Gluetech 30 En

KRS GlueTech V3.0 11.04.01 en

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SOFTWARE

KR C...

KUKA GlueTech 3.0

KUKA SystemTech (KRS)

Release 5.2, 5.3, 5.4

Issued: 22 Nov 2004 Version: 01

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� Copyright KUKA Roboter GmbHThis documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, inthe case of a replacement or service work.We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepanciescannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on aregular basis, however, and necessary corrections will be incorporated in subsequent editions.Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

1 Introduction 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Characteristics 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 System requirements 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1 Software 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.2 Hardware 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 About this documentation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Hardware (short description) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Adhesive/sealant application system (example) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Swirl spraying method (bead shaping) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Installation / uninstallation / update 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 General 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 New files added 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Additional menus for KUKA GlueTech 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1 Menus for setup and operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.2 Menu for changing the status keys 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Configuration and start–up 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Configuration program GluetechData.exe 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Functional description 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1.1 Menu keys 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Softkeys 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3 Application with more than one dispensing controller 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Configuring the inputs and outputs 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Linear characteristic 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 I/O interface adaptation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Configuring equipment–specific data 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 Equipment–specific data – Description 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2 Adapting the variable values using “GluetechData.exe 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3 Calibration with the aid of the KRL program “Calibrate_Equipment” 21. . . . . . . . . . . . . . . . . . . 4.3.3.1 Determining the CP velocity 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3.2 Data used for calibration 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3.3 Calibration variables 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3.4 Gun times 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3.5 Verifying the setup data 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3.6 Function selection 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3.7 Performing the selected function 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3.8 Verifying the switching points 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3.9 Correcting the switching point 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Configuring technology–specific data 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1 Technology–specific data – Description 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Configuring technology–specific options 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1 Technology–specific options – Description 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5 Programming 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Program example 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Standard program 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2 Main program 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.3 Subprogram 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Creating an adhesive application task 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Entering commands 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Motion instructions 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1.1 Gun on – GLUE ON LIN 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1.2 Switching gluing parameters – GLUE SWITCH LIN 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1.3 Gun off – GLUE OFF LIN 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1.4 Gun on – GLUE ON CIRC 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1.5 Switching the bonding parameters – GLUE SWITCH CIRC 37. . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1.6 Gun off – GLUE OFF CIRC 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1.7 Gun on – GLUE ON PTP 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1.8 Gun off – GLUE OFF PTP 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2 Gluing instructions 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2.1 Initialize system 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2.2 Set program number 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2.3 Set motion parameter 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2.4 Reset motion parameter 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2.5 Dispense complete 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2.6 Reload doser 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2.7 Error check 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2.8 Purge gun 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2.9 Monitoring purge gun 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2.10 Teaching the purging position 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2.11 Enable for purging 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Variables 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 I/O interface variables 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Variables in $Config.dat 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Variables in Glue.dat 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Messages 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 Introduction

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1 Introduction

1.1 Characteristics

The technology package “GlueTech” is used for convenient programming of adhesiveapplication tasks using KUKA KR C... robot controllers.

It can be used to control up to three dispensing controllers, one of which can be operatedat any given time.

1.2 System requirements

1.2.1 Software

The basic system requirements for the GlueTech technology package are:

– GlueTech Release 3.0 KRC... System Software Release 5.2, 5.3, 5.4

1.2.2 Hardware

� Standard KR C... robot controller

� Field bus card

� Dispensing controller SCA ASC 5000

While the configuration and programming of GlueTech applications require no specialtraining, adequate knowledge of the KR C... robot controllers and their configuration andprogramming is necessary.

To parameterize GlueTech commands properly, expertise is required with adhesiveapplication systems and the additional devices adapted for use on the robot.

1.3 About this documentation

This documentation contains a description of the software for the “GlueTech” technology package, including:

� instructions for the dispensing controller hardware;

� installation, uninstallation and reinstallation of the “GlueTech” software;

� configuration and commissioning;

� programming of adhesive bonding applications;

� description of the system messages.

