robot or

fixture will always set the

Reposition Tooling bit to

the delivering robot or

fixture

Note: Reposition Tooling

bits only required when

Robot to Robot/Fixture

handshaking is needed

Set Clear of Dropoff 1

DO[51]

Set Clear of Interference

Zone (if necessary) DO[33]



Move Home

(Macro)


Reset Robot at Work DO[18]

Move Clear of

Transfer

Note: Material Handling

functions may require

process recovery. Refer

to the MH process

recovery section.

AS OF 1/12/2012 71 CUSW REL1.3



Abort Pick/Abort Override Example

(if required)

Note: Abort outputs are

automatically set when

the user selects a

designated recovery

option during standard

material handling fault

recovery (DO[89,94]).

The user must manually

reset these outputs when

the recovery process is

complete.

Abort Pick or

Abort Over Ride

Requested?

DO[89,94]

No

Yes

MH Function Macro

(Ex: Check Part

Present)

Continue Standard Material

Handling Process

User Specified Macro

(Ex: Abort Pick)

Jump to Program Label

(Ex: End Program)

From Standard Material

Handling Process

AS OF 1/12/2012 72 CUSW REL1.3


Dispense

Start

A

Move to Pounce


Go to Work or

Return Home

From

Pounce?Move Home from

Pounce (Macro)

Return Home

DI[25]

Go To Work DI[31]

Zone Check (if

necessary) (Macro)


Reset Robot at Pounce DO[25]

Move To Seal

Start and Turn

on Gun


DO[31]





I/O (Macro)

Move Along Path

Move To Seal

End and Turn off

Gun

A

Wait for Work

Complete Ack.

DI[32]

Reset Work Complete DO[19]End

Move Home

(Macro)



Set Clear of Zone DO[33]

End


Sensitivity R[41]

Set Collision Guard

Sensitivity R[42]

Note: Collision Guard

sensitivity increased prior

to moving into tooling to

help prevent damage if a

collision occurs



Move Clear of

Part

Wait for

Dispenser Ready

DI[385]

Set Dispense Robot in

Process DO[393]

Set Dispense Style GO[31]

Set Dispense Style Strobe

DO[394]

Wait for

Dispense In

Process DI[386]

Reset Dispense Style

GO[31]

Reset Dispense Style Strobe

DO[394]

Set Dispense Complete

DO[401]

Reset Dispense Complete

DO[401]

Reset Dispense Robot in

Process DO[393]

Wait for Dispense

Vol. OK

Note: The Nordson

controller requires approx

500ms between the final

gun off command and

setting dispense

complete. Therefore a

move clear of part is

performed between these

commands to allow this

time to elapse.

Pre-processing for Dispense

Equipment

Post-processing for

Dispense Equipment

Note: The Nordson

controller requires 100ms

delay time between

setting robot in process,

dispense style, and

dispense style strobe.

Wait statements are used

here to allow the Nordson

to see the delay.

Wait 100ms

Wait 100ms

AS OF 1/12/2012 73 CUSW REL1.3


Spot Welding

Start

A

Move to Pounce


Go to Work or

Return Home

From

Pounce?

Move Home from

Pounce (Macro)

Return Home

DI[25]

Go To Work DI[31]

Zone Check (if

necessary) (Macro)



Move To Weld 1

Select Schedule, Weld 1

Move To Weld 2


Move Clear of

Clamps


DO[31]





I/O (Macro)

End

AS OF 1/12/2012 74 CUSW REL1.3


Spot Welding (cont’d)

AS OF 1/12/2012 75 CUSW REL1.3


Stud Welding

Start

A

Move to Pounce


Go to Work or

Return Home

From

Pounce?

Move Home from

Pounce (Macro)

Return Home

DI[25]

Go To Work DI[31]

Zone Check (if

necessary) (Macro)



Move To Weld 1


Move To Weld 2


Move Clear of

Clamps


DO[31]





I/O (Macro)

End

A

Wait for Work

Complete Ack.

DI[32]

Reset Work Complete DO[19]

End

Move Home

(Macro)



Set Clear of Zone DO[33]

Set Clear to Unclamp Early

DO[65]

AS OF 1/12/2012 76 CUSW REL1.3


Tip Change (Style #3)

Start





I/O (Macro)

Move to Tip

Change Position

Set Robot at Service DO[26]

Set Ready for Tip Change

DO[30]

Wait for Service

Complete DI[26]

Move Dress

Approach (if

necessary)

Note: Tip dress macros

perform burn in and wear

compensation after dress.

Refer to macros for

details.

Note: Tip wear compensation

to be performed without

measurement error checking.

Reset Robot at Service DO[26]

Reset Ready for Tip Change

DO[30]

Seat Caps Gun 1 (Macro)

Do Tip Wear Compensation

Gun 1 (Macro)

Reset Stepper (Macro)

Move Dress

Approach (if

necessary)

Do Tip Dress Gun 1 –

Schedule 0 (Macro)Note: A tip dress is

performed prior to cap

change to allow operator

to verify tip dresser is

properly dressing caps.Reset Tip Dress Complete

DO[29]

Pulse W1 Water Off DO[587]

Move Home

(Macro)End

Do Tip Dress Gun 1 –

(Macro)

Pulse W1 Reset Water Saver

DO[586]

Note: Tip Dress Macros

use an argument call for

the burn in schedule.

Schedule 0 skips the burn

in.

DELAY for TipDress

Complete (wait 1.0 sec)

Wait W1OKToWeld DI[785]=OFF

AND W1ValveClosed DI[786]=ON

Note: 4.0 sec puls

required to allow the

watersaver to turn OFF

and Blead down.

Wait W1OKtoWeld

DI[785]=ON

AS OF 1/12/2012 77 CUSW REL1.3


Purge (Style #4)

Start



I/O (Macro)


Equipment

Set Ext Purge 1 in Progress

DO[97]

End

Reset Ext Purge 1 in

Progress DO[97]

Set Dispense 1 Purge

DO[416]

Wait „X‟ Seconds

Reset Dispense 1 Purge

DO[416]

Post-processing for

Dispense Equipment

Home IO (if necessary)

(Macro)

Note: Home IO may

need to be manually

initiated if the style

program does not have

any robot motion.

AS OF 1/12/2012 78 CUSW REL1.3


Tip Burn In (Style #5)

Start





I/O (Macro)

Move to Service

Position (if

necessary)

Move Home

(Macro) (if

necessary)

End

Tip Burn In (Macro)

Home IO

(Macro) (if

necessary)

AS OF 1/12/2012 79 CUSW REL1.3


Service (Style #6)

Start





I/O (Macro)

Move to Service

Position


Wait for Service

Complete Req.

DI[26]


Move Home

(Macro)

End

AS OF 1/12/2012 80 CUSW REL1.3


Tip Dress Gun 1 (Style #7)

Start





I/O (Macro)

Move Home

(Macro)

Tip Dress Gun 1 – (Macro)

End

Approach Move

(if necessary)




Refer to macros for

details.





in.

AS OF 1/12/2012 81 CUSW REL1.3


Tip Dress Gun 2 (Style #8)

Start





I/O (Macro)

Move Home

(Macro)

Tip Dress Gun 2 – (Macro)

End

Approach Move

(if necessary)




Refer to macros for

details.





in.

AS OF 1/12/2012 82 CUSW REL1.3


Tool Change (Style #9)

Start





I/O (Macro)

Set Desired Tool ID GI[41]

End

Move Home

(Macro)

Check Tool (Macro)

AS OF 1/12/2012 83 CUSW REL1.3


Set Application IO (Macro)

Start

Set Application Specific IO

End

AS OF 1/12/2012 84 CUSW REL1.3


Check ATI Errors (Macro)

Start

Select Current Sequence

AR[1]

Reset Clear Errors DO[635]

Reset Latch Tool DO[632] Set Clear Errors DO[635]

Set ATI Recovery Method

R[17]

Reset Unlatch Tool DO[633] Wait „x‟ seconds for ATI to

reset

ATI Error

Present?

End

Post User Alarm for ATI Error

and Pause Program

Select

Recovery

Method R[17]

A

Reset Clear Errors DO[635]

Set Clear Errors DO[635]

Wait „x‟ seconds for ATI to

reset

A

End

No

Yes

Sequence List AR[1]:

A. Ready to Pick/Latch/Unlatch

B. Ready to Latch

C. Exit Pick/Ready to Drop/Exit Drop

D. Ready to Unlatch

R[17]=1 R[17]=0

Note: This recovery method

will retry the latch or unlatch

operation in the pick or drop

macro upon exiting.

AS OF 1/12/2012 85 CUSW REL1.3


Check Tool (Macro)

Start

Pick Preparation and Pick

Tool (Macro)

Set Tool ID R[1], Line

Number R[8], and Tool ID for

PLC GO[3]

Is Tool on

Wrist? DI[644]

R[1]

Yes

No

Drop Preparation and Drop

Tool (Macro)

Does Current

Tool ID Match

Desired Tool

ID?

NoEnd

Yes

AS OF 1/12/2012 86 CUSW REL1.3


Drop Tool Nest 1 (Macro)

Start

Move to Tool

Nest Perch

Wait for Clear to

Enter Tool Nest

DI[81]

Set Request to Enter Tool

Nest DO[71]

Reset Request to Enter Tool

Nest DO[71]

Reset Clear of Tool Nest

DO[72]

Reset Out of Nest DO[637]

Note: Turn Out of Nest off

before TSIV switches are

made.

When the Out of Nest Output is

set high, the tool changer

globally disables the unlatch

command. This output must

be turned off to unlatch the tool

changer.

Move to Tool

Nest

Wait for Tool in

Nest 1 DI[73]

A

ATI State Check – Sequence

5 (Macro)


6 (Macro)

ATI General

Error DO[645]

High?

Yes

No

Note: (if applicable) Tool nest

1 approach and retreat

positions are to use the same

position as the couple position,

PR[6]. This position is then

offset by a distance using a

tool offset via position register,

PR[14].

Set Robot UTOOL and

UFRAME

Clear ATI Errors

DO[635]

Set Tool Device Offline

(Macro)

AS OF 1/12/2012 87 CUSW REL1.3


Drop Tool Nest 1 (cont’d)

EndMove Clear of

Tool Nest

Move Clear of

Tool in Nest

Inputs

Wait for Tool in

Nest 1 DI[73]

Reset Unlatch Tool DO[633]

A


8 (Macro)

Set Unlatch Tool DO[633]

Reset Latch Tool DO[632]


7 (Macro)

General Error DO[645]

Tool Unlocked DI[633]

Not Tool Locked DI[632]

ATI Unlatched

or General

Error?