Information about the robot controller can be found in the operating and programminghandbooks supplied with the robot.

With regard to the configuration, commissioning and operation of the adhesive applicationsystem being used and its associated controller, please refer to the correspondingdocumentation of the equipment manufacturer.

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2 Hardware (short description)This section contains a short description of the hardware for an adhesive application systemand the associated dispensing controller.

All technical specifications in this documentation which refer to non–KUKA dispensingcontrollers are provided for informational purposes only, and no guarantee is maderegarding the completeness or accuracy of such specifications.

For detailed information, please refer to the documentation of the dispensing controllermanufacturer.

2.1 Adhesive/sealant application system (example)

Adhesive and sealant application systems consist principally of the following main components:

– Dispensing controller

– Proportional valve for material

– Proportional valve for air

– Adhesive gun (adhesive nozzle)

Air

Adhesive

1

3

2

4

5

6

1. Dispensing controller

2. Dispenser

3. Proportional valve for air

4. Infeed for material

5. Gun

6. Nozzle

Fig. 1 Schematic diagram of adhesive application system

2 Hardware (short description) (continued)

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Additional components are the adhesive supply (adhesive drum pump), compressed airsupply, power supply and connection with the robot controller and, if necessary, the PLC.

The adhesive application system has two independent control loops:

� Adhesive delivery rate

� Air spray rate

These two control parameters can be specified using the velocity–proportional analog voltage.Control functions are performed by analog outputs of the robot controller via a field bus.

2.2 Swirl spraying method (bead shaping)

In the swirl spraying method (bead shaping), a rapidly rotating “air funnel” is formed by meansof air slits arranged radially about the adhesive aperture. This causes the adhesive bead tospin as it exits the nozzle. The mode of functioning is shown schematically below:

Adhesiveaperture Air slits

Direction of rotation

Adhesive gun

Component

Adhesive

Adhesive bead

Rotatingcone–shaped“air funnel”

Fig. 2 Swirl spraying method

During spray application, the distance from the component is generally between 20 and50 mm. Because the rotating adhesive bead is cone–shaped, the width of adhesiveapplication depends on this distance. Thus the spray pattern along an adhesive applicationpath generally becomes wider as the distance increases.

In addition to the distance of the adhesive gun from the component, the air spray parameters(higher or lower pressure) can also be used to change the width of the material application.

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3 Installation / uninstallation / update

3.1 General

Technology packages are offered exclusively as add–on software modules on CD–ROM.

Fundamental information about the installation, uninstallation, reinstallation andupdate of technology packages is contained in the documentation “Installation/Uninstallation/Update of Tech Packages”.

3.2 New files added

The following files are added during installation of the GlueTech technology package:

Directory C:\Krc\Roboter\Krc\R1\Tp\Gluetech

File name Function / Short description

Calibrate_Equip-ment.src

Program with routines for determining the application–specific delay times of the adhesive application equipmentbeing used, for example reaction time for adhesive gunON/OFF.

Calibrate_Equip-ment.dat

Data list for “Calibrate_Equipment.src”.

Glue.src KRL routines of the GlueTech technology package.

Glue.dat Data list for “Glue.src”.

GlueBackground.sub Routine for cyclical monitoring of the GlueTech technologypackage.

GlueBackground.dat Data list for “GlueBackground.Sub”.

GlueUser.src KRL routines for users.

Directory C:\Krc\Tp\Gluetech\Data


GlueCal.mdb Language database for the program “Calibrate_Equipment.src”.

GlueIO.mdb Language database of signal names contained in theGlueTech technology package.

GlueTech.mdb Language database of the GlueTech technology package.

Directory C:\Krc\Tp\Gluetech\Lib


TPGLUE.dll DLL for the GlueTech technology package.

3 Installation / uninstallation / update (continued)

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Directory C:\Krc\Tp\Gluetech\Util


GluetechData.exe Offline program for displaying and configuring data of theGlueTech technology package, for example times, inputs,outputs, etc.