ATI General

Error DO[645]

High?

Yes

No

Set Out of Nest DO[637]

Move 4 Inches

Above Clear of

Tool in Nest

Wait for Tool in

Nest 1 DI[73]

Note: Check for

disengagement of

tool changer

Set Robot Payload without

Tool








PR[14].

This move must be 1 inch

further than complete

separation of the tool and be

of “FINE” type

RbtOKtoUnCouple DO[654]

Note:

In the robot ladder logic, PMC the following logic is

added: (Even if you ONLY have one tool, you must

define a Reference Position (below) in order to

UnCouple a tool.)

IF DO[646:UnCoupleToolPos1]=ON ReferncePos[11]

or DO[647:UnCoupleToolPos2]=ON ReferncePos[12]







THEN

turn DO[RbtOKtoUnCouple]=ON

Code in KAREL to Unlock:

IF (DO[637] = OFF) AND (DO[633]+) AND

(DO[654]=ON)

THEN DO[633]=ON

Note: You do NOT need to set

this DO[654] output in robot

TP, this will be handled in

robot code. It is FYI for you.

Unlatch

DI[633] High?

Yes No - Timeout

Set Robot UTOOL and

UFRAME

Clear ATI Errors

DO[635]

Set Robot UTOOL and

UFRAME

AS OF 1/12/2012 88 CUSW REL1.3


Enter Zone 1 (Macro)

Start

Reset Clear of Zone 1

DO[33]

End

Wait for OK to

Enter Zone 1

DI[33]

Home IO (Macro)

Start

Set Housekeeping Outputs

End

Move Home (Macro)

Start

Move Home

End

NOTE: Fine Move Required

Call Get_HOME (Karel Program)

NOTE: Get_Home Karel

program will copy the position

taught in Reference position to

PR[Home]

Move Home From Pounce (Macro)

Start

Move Home

From Pounce

End

AS OF 1/12/2012 89 CUSW REL1.3


Pick Tool Nest 1 (Macro)

Start

Move to Tool

Nest Perch

Wait for Clear to

Enter Tool Nest

DI[81]

Set Request to Enter Tool

Nest DO[71]

Reset Request to Enter Tool

Nest DO[71]

Reset Clear of Tool Nest

DO[72]

Move to Tool

Nest Approach

Reset Out of Nest DO[637]

Set Unlatch Tool DO[633]

Reset Latch Tool DO[632]

Move to Tool

Nest

A


1 (Macro)


2 (Macro)

ATI Unlatched

or Error

Posted?


Tool Unlocked

DI[633]

Tool Locked

and Tool

Unlocked

Low?

Yes

No

User Alarm – Lock or Unlock

Sensor Incorrect State








PR[10].

Note: Turn Out of Nest off

before TSI switches are made.

When the Out of Nest Output is

set high, the tool changer

globally disables the unlatch

command. This output must

be turned off to unlatch the tool

changer.

Set Robot UTOOL and

UFRAME

Clear ATI Errors

DO[635]

Unlatch

DI[633] High?

Yes No - Timeout

AS OF 1/12/2012 90 CUSW REL1.3


Pick Tool Nest 1 (cont’d)

A

Reset Unlatch Tool DO[633]

Set Latch Tool DO[632]

Move Clear of

Tool in Nest

Inputs

Set Out Of Nest DO[637]Move Clear of

Tool Nest

End

Is Tool ID

correct?

Yes

No

User Alarm – Unexpected

Tool Present

End


3 (Macro)


4 (Macro)


Tool Locked DI[632]

Not Tool Unlocked DI[633]

ATI Latched

or Error

Posted?

ATI General

Error DO[645]

High?

Yes

No

Set Robot Payload with Tool








PR[10].

Set Tool Device Online

(Macro)

Latch DI[632]

High?

Yes No - Timeout

Set Robot UTOOL and

UFRAME

Set Robot UTOOL and

UFRAME

Move Clear of

Tool NestCheck Device

Online

Set Tool Device Online

(Macro)

Yes

No

AS OF 1/12/2012 91 CUSW REL1.3


Process Application Macros (Spot, Dispense, Stud)

MH Ped Spot Weld

Tip Dress, Tip

Change, Burn

In, Service or

Go To

Dropoff?

Tip Dress Ped Gun –

Schedule 62 (Macro)

Tip Dress

DI[28]Tip Change Ped Gun

(Macro)

Tip Change

DI[105]

Note: Refer to flow charts

for tip change and tip

dress macro details

Move To Weld 1


Move To Weld 2


Move Clear of

Ped Welder

Start

End

Dropoff 1

DI[51]Tip Dress Ped Gun –

Schedule 0 (Macro)

Note: A tip dress is

performed prior to tip

change to allow operator

to verify tip dresser is

properly dressing caps.

Reset Tip Dress Complete

DO[29]

Tip Burn In (Macro)

Tip Burn In

DI[104]

Tip Dress Ped Gun –

Schedule 58 (Macro)





in.

MH Service with Part –

(Macro)

Service Request DI[27]

AS OF 1/12/2012 92 CUSW REL1.3


Process Application Macros (cont’d)

Move To Seal

Start and Turn

on Gun

Move Clear of

Nozzle

Move Along Path

Move To Seal

End and Turn off

Gun

MH Ped Dispense

Start

Purge or Go

To Dropoff?Purge Gun 1

DI[95]

End

Dropoff 1

DI[51]Purge Ped Gun 1 (Macro)

Wait for

Dispenser Ready

DI[385]

Set Dispense Robot in

Process DO[393]

Set Dispense Style GO[31]

Set Dispense Style Strobe

DO[394]

Wait for

Dispense In

Process DI[386]

Reset Dispense Style

GO[31]

Reset Dispense Style Strobe

DO[394]

Set Dispense Complete

DO[401]

Wait for

Dispense Vol.

OK

Reset Dispense Complete

DO[401]

A

A

Reset Dispense Robot in

Process DO[393]

Note: The Nordson

controller requires approx

500ms between the final

gun off command and

setting dispense complete.

Therefore a move clear of

part is performed between

these commands to allow

this time to elapse.


Equipment

Post-processing for

Dispense Equipment


Sensitivity R[41]

Set Collision Guard

Sensitivity R[42]

Note: The Nordson

controller requires 100ms

delay time between

setting robot in process,

dispense style, and

dispense style strobe.

Wait statements are used

here to allow the Nordson

to see the delay.

Wait 100ms

Wait 100ms

AS OF 1/12/2012 93 CUSW REL1.3


Process Application Macros (cont’d)

MH Ped Stud Weld

Move To Weld 1


Move To Weld 2


Move Clear of

Ped Welder

Start

End

AS OF 1/12/2012 94 CUSW REL1.3


Purge Ped Gun (Macro)

Start


Equipment

Set Ext Purge 1 in Progress

DO[97]

End

Reset Ext Purge 1 in

Progress DO[97]

Set Dispense 1 Purge

DO[416]

Wait „X‟ Seconds

Reset Dispense 1 Purge

DO[416]

Post-processing for

Dispense Equipment


Start

Set W1 Reset Stepper DO[590]

Wait for Stepper

Reset DI[204]

End

Reset W1 Reset Stepper

DO[590]

AS OF 1/12/2012 95 CUSW REL1.3


Tip Burn In (Macro)

Start

End

Reset Register for Burn Ins

Complete R[14]

Do Tip Burn In

Weld Schedule

62

Completed #

of Burn In‟s

Required?

Yes

No

Set Tip Burn In Complete

DO[104]


Gun 1 (Macro)

Note: Number of required

burn in‟s to be set by user

via register value 15.




AS OF 1/12/2012 96 CUSW REL1.3


Tip Change Ped Gun (Macro)


Set Ready for Tip Change

DO[30]

Wait for Service

Complete DI[26]


Reset Ready for Tip Change

DO[30]

Seat Caps Gun 1 (Macro)


Gun 1 (Macro)

Start

End


Pulse W1 Water Off DO[587]

Pulse W1 Reset Water Saver

DO[586]

AS OF 1/12/2012 97 CUSW REL1.3


Tip Dress Gun 1 (Macro)

Start

Move To

Dresser

Set Turn on Tip Dresser

DO[101]

Do Tip Dress

Weld Schedule

60

Set Robot in Tip Dress DO[28]

Wait for Tip

Dress Motor On

DI[101]

Move Common

Dress

Approach

Move Away

from Dress

Reset Turn On Tip Dresser

DO[101]

End

Do Tip Burn In

Weld Schedule

R[19]


Gun 1 (Macro)

Reset Tip Dress Request 1

DO[100]

Set Tip Dress Complete DO[29]

Reset Robot in Tip Dress

DO[28]




Setup Gun 1 Burn in

Schedule R[19]

Tip Burn In

Required

R[19]

No

Yes

Note: Tip burn in and wear

compensation can be

skipped. This is to be used

only prior to tip change when

burn in and wear

compensation is not required

after a tip dress.

[PR Home – Fine Move]

Tip dress

Bypassed

R[127]

No

Yes

AS OF 1/12/2012 98 CUSW REL1.3


Tip Dress Gun 2 (Macro)

Start

Move To

Dresser

Set Turn on Tip Dresser

DO[101]

Do Tip Dress

Weld Schedule

61

Set Robot in Tip Dress DO[28]

Wait for Tip

Dress Motor On

DI[101]

Move Common

Dress

Approach

Move Away

from Dress

Reset Turn On Tip Dresser

DO[101]

End

Do Tip Burn In

Weld Schedule

R[20]


Gun 2 (Macro)


DO[100]



DO[28]




Setup Gun 2 Burn in

Schedule R[20]

Tip Burn In

Required

R[20]

No

Yes

Note: Tip burn in and wear

compensation can be

skipped. This is to be used

only prior to tip change when

burn in and wear

compensation is not required

after a tip dress.

[PR Home – Fine Move]

Tip dress

Bypassed

R[127]

No

Yes

AS OF 1/12/2012 99 CUSW REL1.3


Tip Dress Ped Gun (Macro)

Wait for Tip

Dress Dump Ext

DI[99]

Turn on Tip Dresser DO[101]

Wait for Tip

Dress Motor On

DI[101]

Do Tip Dress

Weld Schedule

60

Reset Turn on Tip Dresser

DO[101]

Set Robot in Tip Dress

DO[28]

Do Tip Burn In

Weld Schedule

R[19]


Gun 1 (Macro)


DO[100]



DO[28]

Wait for Tip Dress

Dump Retracted

DI[100]

Start

End

Setup Gun 1 Burn in

Schedule R[19]

Tip Burn In

Required

R[19]

No

Yes

AS OF 1/12/2012 100 CUSW REL1.3


Tool Drop Preparation (Macro)

Start

User Alarm – Unexpected

Tool Present

Select Tool from Tool

Number R[16]

End





Tool Nest 1

Empty?