GluetechIO.txt File for the offline program “GluetechData.exe”.

3.3 Additional menus for KUKA GlueTech

3.3.1 Menus for setup and operation

Once the robot controller has rebooted, the menus “Setup” and “Technology” each containa new menu item (caution: the type and number of technology packages displayed dependon your software configuration):

3.3.2 Menu for changing the status keys

You can change the left–hand status key bar by means of the “Configure” menu.

The menu function “Configure” � “GLUE Tech” makes available a special status key for“GLUETech” applications, making it possible to switch between normal program execution(i.e. the actual adhesive application process) and merely moving over the programmed path(without material).

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Three different status key bars are available; you can switch between them using the “NextMenu” status key at the bottom left. This status key has a toggle function.

Status key menu 1

The following status keys are available in status key menu 1:

Dispensing controller error messages can be acknowledged using the [Quit] status key.

The [Wet] status key corresponds to normal program execution (with material).

If the [Dry] status key is activated, the robot merely moves over the programmed path (“dryrun”, without material).

Status key menu 2


Selects the dispensing controller for manual processes. The numeral (in this example “1”)indicates the dispensing controller (1...3) in accordance with the configuration.

Selects the adhesive gun for manual processes.

Selects the dispenser for manual processes.

3 Installation / uninstallation / update (continued)

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Status key menu 3


The selected dispensing controller is purged for as long as this status key is held down.

The selected adhesive gun is cleared with compressed air for as long as this status key isheld down.

The selected dispenser is filled.

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4 Configuration and start–upThe configuration and setup of the GlueTech technology package are described in thefollowing sections. The intention is to give you as the user the ability to configure thehardware and applications you are using in accordance with the particular circumstances.

4.1 Configuration program GluetechData.exe

The program “GluetechData.exe” contained in the GlueTech technology package can beused to easily display and configure the inputs, outputs, and equipment–specific andtechnology–specific data.

This program can be called using various menu functions:

� “Setup” � “GLUE Tech” � “Configure process data”;

� “Setup” � “GLUE Tech” � “I/O Configuration”;

� “Technology” � “GLUE Tech” � “Show dispense data”;

The technology packages displayed depend on the specific software configuration.

When “GLUE Tech” is selected, the program “GluetechData.exe” is started in display mode.The display is dependent on the specific selection that is made.

4 Configuration and start–up (continued)

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4.1.1 Functional description

Navigation is carried out using the menu keys and softkeys of the KUKA Control Panel (KCP)or a mouse connected to the control PC.

Operator control using the KCP menu keys and softkeys is described below.

4.1.1.1 Menu keys

Five menu keys are available for displaying technology–specific and equipment–specificdata, configured inputs and outputs, and various settings:

Display technology–specific data.

Display equipment–specific data.

Display configured inputs.

Display configured outputs.

Display configured settings.

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4.1.2 Softkeys

Three softkeys are available for switching from display to edit mode, for saving changes tosettings, and for terminating the program:

Switch from display mode to edit mode(this is only possible in expert mode).

Save in the kernel system any changes which have been made.

Terminate the program.

Use the arrow keys to select the box to be edited. Navigate within a line by means of the �

(left) or � (right) arrow keys, and within a column by means of the � (up) and � (down) arrowkeys. The selected box is displayed with a blue background.

To change the value displayed in a selected box, press the “Change” softkey or the Enterkey.

Accept change

Discard change

This switches you from display mode to edit mode. The selected box is now displayed witha yellow background. You can change the value by means of the numeric keypad on the KCP.

Some boxes allow you to select one of several preset values, for example:

Acceptchange

Discardchange

After pressing the “Change” softkey or the Enter key you can use the � and � arrow keys toselect the desired value.

After making your selection, press the Enter key to accept the changed value. You candiscard the change by pressing the ESC key. Either of these two keys will take you out ofedit mode and return you to display mode.

The changes which have been made have not yet been saved in the kernel system. To dothis, press the “Save” softkey.