Yes

No

Tool Nest 2

Empty?

Yes

No

Tool Nest 3

Empty?

Yes

No

Tool Nest 4

Empty?

Yes

No

Set Active MH Tool and

Gripper State for Drop

(Macro)



(Macro)



(Macro)



(Macro)

Verify Part Not Present

(Macro)


(Macro)


(Macro)


(Macro)

A

User Alarm – Tool Nest Not

Empty

A

A

A

A

Set Application Error Output

Reset App Error Output

Set Application Error Output

Reset App Error Output

Tool 1

Tool 2

Tool 3

Tool 4

Unknown

Tool

AS OF 1/12/2012 101 CUSW REL1.3


Tool Pick Preparation (Macro)

Start

User Alarm – Invalid Tool

Requested

Select Tool Nest from Pick

Tool GI[4] or Style Program

End

Pick Tool Nest 1 (Macro)Tool Nest 1

Empty?

Yes

No


Empty?

Yes

No


Empty?

Yes

No


Empty?

Yes

No

User Alarm – Tool Nest

Empty

A

Set Application Error Output Set Application Error Output

A

A

A

A

Reset App Error Output Reset App Error Output

Tool 1

Tool 2

Tool 3

Tool 4

Unknown

Tool

AS OF 1/12/2012 102 CUSW REL1.3


TEACH PENDANT LOGIC EXAMPLES Contained in the following pages are examples of TP logic of the processes required for the PF program. The information contained in each section is for REFERENCE ONLY.

AS OF 1/12/2012 103 CUSW REL1.3


Material Handling 1: !Material Handling Template ;

2: !****************************** ;

3: !Remove these comments ;

4: !Before Build!!! ;

5: !Rename Program as Necessary ;

6: !Edit Program to Match Part Type ;

7: ;

8: !Modify Zone Numbers and ;

9: !Locations as Required ;

10: ;

11: !Uncomment the MACROs before ;

12: ! finalizing the OLPs ;

13: ;

14: !EXAMPLE PROGRAM ONLY ;

15: !****************************** ;

16: ;

17: !Set Robot Payload ;

18: PAYLOAD[2] ;

19: ;

20: !Set Robot UTOOL Number ;

21: UTOOL_NUM=1 ;

22: ;

23: !Set Robot UFRAME Number ;

24: UFRAME_NUM=1 ;

25: ;

26: !MACRO-Setup App Specific IO ;

27: CALL APP_IO ;

28: ;

29: !Set Acknowledge Style ;

30: GO[1:ActiveStyleBits]=10 ;

31: ;

32: !Reset Coll Guard Sensitivity ;

33: COL GUARD ADJUST ;

34: ;

35: !****************************** ;

36: !TOOL CHANGE APPLICATION ONLY ;

37: ;

38: !Set Desired Tool ID Register ;

39: R[2:Desired Tool ID]=2 ;

40: ;

41: !MACRO-Check Tool ;

42: CALL CHK_TOOL ;

43: ;

44: !MACRO-Set MH Tool ;

45: Set MH Tool(1) ;

46: !****************************** ;

47: ;

48: !MACRO-Set Additional Gripper ;

49: !States (if necessary) ;

50: !Grip Part(2) ;

51: ;

52: !Move to Pounce ;

53:J P[1] 100% CNT100 ;

54: ;

55: !Set At Pounce Position Bit ;

56: DO[25:RbtAtPounce]=ON ;

57: ;

58: !MACRO-Verify Part Not Present ;

59: Check No Part(1) ;

60: ;

61: !MACRO-Open the Gripper ;

62: Release Part(1) ;

63: ;

64: DO[89:PickOverride]=OFF ;

65: DO[94:AbortPickReq]=OFF ;

66: ;

67: !Wait For Go To Work ;

68: !or Return Home From Pounce ;

69: WAIT DI[31:GoToWork]=ON OR

DI[25:RetFromPounce]=ON ;

70: ;

71: !Check For Go To Work ;

72: IF DI[31:GoToWork]=ON,JMP LBL[20] ;

73: ;

74: !Return Home From Pounce ;

75: CALL MVHMPNCE ;

76: ;

77: !Jump To Program End ;

78: JMP LBL[1000] ;

79: ;

80: LBL[20:Go To Work] ;

81: ;

82: !Set Robot At Work ;

83: DO[18:RbtAtWork]=ON ;

84: ;

85: !Reset Robot At Pounce ;

86: DO[25:RbtAtPounce]=OFF ;

87: ;

88: !Wait For Go To Pickup 1 ;

89: WAIT DI[49:GoToPickup1]=ON ;

90: ;

91: !Reset Clear Of Pickup 1 ;

92: DO[49:ClrOfPickup1]=OFF ;

93: ;

94: !Reset Clear To Transfer ;

95: DO[31:CleartoTransfer]=OFF ;

96: ;

97: !MACRO-Zone Check ;

98: !(if necessary) ;

99: CALL ENTRZON1 ;

100: ;

101: !Move Over Pickup 1 ;

102:L P[2] 1000mm/sec CNT100 ;

103: ;

104: !MACRO-Verify Correct Tool ;

105: !Call TOOL_VER ;

106: ;

107: !MACRO-Verify Part Not Present ;


109: ;



112: ;

113: !Set Coll Guard Sensitivity ;

114: COL GUARD ADJUST R[42];

115: ;

116: !Move To Pickup 1 ;

117:L P[3] 500mm/sec FINE ;

118: ;

119: !MACRO-Check For Part Present ;

120: Part Present(1) ;

121: ;

122: !Set Reposition Tooling ;

123: !GO[2:ReposTooling]=1 ;

124: ;

125: !Wait for Tooling Repositioned ;

126: !WAIT GI[5:ToolingRepod1]=1 ;

127: ;

128: !MACRO-Close The Gripper ;

129: Grip Part(1) ;

130: ;

131: !Set At Pickup 1 ;

132: DO[50:AtPickup1]=ON ;

133: ;

134: !Select Payload With Parts ;

135: PAYLOAD[3] ;

136: ;

137: !Wait for Tooling Repositioned ;


139: ;

140: !Reset Reposition Tooling ;


142: ;

143: !Move Clear Fixt Part Presence ;

144:L P[4] 1000mm/sec FINE ;

145: ;

146: !Wait For Exit Pickup 1 ;

147: WAIT DI[50:ExitPickup1]=ON ;

148: ;



151: ;

AS OF 1/12/2012 104 CUSW REL1.3


152: !MACRO-Check For Part Present ;

153: Part Present(1) ;

154: ;

155: !Reset At Pickup 1 ;

156: DO[50:AtPickup1]=OFF ;

157: ;

158: !Move Clear Of Pickup 1 ;

159:L P[5] 1000mm/sec FINE ;

160: ;

161: !Set Clear Of Pickup 1 ;

162: DO[49:ClrOfPickup1]=ON ;

163: ;

164: !Set Clear To Transfer ;

165: DO[31:CleartoTransfer]=ON ;

166: ;

167: !Set Clear Of Interference ;

168: !Zone (If Necessary) ;

169: DO[33:RbtClrZone1]=ON ;

170: ;

171: !Move ;

172:L P[6] 1000mm/sec FINE ;

173: ;

174: !Insert Process Application ;

175: !as Required ;

176: !CALL (MACRO) ;

177: ;

178: !Wait For Go To Dropoff 1 ;

179: WAIT DI[51:GoToDropoff1]=ON ;

180: ;


182: !(If Necessary) ;

183: CALL ENTRZON1 ;

184: ;

185: !Reset Clear Of Dropoff 1 ;

186: DO[51:ClrOfDropoff1]=OFF ;

187: ;



190: ;

191: !Move Over Dropoff 1 ;

192:L P[7] 1000mm/sec CNT100 ;

193: ;

194: !MACRO-Verify Correct Tool ;

195: !Call CHK_TOOL ;

196: ;


198: COL GUARD ADJUST R[42] ;

199: ;

200: !Move To Dropoff 1 ;

201:L P[8] 1000mm/sec FINE ;

202: ;

203: !Set At Dropoff 1 ;

204: DO[52:AtDropoff1]=ON ;

205: ;

206: !Wait for Reposition Tooling ;


208: ;



211: ;

212: !Select Payload Without Parts ;

213: PAYLOAD[2] ;

214: ;


216: UTOOL_NUM=1 ;

217: ;


219: !If Necessary ;

220: UFRAME_NUM=1 ;

221: ;

222: !Set Tooling Repositioned ;


224: ;

225: !Move Clr Robot Part Present ;

226:L P[9] 1000mm/sec FINE ;

227: ;

228: !MACRO-Verify No Part Present ;


230: ;

231: !Wait For Exit Dropoff 1 ;


233: WAIT DI[52:ExitDropoff1]=ON ;

234: ;



237: ;

238: !Reset At Dropoff 1 ;

239: DO[52:AtDropoff1]=OFF ;

240: ;

241: !Reset Tooling Repositioned ;


243: ;

244: !Move Clear Of Dropoff 1 ;

245:J P[10] 100% CNT100 ;

246: ;

247: !Set Clear Of Dropoff 1 ;

248: DO[51:ClrOfDropoff1]=ON ;

249: ;

250: !Set Clear Of Interference Zone ;


252: ;

253: !Move Clear of Transfer ;

254:J P[11] 100% FINE ;

255: ;



258: ;

259: !Reset Robot At Work ;

260: DO[18:RbtAtWork]=OFF ;

261: ;

262: !MACRO-Return To Home ;

263: CALL MOV_HOME ;

264: ;

265: !Set Work Complete ;

266: DO[19:WorkComplete]=ON ;

267: ;

268: !Wait For Work Complete Ack ;

269: WAIT DI[32:WorkCompleteAck]=ON ;

270: ;

271: !Reset Work complete ;

272: DO[19:WorkComplete]=OFF ;

273: ;

274: LBL[1000:End] ;

275: ;

AS OF 1/12/2012 105 CUSW REL1.3


Dispense 1: !Carried Dispense Template ;

2: !******************************** ;





7: ;



10: ;



13: ;


15: !******************************** ;

16: ;


18: PAYLOAD[2] ;

19: ;


21: UTOOL_NUM=1 ;

22: ;


24: UFRAME_NUM=1 ;

25: ;


27: CALL APP_IO ;

28: ;



31: ;



34: ;



37: ;


39:J P[1] 100% FINE ;

40: ;



43: ;





47: ;



50: ;


52: CALL MVHMPNCE ;

53: ;


55: JMP LBL[1000] ;

56: ;


58: ;



61: ;



64: ;



67: !CALL ENTRZON1 ;

68: ;

69: !Pre-process Dispense Equipment ;

70: !(insert statements) ;

71: ;

72: !Wait for Dispenser Ready ;

73: WAIT (DI[385:Dsp1DispenRdy]=ON) ;

74: ;

75: !Set Disp Robot in Process ;

76: DO[393:Disp1RbtinPrc]=ON ;

77: ;

78: WAIT .10(sec) ;

79: ;

80: !Set Dispense Style ;

81: GO[31:Disp1StyBits]=1 ;

82: ;

83: WAIT .10(sec) ;

84: ;

85: !Set Disp Style Strobe ;

86: DO[394:Disp1StyStrobe]=ON ;

87: ;

88: !Wait for Disp in Process ;

89: WAIT DI[386:Dsp1DispenInPrc]=ON ;

90: ;

91: !Reset Dispense Style ;


93: ;

94: !Reset Disp Style Strobe ;

95: DO[394:Disp1StyStrobe]=OFF ;

96: ;



99: ;

100: !Move Seal Start, Turn On Gun ;

101:L P[2] 1000mm/sec CNT100 SS[1] ;

102: ;

103: !Move along Path ;

104:L P[3] 1000mm/sec CNT100 ;

105: ;

106: !Move To Seal End, Turn Off Gun ;

107:L P[4] 1000mm/sec CNT100 SE ;

108: ;

109: !Move Clear of Part ;

110:L P[5] 1000mm/sec FINE ;

111: ;



114: ;

115: !Set Dispense Complete ;

116: DO[401:Disp1Complete]=ON ;

117: ;

118: !Wait for Dispense Vol. OK ;

119: WAIT DI[387:Dsp1VolumeOK]=ON ;

120: ;

121: !Reset Dispense Complete ;

122: DO[401:Disp1Complete]=OFF ;

123: ;

124: !Reset Disp Robot in Process ;

125: DO[393:Disp1RbtinPrc]=OFF ;

126: ;

127: !Post-process Dispense Equip ;


129: ;



132: ;



135: ;



138: ;



141: ;



144: ;



147: ;

148: LBL[1000:End] ;

149: ;

AS OF 1/12/2012 106 CUSW REL1.3


Spot Welding 1: !Carried Spot Welding Template ;

2: !******************************** ;





7: ;



10: ;



13: ;


15: !******************************** ;

16: ;


18: PAYLOAD[2] ;

19: ;


21: UTOOL_NUM=1 ;

22: ;


24: UFRAME_NUM=1 ;

25: ;


27: CALL APP_IO ;

28: ;



31: ;



34: ;


36:J P[1] 100% FINE ;

37: ;



40: ;





44: ;



47: ;


49: CALL MVHMPNCE ;

50: ;


52: JMP LBL[1000] ;

53: ;


55: ;



58: ;



61: ;



64: CALL ENTRZON1 ;

65: ;

66: !Move to Weld 1 ;

67: !insert motion if necessary ;


69: ;

70: !Select Schedule Weld 1 ;

71:L P[3] 100mm/sec FINE

: SPOT[SD=1,P=1,S=1,ED=1] ;

72: ;




76: ;



: SPOT[SD=1,P=1,S=1,ED=1] ;

79: ;

80: !Move Clear of Clamps ;


82: ;

83: !Set Clear to Unclamp Early ;

84: DO[65:Clr2UnclampEarly]=ON ;

85: ;

86: !Check for Tip Dress Req ;

87: IF DI[28:TipDressGunReq]=ON,JMP LBL[30] ;

88: ;


90: CALL MOV_HOME ;

91: ;



94: ;



97: ;



100: ;



103: ;



106: ;

107: JMP LBL[1000] ;

108: ;

109: LBL[30] ;

110: ;

111: !Move Clear of Transfer ;

112: !To Tip Dress ;

113:J P[7] 50% FINE ;

114: ;



117: ;



120: ;



123: ;



126: ;



129: ;

130: !MACRO-Tip Dress Gun 1 ;

131: CALL TPDRSGN1(62) ;

132: ;



135: ;

136: CALL WR_UPDAT(1,0) ;

139: ;

140: LBL[1000:End] ;

;

AS OF 1/12/2012 107 CUSW REL1.3


Stud Welding 1: !Carried Stud Welding Template ;

2: !******************************** ;





7: ;



10: ;



13: ;


15: !******************************** ;

16: ;


18: PAYLOAD[2] ;

19: ;


21: UTOOL_NUM=1 ;

22: ;


24: UFRAME_NUM=1 ;

25: ;


27: CALL APP_IO ;

28: ;



31: ;



34: ;


36:J P[1] 100% FINE ;

37: ;



40: ;





44: ;



47: ;


49: CALL MVHMPNCE ;

50: ;


52: JMP LBL[1000] ;

53: ;


55: ;



58: ;



61: ;



64: CALL ENTRZON1 ;

65: ;




69: ;



: SPOT[S=1] ;

72: ;




76: ;



: SPOT[S=1] ;

79: ;

80: !Move Clear of Clamps ;


82: ;

83: !Set Clear to Unclamp Early ;

84: DO[65:Clr2UnclampEarly]=ON ;

85: ;


87: CALL MOV_HOME ;

88: ;



91: ;



94: ;



97: ;



100: ;



103: ;

AS OF 1/12/2012 108 CUSW REL1.3


Tip Change (Style #3) 1: !Tip Change Template ;

2: !****************************** ;





7: ;



10: ;



13: ;


15: !****************************** ;

16: ;


18: PAYLOAD[2] ;

19: ;


21: UTOOL_NUM=1 ;

22: ;


24: UFRAME_NUM=1 ;

25: ;


27: CALL APP_IO ;

28: ;



31: ;

32: !Insert Dress Approach Movement ;


34: ;



37: ;

37: !Wait for TipDressComplete ;

37: WAIT (1) sec. ;

37: ;

38: !Reset Tip Dress Complete ;

39: DO[29:TipDressComplt]=OFF ;

40: ;

41: !Move to Tip Change Position ;

42:J P[1] 100% FINE ;

43: ;

44: !Set Robot at Service ;

45: DO[26:RbtAtService]=ON ;

46: ;

47: !Set Ready for Tip Change ;

48: DO[30:RdyForTipChg]=ON ;

49: ;

50: !Wait for Service Complete ;

51: WAIT (DI[26:ServiceCompltReq]=ON) ;

52: ;

53: !Reset Robot at Service ;

54: DO[26:RbtAtService]=OFF ;

55: ;

56: !Reset Ready for Tip Change ;

57: DO[30:RdyForTipChg]=OFF ;

58: ;

59: !MACRO-Reset Stepper ;

60: CALL RST_STPR ;

61: ;

62: !MACRO-Seat Caps Gun 1 ;

63: CALL TW_PRSRT(1,500,2,4,1,10,5,15) ;

64: ;

65: !Tip Wear Compensation Gun 1 ;


67: ;

68: !Insert Dress Approach Movement ;


70: ;

71: !Pulse W1 Reset Water Saver ;

72: DO[586:W1RstWtrSvr]=PULSE,1.0sec ;

73: ;

74: !Wait for WaterOK ;

75: WAIT (DI[785:W1OKtoWeld]=ON) ;

76: ;



79: ;


81: CALL MOV_HOME ;

82: ;

Purge (Style #4)

1: !Purge Template ;

2: !****************************** ;





7: ;



10: ;



13: ;


15: !****************************** ;

16: ;


18: CALL APP_IO ;

19: ;



22: ;

23: !Set Ext Purge 1 in Progress ;

24: DO[97:ExtPurg1InProgrs]=ON ;

25: ;



28: ;

29: !Turn On Gun-Purge Schedule ;

30: DO[416:Disp1Purge]=ON ;

31: ;

32: !Wait 'X' Seconds ;

33: WAIT 7.00(sec) ;

34: ;

35: !Turn Off Gun ;

36: DO[416:Disp1Purge]=OFF ;

37: ;

38: !Post-process Disp Equipment ;


40: ;

41: !Reset Ext Purge 1 in Progress ;

42: DO[97:ExtPurg1InProgrs]=OFF ;

43: ;

44: !MACRO-Home IO (if necessary) ;

45: CALL HOME_IO ;

46: ;

AS OF 1/12/2012 109 CUSW REL1.3


Tip Burn In (Style #5) 1: !Tip Burn In Template ;

2: !****************************** ;





7: ;



10: ;



13: ;


15: !****************************** ;

16: ;


18: PAYLOAD[2] ;

19: ;


21: UTOOL_NUM=1 ;

22: ;


24: UFRAME_NUM=1 ;

25: ;



31: ;

32: !Move to Service Position ;

33: !if necessary ;

34:J PR[5] 100% FINE ;

35: ;

36: !MACRO-Tip Burn In ;

37: CALL TPBURNIN ;

38: ;


40: CALL MOV_HOME ;

41: ;

42: !MACRO-Home IO ;

43: CALL MOVE_IO ;

Service Program (Style #6)

1: !Service Program Template ;

2: !****************************** ;





7: ;



10: ;



13: ;


15: !****************************** ;

16: ;


18: PAYLOAD[2] ;

19: ;


21: UTOOL_NUM=1 ;

22: ;


24: UFRAME_NUM=1 ;

25: ;


27: CALL APP_IO ;

28: ;



31: ;

32: !Move to Service Position ;

33:J PR[5] 100% FINE ;

34: ;



37: ;

38: !Wait for Service Complt Req ;


40: ;



43: ;


45: CALL MOV_HOME ;

46: ;

Tip Dress Gun 1 (Style #7) 1: !Tip Dress 1st Gun Template ;

2: !****************************** ;





7: ;



10: ;



13: ;


15: !****************************** ;

16: ;


18: PAYLOAD[2] ;

19: ;


21: UTOOL_NUM=1 ;

22: ;


24: UFRAME_NUM=1 ;

25: ;


27: CALL APP_IO ;

28: ;



31: ;

32: !Insert Approach Movement ;


34: ;



37: ;


39: CALL MOV_HOME ;

40: ;

AS OF 1/12/2012 110 CUSW REL1.3


Tip Dress Gun 2 (Style #8) 1: !Tip Dress 2nd Gun Template ;

2: !****************************** ;





7: ;



10: ;



13: ;


15: !****************************** ;

16: ;


18: PAYLOAD[2] ;

19: ;


21: UTOOL_NUM=1 ;

22: ;


24: UFRAME_NUM=1 ;

25: ;


27: CALL APP_IO ;

28: ;



31: ;

32: !Insert Approach Movement ;


34: ;



37: ;


39: CALL MOV_HOME ;

40: ;

Tool Change (Style #9)

1: !Tool Change Template ;

2: !****************************** ;





7: ;



10: ;



13: ;


15: !****************************** ;

16: ;


18: PAYLOAD[2] ;

19: ;


21: UTOOL_NUM=1 ;

22: ;


24: UFRAME_NUM=1 ;

25: ;


27: CALL APP_IO ;

28: ;



31: ;

32: !Set Desired Tool ID ;

33: R[2]=GI[4:PickToolBits] ;

34: ;

35: !MACRO-Check Tool on Wrist ;

36: CALL CHK_TOOL ;

37: ;


39: CALL MOV_HOME ;

40: ;

AS OF 1/12/2012 111 CUSW REL1.3


Check ATI Errors (Macro) 1: !****************************** ;

2: !MACRO CHECK ATI ERRORS ;

3: !****************************** ;

4: !Parameters: AR[] ;

5: !1: Current Sequence ;

6: !****************************** ;

7: ;

8: !Jump to Current Sequence ;

9: R[16]=AR[1] ;

10: JMP LBL[R[16]] ;

11: ;

12: !****************************** ;

13: !READY TO PICK/LATCH/UNLATCH ;

14: !****************************** ;

15: LBL[1:ReadyToPick] ;

16: LBL[3:Latch] ;

17: LBL[7:Unlatch] ;

18: ;

19: !Set ATI Recovery Method ;

20: R[17]=1 ;

21: ;

22: IF (DI[648:RTLMismatch]),JMP LBL[648] ;

23: IF (DI[649:TSIVMismatch]),JMP LBL[649] ;

24: IF (DI[650:LatchOverLoad]),JMP LBL[650] ;

25: IF (DI[651:UnlatchOverLoad]),JMP LBL[651] ;

26: IF (DI[652:SpareOverload]),JMP LBL[652] ;

27: IF (DI[659:TSIVFault]),JMP LBL[659] ;

28: IF (DI[660:RTLFault]),JMP LBL[660] ;

29: IF (DI[653:RTLrtlvMismatch]),JMP LBL[653] ;

30: IF (DI[654:TSIVtsrvMismatch]),JMP LBL[654] ;

31: IF (DI[655:UnsafeUnlatch]),JMP LBL[655] ;

32: IF (DI[656:LckUnlckSensFlt]),JMP LBL[656] ;

33: IF (DI[657:LatchNotComplt]),JMP LBL[657] ;

34: IF (DI[658:UnlatchNotComplt]),JMP LBL[658] ;

35: ;

36: !OK - Exit ;

37: JMP LBL[999] ;

38: ;

39: !****************************** ;

40: !READY TO LATCH ;

41: !****************************** ;

42: LBL[2:ReadyToLatch] ;

43: ;


45: R[17]=0 ;

46: ;

47: IF (!DI[636:ReadyToLock1]),JMP LBL[636] ;

48: IF (!DI[637:ReadyToLock2]),JMP LBL[637] ;

49: ;

50: !OK - Exit ;

51: JMP LBL[999] ;

52: ;

53: !****************************** ;

54: !EXIT PICK/RDY TO DROP/EXT DROP ;

55: !****************************** ;

56: LBL[4:ExitPick] ;

57: LBL[5:ReadyToDrop] ;

58: LBL[8:ExitDrop] ;

59: ;


61: R[17]=0 ;

62: ;

63: IF (DI[648:RTLMismatch]),JMP LBL[648] ;

64: IF (DI[649:TSIVMismatch]),JMP LBL[649] ;

65: IF (DI[650:LatchOverLoad]),JMP LBL[650] ;

66: IF (DI[651:UnlatchOverLoad]),JMP LBL[651] ;

67: IF (DI[652:SpareOverload]),JMP LBL[652] ;

68: IF (DI[659:TSIVFault]),JMP LBL[659] ;

69: IF (DI[660:RTLFault]),JMP LBL[660] ;

70: IF (DI[653:RTLrtlvMismatch]),JMP LBL[653] ;

71: IF (DI[654:TSIVtsrvMismatch]),JMP LBL[654] ;

72: IF (DI[655:UnsafeUnlatch]),JMP LBL[655] ;

73: IF (DI[656:LckUnlckSensFlt]),JMP LBL[656] ;

74: IF (DI[657:LatchNotComplt]),JMP LBL[657] ;

75: IF (DI[658:UnlatchNotComplt]),JMP LBL[658] ;

76: ;

77: !OK - Exit ;

78: JMP LBL[999] ;

79: ;

80: !****************************** ;

81: !READY TO UNLATCH ;

82: !****************************** ;

83: LBL[6:ReadyToUnlatch] ;

84: ;


86: R[17]=0 ;

87: ;

88: IF (!DI[640:ToolStndIntlkV1]),JMP LBL[640] ;

89: IF (!DI[641:ToolStndIntlkV2]),JMP LBL[641] ;

90: ;

91: !OK - Exit ;

92: JMP LBL[999] ;

93: ;

94: !****************************** ;

95: !ERROR HANDLING ;

96: !****************************** ;

97: ;

98: !AUX POWER ;

99: LBL[635] ;

100: UALM[7] ;

101: JMP LBL[900] ;

102: ;

103: !READY TO LOCK1 ;

104: LBL[636] ;

105: UALM[8] ;

106: JMP LBL[900] ;

107: ;

108: !READY TO LOCK2 ;

109: LBL[637] ;

110: UALM[9] ;

111: JMP LBL[900] ;

112: ;

113: !TOOL STAND INTERLOCK1 ;

114: LBL[640] ;

115: UALM[10] ;

116: JMP LBL[900] ;

117: ;

118: !TOOL STAND INTERLOCK2 ;

119: LBL[641] ;

120: UALM[11] ;

121: JMP LBL[900] ;

122: ;

123: !RTL MISMATCH ;

124: LBL[648] ;

125: UALM[12] ;

126: JMP LBL[900] ;

127: ;

128: !TSIV MISMATCH ;

129: LBL[649] ;

130: UALM[13] ;

131: JMP LBL[900] ;

132: ;

133: !LATCH OVERLOAD ;

134: LBL[650] ;

135: UALM[14] ;

136: JMP LBL[900] ;

137: ;

138: !UNLATCH OVERLOAD ;

139: LBL[651] ;

140: UALM[15] ;

141: JMP LBL[900] ;

142: ;

143: !SPARE OVERLOAD ;

144: LBL[652] ;

145: UALM[16] ;

146: JMP LBL[900] ;

147: ;

148: !RTLRTLV MISMATCH ;

149: LBL[653] ;

150: UALM[17] ;

AS OF 1/12/2012 112 CUSW REL1.3


151: JMP LBL[900] ;

152: ;

153: !TSIVTSRV MISMATCH ;

154: LBL[654] ;

155: UALM[18] ;

156: JMP LBL[900] ;

157: ;

158: !UNSAFE UNLATCH ;

159: LBL[655] ;

160: UALM[19] ;

161: JMP LBL[900] ;

162: ;

163: !LOCK UNLOCK SENSOR FAULT ;

164: LBL[656] ;

165: UALM[20] ;

166: JMP LBL[900] ;

167: ;

168: !LATCH NOT COMPLETE ;

169: LBL[657] ;

170: UALM[21] ;

171: JMP LBL[900] ;

172: ;

173: !UNLATCH NOT COMPLETE ;

174: LBL[658] ;

175: UALM[22] ;

176: JMP LBL[900] ;

177: ;

178: !TSIV FAULT ;

179: LBL[659] ;

180: UALM[23] ;

181: JMP LBL[900] ;

182: ;

183: !RTL FAULT ;

184: LBL[660] ;

185: UALM[24] ;

186: JMP LBL[900] ;

187: ;

188: !****************************** ;

189: !RECOVERY ;

190: !****************************** ;

191: ;

192: LBL[900:Recovery] ;

193: ;

194: !Check Recovery Type ;

195: IF R[17]=1,JMP LBL[910] ;

196: ;

197: !Set Clear Errors ;

198: DO[635:ClearErrs]=ON ;

199: ;

200: !Wait 2 Seconds ;

201: WAIT 2.00(sec) ;

202: ;

203: !Reset Clear Errors ;

204: DO[635:ClearErrs]=OFF ;

205: ;

206: !Retry ;

207: JMP LBL[R[16]] ;

208: ;

209: LBL[910] ;

210: ;

211: !Reset Latch and Unlatch Tool ;

212: DO[632:LatchOrLock]=OFF ;

213: DO[633:UnlatchOrUnlock]=OFF ;

214: ;

215: !Set Clear Errors ;

216: DO[635:ClearErrs]=ON ;

217: ;

218: !Wait 2 Seconds ;

219: WAIT 2.00(sec) ;

220: ;

221: !Reset Clear Errors ;

222: DO[635:ClearErrs]=OFF ;

223: ;

224: LBL[999:End] ;

225: ;

Check Tool (Macro) 1: !****************************** ;

2: !MACRO CHECK TOOL ON WRIST ;

3: !****************************** ;

4: ;

5: LBL[1:Verify Tool] ;

6: ;

7: !Set Current Tool ID and ;

8: !Line Number ;

9: R[1]=(GI[41:ToolIDswtch1Bits]) ;

10: R[8]=(GI[45:ToolIDSwtch5Bits]) ;

11: GO[3:ToolIDOnWrstBits]=R[1] ;

12: ;

13: !Is Tool ID Correct? ;

14: IF R[1]=R[2],JMP LBL[999] ;

15: ;

16: !Is Tool on Wrist? ;

17: IF (!DI[644:ToolPresent] AND R[1]=15),JMP

LBL[2] ;

18: ;

19: !Drop Prep and Drop Tool ;

21: CALL PREPDROP ;

22: ;

23: JMP LBL[1] ;

24: ;

25: LBL[2:Pick Tool] ;

26: ;

27: !Select Pick Fixture & Pick ;

28: CALL PREPPICK ;

29: ;

30: JMP LBL[1] ;

31: ;

32: LBL[999:End] ;

33: ;

AS OF 1/12/2012 113 CUSW REL1.3


Drop Tool Nest 1 (Macro) 1: !****************************** ;

2: !MACRO DROP TOOL IN NEST 1 ;

3: !****************************** ;

4: ;

5: UTOOL_NUM=5 ;

6: UFRAME_NUM=0 ;

7: ;

8: DO[635:ClearErrs]=PULSE,1.0sec ;

9: ;

10: !Set Request to Enter Tool Nest ;

11: DO[71:Req2EntrToolNest]=ON ;

12: ;

13: !Wait Clear to Enter Tool Nest ;

14: WAIT DI[81:Clr2EntToolNest]=ON ;

15: ;

16: !Reset Clear of Tool Nest ;

17: DO[72:ClearOfToolNest]=OFF ;

18: ;

19: !Reset Request to Enter Nest ;

20: DO[71:Req2EntrToolNest]=OFF ;

21: ;

22: !MACRO-Set Tool Device Offline ;

23: CALL DV_OFFLN(2,31,10) ;

23: CALL DV_OFFLN(2,39,10) ;

24: ;

25: !Move to Tool Nest Perch/Approach ;

26:J P[3:Perch In] 100% FINE ;

27: ;

28: !PR[111:ToolOffset1] ;

29: !X=-150 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ;

30:L PR[101:ToolNest1Drop] 1200mm/sec FINE

Tool_Offset,PR[111:ToolOffset1]

: ;

31: ;


33: !X=-5 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ;



: ;

35: ;


37: !X=0 Y=0 Z=25 Rx=0 Ry=0 Rz=0 ;



: ;

39: ;

40: !MACRO-ATI State Check - Seq5 ;

41: IF DO[645:GeneralFaults]=ON,CALL ATI_CHCK(5) ;

42: ;

43: !Reset Out of Nest ;

44: DO[637:OutOfNest]=OFF ;

45: ;

46: !Move to Tool Nest ;

47: UTOOL_NUM=5 ;

48:L PR[101:ToolNest1Drop] 50mm/sec FINE ;

49: ;

50: !Wait for Tool in Nest 1 ;

51: WAIT DI[73:ToolInNest1]=ON ;

52: ;


54: CALL ATI_CHCK(6) ;

55: ;

56: LBL[7:RetryATISeq7] ;

57: ;

58: !Reset Latch Tool ;


60: ;

61: !Set Unlatch Tool ;

62: DO[633:UnlatchOrUnlock]=ON ;

63: ;

64: !Wait for ATI switches to settle in ;

64: WAIT DI[633:ToolUnLocked]=ON TIMEOUT,LBL[633] ;

65: LBL[633] ;

66: ;

67: !Wait for ATI ;

68: WAIT ((DI[633:ToolUnLocked] AND

!DI[632:ToolLocked]) OR

: DO[645:GeneralFaults]) ;

69: ;

70: !Check for Errors ;

71: IF DO[645:GeneralFaults]=OFF,JMP LBL[17] ;

72: ;



75: ;

76: JMP LBL[7] ;

77: ;

78: LBL[17:ATIUnlocked] ;

79: ;

80: !Set Payload Without Tool ;

81: PAYLOAD[2] ;

82: ;

83: UTOOL_NUM=9 ;

84: UFRAME_NUM=0 ;

85: ;

86:L PR[106:ToolNest1Pick] 150mm/sec FINE ;

87: ;

87: !Move Clear of Tool in Nest IO ;


89: !X=0 Y=0 Z=-15 Rx=0 Ry=0 Rz=0 ;

90:L PR[106:ToolNest1Pick] 150mm/sec FINE


: ;

91: ;


93: !Check for Disengagement ;

94: !of Tool Changer ;


96: ;



99: ;

100: !MACRO-ATI State Check ;


102: ;


104: !Check for Disengagement ;

105: !of Tool Changer ;


107: ;

108: LBL[8] ;

109: !Clear of Tool in Nest ;

110: ;


112: !X=0 Y=0 Z=-155 Rx=0 Ry=0 Rz=0 ;



: ;

114: ;

115: !Reset Unlatch Tool ;


117: ;

118: !Set Out of Nest ;

119: DO[637:OutOfNest]=ON ;

120: ;

121: !Clear Ati Errors ;


123: ;

124: UTOOL_NUM=9 ;

125: UFRAME_NUM=0 ;

126: ;

127: !Move Clear of Tool Nest ;

128:J P[2:Perch Out] 50% FINE ;

AS OF 1/12/2012 114 CUSW REL1.3


Pick Tool Nest 1 (Macro) 1: !****************************** ;

2: !MACRO PICK TOOL FROM NEST 1 ;

3: !****************************** ;

4: ;

5: UTOOL_NUM=9 ;

6: UFRAME_NUM=0 ;

7: ;

8: !Move to Tool Nest Perch ;

9:J P[1:Perch In] 100% FINE ;

10: ;

11: !Clear Ati Errors ;


13: ;

14: !Set Request to Enter Tool Nest ;

15: DO[71:Req2EntrToolNest]=ON ;

16: ;

17: !Wait Clear to Enter Tool Nest ;

18: WAIT DI[81:Clr2EntToolNest]=ON ;

19: ;

20: !Reset Clear of Tool Nest ;

21: DO[72:ClearOfToolNest]=OFF ;

22: ;

23: !Reset Request to Enter Nest ;

24: DO[71:Req2EntrToolNest]=OFF ;

25: ;

26: !

27: ;



30: !X=0 Y=0 Z=-155 Rx=0 Ry=0 Rz=0 ;



: ;

32: ;


34: !X=0 Y=0 Z=-50 Rx=0 Ry=0 Rz=0 ;



: ;

36: !Reset Out of Nest ;

37: DO[637:OutOfNest]=OFF ;

38: ;

39: LBL[10] ;

40: ;

41: !Check ATI Sensor States ;

42: WAIT (!DI[632:ToolLocked] AND

!DI[633:ToolUnLocked]) TIMEOUT,LBL[90] ;

43: ;


45: ;

46: !Reset Latch Tool ;


48: ;

49: !Set Unlatch Tool ;

50: DO[633:UnlatchOrUnlock]=ON ;

51: ;

52: WAIT DI[633:ToolUnLocked]=ON TIMEOUT,LBL[633] ;

53: LBL[633] ;

54: ;

55: !Wait for ATI Feedback ;

56: WAIT (DI[633:ToolUnLocked] OR

DO[645:GeneralFaults]) ;

57: ;

58: !Check for General Errors ;


60: ;

61: !ATI State Check - Seq1 ;


63: ;

64: JMP LBL[1] ;

65: ;

66: LBL[11:ToolUnlocked] ;

67: ;

68: !Move to Tool Nest ;

69: ;


71: !X=0 Y=0 Z=-25 Rx=0 Ry=0 Rz=0 ;



: ;

73:L PR[106:ToolNest1Pick] 50mm/sec FINE ;

74: ;



77: ;


79: ;

80: !Reset Unlatch Tool ;


82: ;

83: !Set Latch Tool ;

84: DO[632:LatchOrLock]=ON ;

85: ;

86: !MACRO-Set Tool Devices Online ;

87: CALL DV_ONLN(2,31,0) ;

87: CALL DV_ONLN(2,39,0) ;

88: ;

89: WAIT DI[632:ToolLocked]=ON TIMEOUT,LBL[632] ;

90: LBL[632] ;

91: ;

92: !Wait for ATI ;

93: WAIT ((DI[632:ToolLocked] AND

!DI[633:ToolUnLocked]) OR

: DO[645:GeneralFaults]) ;

94: ;

95: !Check for Errors ;


97: ;



100: ;

101: JMP LBL[3] ;

102: ;

103: LBL[13:ToolLocked] ;

104: ;

105: !Set Payload With Tool ;

106: PAYLOAD[1] ;

107: ;

108: !Verify Tool ID ;

109: IF GI[41:ToolIDswtch1Bits]<>R[2:Desired Tool

ID],JMP LBL[6] ;

110: ;

111: !Set Frames with new Tool ;

111: UTOOL_NUM=5 ;

112: UFRAME_NUM=0 ;

113: ;


115:L PR[6:ToolNest1] 50mm/sec FINE ;

116: ;


118: !X=0 Y=0 Z=25 Rx=0 Ry=0 Rz=0 ;



: ;


121: IF DO[645:GeneralFaults]=ON,CALL ATI_CHCK(4) ;

122: ;

123: !Set Out of Nest ;


125: ;


127: !X=-5 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ;



: ;

129: !Move Clear Tool Nest ;

130: ;


132: !X=-150 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ;



: ;

AS OF 1/12/2012 115 CUSW REL1.3


134: !Set Frames with new Tool again ;

134: UTOOL_NUM=5 ;

135: UFRAME_NUM=0 ;

136: ;

137: !Move to Tool Nest Perch ;

138:L P[2:Perch Out] 2000mm/sec FINE ;

139: ;

140: !Check If Device Is Online ;

141: CALL DV_STCHK(2,31,3) ;

142: IF R[3:Devnet Status]=2,JMP LBL[99] ;

143: ;

144: !Set Device Online ;

145: CALL DV_ONLN(2,31,30) ;

146: JMP LBL[99] ;

147: ;

148: LBL[6:ToolIDMismatch] ;

149: ;

150: !User Alarm - Unrecognized ;

151: !Tool on End-effector ;

152: UALM[1] ;

153: ABORT ;

154: ;

155: LBL[90:ATILockUnlockSns] ;

156: ;

157: !User Alarm - Lock or Unlock ;

158: !Sensor Incorrect State ;

159: UALM[26] ;

160: JMP LBL[10] ;

161: ;

162: LBL[99:End] ;

AS OF 1/12/2012 116 CUSW REL1.3


Enter Zone 1 (Macro) 1: !****************************** ;

2: !Enter Zone 1 Macro ;

3: !****************************** ;

4: ;

5: !Reset Clear of Zone 1 ;

6: DO[33:RobotClrZone1]=OFF ;

7: ;

8: !Wait for OK To Enter Zone 1 ;

9: WAIT DI[33:Zone1ClrToEnter]=ON ;

10: ;

Home IO (Macro) 1: !****************************** ;

2: !MACRO Setup Outputs ;

3: !****************************** ;

4: ;

5: GO[1:ActiveStyle]=0 ;

7: ;

8: DO[18:RbtAtWork]=OFF ;




12: DO[28RbtInTipDress]=OFF ;


14: DO[31:ClearToTransfer]=ON ;

15: ;

16: !Zones ;









25: ;

26: !Pickup/Dropoff ;

















43: ;

44: DO[65:Clr2UnclampEarly]=OFF;

45: DO[71:Req2ToEnterTN]=OFF ;

46: DO[72:ClrOfToolNest]=ON ;

47: DO[89:PickOverride]=OFF ;

48: DO[94:AbortPickReq]=OFF ;

49: DO[102:StepperRst1Ack]=OFF ;

50: DO[103:StepperRst2Ack]=OFF ;

51: DO[104:TipBurnInComplt]=OFF ;

52: DO[105:RbtClrFixt1]=ON ;



55: GO[2:ReposTooling]=0 ;

56: ;

57: GO[31:Disp1StyleBits]=0 ;




61: ;


63: DO[640:ToolNotPresent]=OFF ;

64: DO[641:InvalidToolReqd]=OFF ;

65: DO[642:UnxpctdToolPrsnt]=OFF ;

66: DO[643:Nest not Empty]=OFF ;

67: DO[644:Nest is Empty]=OFF ;

68: ;

AS OF 1/12/2012 117 CUSW REL1.3


Process Application – Ped Spot (Macro) 1: !****************************** ;

2: !MACRO PED SPOT WELD;

3: !****************************** ;

4: ;




8: ;



: SPOT[SD=1,P=1,S=1,ED=1] ;

11: ;




15: ;



: SPOT[SD=1,P=1,S=1,ED=1] ;

18: ;

19: !Move Clear of Ped Welder ;


21: ;

22: LBL[20] ;

23: ;

24: !Dropoff/Tip Change/Tip Dress ;

25: WAIT (DI[51:GoToDropoff1]=ON OR

DI[28:TipDressGunReq]=ON OR

DI[105:TipChangeReq]=ON OR

DI[104: TipBurnInReq]=ON OR

DI[27: ServiceRequest]=ON);

26: ;

27: !Check for Tip Change ;

28: IF DI[105:TipChangeReq]=ON,JMP LBL[30] ;

29: ;

30: !Check for Tip Dress ;

31: IF DI[28:TipDressGunReq]=ON,JMP LBL[40] ;

32: ;

33: !Check for Tip Burn In ;

34: IF DI[104:TipBurnInReq]=ON,JMP LBL[50] ;

35: ;

36: !Check for Service Request ;

37: IF DI[27:ServiceRequest]=ON,JMP LBL[60]

38: ;

39: !Check for go to Dropoff ;

40: IF DI[51:GoToDropoff1]=ON,JMP LBL[70] ;

41: ;

42: !****************************** ;

43: LBL[30:TipChange] ;

44: ;

45: !MACRO-Tip Dress Ped ;

46: CALL TPDRSPD(0) ;

47: ;

48: !Reset Tip Dress Complete ;


50: ;

51: !MACRO-Tip Change Ped ;

52: CALL TPCHGPD ;

53: ;



56: ;

57: JMP LBL[20] ;

58: ;

59: !****************************** ;

60: LBL[40:TipDress] ;

61: ;



64: ;

65: JMP LBL[20] ;

66: ;

67: !****************************** ;

68: LBL[50:TipBurnIn] ;

69: ;

70: !MACRO-Tip Burn In ;

71: CALL TPBURNIN ;

72: ;

73: JMP LBL[20] ;

74: ;

75: !****************************** ;

76: LBL[60:Service_W_Part] ;

77: ;

78: !MACRO-Srv_With_Prt ;

79: CALL Srv_With_Prt ;

80: ;

81: JMP LBL[20] ;

82: ;

83: !****************************** ;

84: LBL[70:Dropoff] ;

85: ;

AS OF 1/12/2012 118 CUSW REL1.3


Process Application – Ped Dispense (Macro) 1: !****************************** ;

2: !MACRO PED DISPENSE ;

3: !****************************** ;

4: ;

5: !Pre-processing for Disp Equip ;

6: !Insert Statements ;

7: ;

8: !Wait for Dispenser Ready ;

9: WAIT (DI[385:Dsp1DispenRdy]=ON) ;

10: ;

11: !Set Disp Robot in Process ;

12: DO[393:Disp1RbtinPrc]=ON ;

13: ;

14: WAIT .10(sec) ;

15: ;

16: !Set Dispense Style ;


18: ;

19: WAIT .10(sec) ;

20: ;

21: !Set Disp Style Strobe ;

22: DO[394:Disp1StyStrobe]=ON ;

23: ;

24: !Wait for Disp in Process ;

25: WAIT DI[386:Dsp1DispenInPrc]=ON ;

26: ;

27: !Reset Dispense Style ;


29: ;

30: !Reset Disp Style Strobe ;


32: ;



35: ;

36: !Move Seal Start, Turn On Gun ;

37:L P[1] 1000mm/sec CNT100 SS[1] ;

38: ;

39: !Move along Path ;

40:L P[2] 100mm/sec CNT100 ;

41: ;

42: !Move To Seal End, Turn Off Gun ;

43:L P[3] 1000mm/sec CNT100 SE ;

44: ;

45: !Move Clear of Nozzle ;


47: ;



50: ;

51: !Set Dispense Complete ;

52: DO[401:Disp1Complete]=ON ;

53: ;

54: !Wait for Dispense Vol. OK ;

55: WAIT DI[387:Dsp1VolumeOK]=ON ;

56: ;

57: !Reset Dispense Complete ;


59: ;

60: !Reset Disp Robot in Process ;


62: ;

63: !Post-processing for Disp Equip ;

64: !Insert Statements ;

65: ;

66: LBL[20] ;

67: ;

68: !Purge or Go To Dropoff ;

69: WAIT (DI[51:GoToDropoff1]=ON OR

DI[95:PurgeGun1Req]=ON) ;

70: ;

71: !Check for Dropoff ;

72: IF DI[51:GoToDropoff1]=ON,JMP LBL[30] ;

73: ;

74: !MACRO - Purge Ped Gun 1 ;

75: CALL PRGPDGN1 ;

76: ;

77: JMP LBL[20] ;

78: ;

79: LBL[30:Dropoff] ;

80: ;

Need Fine

term type or

more robot

positions

(delay time).

Because the

SE instruction

is to close to

the

DO[401:dispe

nsecomplete].

The Nordson

may see both

signals turn

ON at the

same time due

to their scan

rate.

Example: SS[1]

–seal schedule is

using BW TCPP

(robot tool center

point position)

changes digital

IO per robot

speed. In the SS

command use

the following per

robot speed

500mm/sec:

200mm=10volt

100mm=5volts

OR

Change SS[1] -

flow rate to be

direct voltage

AS OF 1/12/2012 119 CUSW REL1.3


Process Application – Ped Stud (Macro) 1: !****************************** ;

2: !MACRO PED STUD WELD;

3: !****************************** ;

4: ;




8: ;



: SPOT[S=1] ;

11: ;




15: ;



: SPOT[S=1] ;

18: ;

19: !Move Clear of Ped Welder ;


21: ;

Purge Ped Gun (Macro) 1: !****************************** ;

2: !MACRO PURGE PED GUN 1 ;

3: !****************************** ;

4: ;

5: !Set Ext Purge 1 in Progress ;

6: DO[97:ExtPurg1InProgrs]=ON ;

7: ;



10: ;

11: !Turn On Gun-Purge Schedule ;

12: DO[416:Disp1Purge]=ON ;

13: ;

14: !Wait 'X' Seconds ;

15: WAIT 7.00(sec) ;

16: ;

17: !Turn Off Gun ;

18: DO[416:Disp1Purge]=OFF ;

19: ;

20: !Post-process Disp Equipment ;


22: ;

23: !Reset Ext Purge 1 in Progress ;

24: DO[97:ExtPurg1InProgrs]=OFF ;

25: ;

Reset Stepper (Macro) 1: !****************************** ;

2: !MACRO RESET STEPPER ;

3: !****************************** ;

4: ;

5: !Set Weld 1 Reset Stepper ;

6: DO[590:W1ResetStepper]=ON ;

7: ;

8: !Wait for Stepper Reset ;

9: WAIT DI[204:W1 SteppersReset]=ON ;

10: ;

11: !Reset Weld 1 Reset Stepper ;

12: DO[590:W1ResetStepper]=OFF ;

13: ;

Tip Burn In (Macro) 1: !****************************** ;

2: !MACRO TIP BURN IN ;

3: !****************************** ;

4: ;

5: !Reset Registers for Burn In ;

6: R[14]=0 ;

7: ;

8: LBL[1] ;

9: ;

10: !Burn In ;


: SPOT[SD=1,P=1,S=62,ED=1] ;

12: ;

13: !Total Number of Burn Ins ;

14: R[14]=R[14]+1 ;

15: ;

16: !Check Number of Burn-ins ;

17: IF R[14]<R[15],JMP LBL[1] ;

18: ;

19: !MACRO-Tip Wear Compensation ;


21: ;

22: !Set Tip Burn-in Complete ;

23: DO[104:TipBurnInComplt]=ON ;

24: ;

Tip Change Ped Gun (Macro) 1: !****************************** ;

2: !MACRO TIP CHANGE PED GUN ;

3: !****************************** ;

4: ;

5: !Pulse W1 Water Off ;

6: DO[587:W1WtrOff]=PULSE,1.0sec ;

7: ;



10: ;

11: !Set Ready for Tip Change ;

12: DO[30:RdyForTipChg]=ON ;

13: ;

14: !Wait for Service Complete ;


16: ;



19: ;

20: !Reset Ready for Tip Change ;

21: DO[30:RdyForTipChg]=OFF ;

22: ;

23: !MACRO-Reset Stepper ;

24: CALL RST_STPR ;

25: ;

26: !MACRO-Seat Caps Gun 1 ;

27: CALL TW_PRSRT(1,500,2,4,1,10,5,15) ;

28: ;

29: !Tip Wear Compensation Gun 1 ;


31: ;

32: !Pulse W1 Reset Water Saver ;

33: DO[586:W1RstWtrSvr]=PULSE,1.0sec ;

34: ;

AS OF 1/12/2012 120 CUSW REL1.3


Tip Dress Gun 1 (Macro) 1: !******************************** ;

2: !MACRO Tip Dress Carried gun 1 ** ;

3: !******************************** ;

4: ;

5: !Setup Weld Register ;

6: R[19:Gun1BurnInSched]=AR[1] ;

7: ;

8: IF DI[127:TipdressBypassed]=ON,JMP LBL[20] ;

9: ;

10: !Set Robot In Tip Dress ;

11: DO[28:RobotInTipDress]=ON ;

12: ;

13: !T/Dress Approach (Common Pos.) ;

14:J PR[4:MHWait/TDCom Pos] 50% FINE ;

15:J P[1] 80% CNT25 ;

16:J P[2] 80% CNT25 ;

17:J P[3] 80% CNT25 ;

18:J P[4] 80% CNT10 ;

19: ;

20: !Turn On Tip Dress Motor ;

21: DO[101:TurnOnTipDresser]=ON ;

22: ;

23: !Wait Tip Dress Motor On ;

24: WAIT DI[101:TipDrsMotorOn]=ON ;

25: ;

26: !Before/After Tip Dress ;


28: ;

29: !At Tip Dress ;


: SPOT[SD=2,P=60,S=60,ED=2] ;

31: ;


33:L P[5] 800mm/sec CNT10 ;

34: ;

35: !Turn Off Tip Dress Motor ;

36: DO[101:TurnOnTipDresser]=OFF ;

37: ;

38:L P[4] 1600mm/sec CNT50 ;

39:J P[3] 80% CNT25 ;

40:J P[2] 80% CNT25 ;

41:J P[1] 80% CNT25 ;

42: ;


44:J PR[4:MHWait/TDCom Pos] 80% CNT50 ;

45: ;

46: !STYLE003 Wear Update & ;

47: !Burn In Skip ;

48: IF R[19:Gun1BurnInSched]=0,JMP LBL[10] ;

49: ;



52: ;

53: !Set Tip Dress Complete ;

54: DO[29:TipDressComplt]=ON ;

55: ;

56: LBL[20:TIPDRESS BYPASS] ;

57: ;


59: ;

60: !Do Tip Burn In Weld Schedule ;

61: SPOT[SD=4,P=62,S=R[19],ED=4] ;

62: ;

63: LBL[10:SKIP TIPBURN] ;

64: ;

65: !******************************** ;

66: !CNT CAN NOT CHANGE MUST BE FINE ;

67:J PR[1:Home 1] 80% FINE ;

68: !******************************** ;

69: ;

70: !Reset Robot In Tip Dress ;

71: DO[28:RobotInTipDress]=OFF ;

Tip Dress Gun 2 (Macro) 1: !******************************** ;

2: !MACRO Tip Dress Carried gun 2 ** ;

3: !******************************** ;

4: ;



7: ;

8: IF DI[127:TipdressBypassed]=ON,JMP LBL[20] ;

9: ;

10: !Set Robot In Tip Dress ;

11: DO[28:RobotInTipDress]=ON ;

12: ;


14:J PR[4:MHWait/TDCom Pos] 50% FINE ;

15:J P[1] 80% CNT25 ;

16:J P[2] 80% CNT25 ;

17:J P[3] 80% CNT25 ;

18:J P[4] 80% CNT10 ;

19: ;

20: !Turn On Tip Dress Motor ;


22: ;



25: ;



28: ;

29: !At Tip Dress ;


: SPOT[SD=2,P=60,S=61,ED=2] ;

31: ;


33:L P[5] 800mm/sec CNT10 ;

34: ;

35: !Turn Off Tip Dress Motor ;


37: ;

38:L P[4] 1600mm/sec CNT50 ;

39:J P[3] 80% CNT25 ;

40:J P[2] 80% CNT25 ;

41:J P[1] 80% CNT25 ;

42: ;


44:J PR[4:MHWait/TDCom Pos] 80% CNT50 ;

45: ;

46: !STYLE003 Wear Update & ;

47: !Burn In Skip ;


49: ;



52: ;



55: ;

56: LBL[20:TIPDRESS BYPASS] ;

57: ;


59: ;


61: SPOT[SD=4,P=62,S=R[19],ED=4] ;

62: ;

63: LBL[10:SKIP TIPBURN] ;

64: ;

65: !******************************** ;

66: !CNT CAN NOT CHANGE MUST BE FINE ;

67:J PR[1:Home 1] 80% FINE ;

68: !******************************** ;

69: ;

70: !Reset Robot In Tip Dress ;

71: DO[28:RobotInTipDress]=OFF ;

AS OF 1/12/2012 121 CUSW REL1.3


Tip Dress Ped Gun (Macro) 1: !****************************** ;

2: !MACRO TIP DRESS PED GUN ;

3: !****************************** ;

4: !Parameters: AR[] ;

5: !1: Burn In Schedule Gun 1 ;

6: !****************************** ;

7: ;



10: ;

11: !Set Robot in Tip Dress ;

12: DO[28:RbtInTipDress]=ON ;

13: ;

14: !Wait for Tip Dress Dump Ext ;

15: WAIT DI[99:TipDressDumpExtd]=ON ;

16: ;

17: !Turn On Tip Dresser ;


19: ;



22: ;

23: !Do Tip Dress Weld Schedule ;


: SPOT[SD=1,P=1,S=60,ED=1] ;

25: ;

26: !Reset Turn On Tip Dresser ;


28: ;

29: !Reset Tip Dress Request ;

30: DO[100:TipDressReq1]=OFF ;

31: ;



34: ;

35: !Wait for Tip Dress Dump Ret ;

36: WAIT DI[100:TipDrsDumpRtrct]=ON ;

37: ;

38: !Check If Burn In Required ;


40: ;



: SPOT[SD=1,P=1,S=R[19],ED=1] ;

43: ;



46: ;

47: LBL[10:SkipBurnIn] ;

48: ;

49: !Reset Robot in Tip Dress ;

50: DO[28:RbtInTipDress]=OFF ;

51: ;

AS OF 1/12/2012 122 CUSW REL1.3


Tool Drop Preperation (Macro) 1: !****************************** ;

2: !MACRO TOOL DROP PREPARATION ;

3: !****************************** ;

4: ;

5: LBL[1:Retry] ;

6: ;

7: !Select Tool ;

8: SELECT R[1]=1,JMP LBL[10] ;

9: =2,JMP LBL[20] ;

10: =3,JMP LBL[30] ;

11: =4,JMP LBL[40] ;

12: ELSE,JMP LBL[90] ;

13: ;

14: LBL[10:Tool1] ;

15: ;

16: !Verify Part Not Present ;

17: Check No Part(1,2,3,4) ;

18: ;

19: !MACRO-Set Active MH Tool ;


21: ;

22: !Set Tool 1 Drop State ;


24: ;

25: !Verify Nest Empty Before Drop ;

26: IF DI[73:ToolInNest1]=ON,JMP LBL[95] ;

27: ;

28: !MACRO-Drop Tool in Nest 1 ;

29: CALL NST1DROP ;

30: ;

31: JMP LBL[99] ;

32: ;

33: ;

34: LBL[20:Tool2] ;

35: ;


37: Check No Part(1,2,3,4) ;

38: ;



41: ;



44: ;



47: ;


49: CALL NST2DROP ;

50: ;

51: JMP LBL[99] ;

52: ;

53: ;

54: LBL[30:Tool3] ;

55: ;


57: Check No Part(1,2,3,4) ;

58: ;



61: ;



64: ;



67: ;


69: CALL NST3DROP ;

70: ;

71: JMP LBL[99] ;

72: ;

73: ;

74: LBL[40:Tool4] ;

75: ;


77: Check No Part(1,2,3,4) ;

78: ;



81: ;



84: ;



87: ;


89: CALL NST4DROP ;

90: ;

91: JMP LBL[99] ;

92: ;

93: !****************************** ;

94: !ALARMS ;

95: !****************************** ;

96: ;

97: !Unexpected Tool Present ;

98: LBL[90:WrongTool] ;

99: ;

100: !Set Application Error Output ;

101: DO[642:UnxpctdToolPrsnt]=ON ;

102: ;

103: !Post User Alarm ;

104: UALM[3] ;

105: ;

106: !Reset Appliction Error Output ;

107: DO[642:UnxpctdToolPrsnt]=OFF ;

108: ;

109: JMP LBL[1] ;

110: ;

111: !Nest not Empty;

112: LBL[95:Nest not Empty] ;

113: ;

114: !Set Application Error Output ;

115: DO[643:Nest not Empty]=ON ;

116: ;


118: UALM[4] ;

119: ;

120: !Reset Not not Empty ;

121: DO[643:Nest not Empty]=OFF ;

122: ;

123: JMP LBL[1] ;

124: ;

125: LBL[99:End] ;

126: ;

AS OF 1/12/2012 123 CUSW REL1.3


Tool Pick Preperation (Macro) 1: !****************************** ;

2: !MACRO TOOL PICK PREPARATION ;

3: !****************************** ;

4: ;

5: LBL[1] ;

6: ;

7: !Select Tool Nest for Pick ;

8: SELECT R[2]=1,JMP LBL[10] ;

9: =2,JMP LBL[20] ;

10: =3,JMP LBL[30] ;

11: =4,JMP LBL[40] ;

12: ELSE,JMP LBL[90] ;

13: ;

14: LBL[10:Tool1] ;

15: ;

16: !Verify Tool in Nest B4 Pick ;

17: IF DI[73:ToolInNest1]=OFF,JMP LBL[95] ;

18: ;

19: !MACRO-Pick Tool in Nest 1 ;

20: CALL NST1PICK ;

21: ;

22: JMP LBL[99] ;

23: ;

24: LBL[20:Tool2] ;

25: ;



28: ;


30: CALL NST2PICK ;

31: ;

32: JMP LBL[99] ;

33: ;

34: LBL[30:Tool3] ;

35: ;



38: ;


40: CALL NST3PICK ;

41: ;

42: JMP LBL[99] ;

43: ;

44: LBL[40:Tool4] ;

45: ;



48: ;


50: CALL NST4PICK ;

51: ;

52: JMP LBL[99] ;

53: ;

54: !****************************** ;

55: !ALARMS ;

56: !****************************** ;

57: ;

58: !Invalid Tool Requested ;

59: LBL[90:WrongTool] ;

60: ;

61: !Set Application Error ;

62: !DO[641:InvalidToolReqd]=ON ;

63: ;


65: UALM[2] ;

66: ;

67: !Reset Application Error ;

68: !DO[641:InvalidToolReqd]=OFF ;

69: ;

70: JMP LBL[1] ;

71: ;

72: !Tool Nest is Empty ;

73: LBL[95:Nest is Empty] ;

74: ;

75: !Set Application Error ;

76: DO[644:Nest is Empty]=ON ;

77: ;


79: UALM[5] ;

80: ;

81: !Reset Application Error ;

82: DO[644:Nest is Empty]=OFF ;

83: ;

84: JMP LBL[1] ;

85: ;

86: LBL[99:End] ;

87: ;

Documents

Chrysler Cusw Fanuc Robot Standard Rel 1.3