To terminate the program, press the “End” softkey. When asked whether you wish toterminate the program, answer “Yes”, or “No” if you do not want to terminate the program.

The program also checks whether all of the changes have been transferred to the kernelsystem using “Save”. If this is not the case, you will be asked again whether you wish to savethe changes. If you answer this question with “Yes”, then the changes will be saved; “No”discards the changes and terminates the program.


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4.1.3 Application with more than one dispensing controller

The configuration program “GluetechData.exe” can be used to configure one, two, or threedispensing controllers. The first time the program is called, data for only one system (System1) are shown.

If you wish to implement an application with two dispensing controllers, you must activatethe second system in the configuration program.

To do this, call the configuration program:

� “Setup” � “GLUE Tech” � “Configure process data”, or

� “Setup” � “GLUE Tech” � “I/O Configuration”, or

� “Technology” � “GLUE Tech” � “Show dispense data”.

When this selection is made, the program “GluetechData.exe” will be started in displaymode. The display is dependent on the specific selection that is made.

Now press the “Settings” menu key.

(System 2 System 3)

By (repeatedly) pressing the Tab key, the focus can be toggled between the option boxes [1],[2] and [3] under “Number of gluing equipments” (deselect “NUM” prior to this; “NUM” mustbe shown in gray in the status bar). In the corresponding option box, press the space bar onthe KCP; this causes the selected option box to be marked with a check.

Depending on the selection, the following data are displayed on the screen:

� [1] Data for dispensing controller, system 1

� [2] Data for dispensing controllers, system 1 and system 2

� [3] Data for dispensing controllers, system 1, system 2 and system 3

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4.2 Configuring the inputs and outputs

4.2.1 Linear characteristic

The range of analog voltages transmitted from the robot controller to the dispensingcontroller is from 0 to 9999 millivolts (i.e. 10 volts). Please note that the lower part of thisanalog voltage range is not evaluated by the dispensing controller. This “dead zone” isbetween 0 and 700 mV.

10000*)

9000

8000

7000

6000

5000

4000

3000

2000

1000

0

700

Vprop Vref

*): Maximum value = 9999 mV

Dead zone 0

KR Cx analog control voltage[mV]

Dispensing controller

4.2.2 I/O interface adaptation

The I/O interface can be adapted by changing the signal declarations in the file “$Config.dat”,fold “GLUE GLOBALS” and fold “GLUETECH APPLICATION IO”.

It is much more convenient, however, to carry out adaptation using the offline program“GluetechData.exe” contained in the GlueTech technology package. You can call thisprogram using the menu function “Setup” � “GLUE Tech” � “I/O Configuration”.


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After the program has been selected, the following screen will be shown:

“System 2” is only shown if the number of dispensingcontrollers was specified as 2 or 3 under “Settings”. See Section 4.1.3.

If the outputs of the dispensing controller are not available during the setup phase, thecorresponding inputs of the robot controller must be configured to input number 1025.Input number 1025 must also be used for signals which are not used by the dispensingcontroller but are expected by the robot controller. This is the case, for example, when adifferent software version is used in the dispensing controller.

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4.3 Configuring equipment–specific data

4.3.1 Equipment–specific data – Description

The variable names of the equipment–specific data and their functions are listed in thefollowing table:

Variable name Function

GunOnDelay Delay in milliseconds [ms] when turning on the adhesive gun.

GunOffDelay Delay in milliseconds [ms] when turning off the adhesive gun.

MaterialDelay Delay in milliseconds [ms] of material flow.

MaterialReactionPosOffs Delay in milliseconds [ms] of material flow increase.

MaterialReactionNegOffs Delay in milliseconds [ms] of material flow decrease.

AirOnDelay Delay in milliseconds [ms] when turning on the air.

AirOffDelay Delay in milliseconds [ms] when turning off the air.

AirDelay Delay in milliseconds [ms] of air flow.

AirReactionPosOffs Delay in milliseconds [ms] of air flow increase.

AirReactionNegOffs Delay in milliseconds [ms] of air flow decrease.

Delays exist between the robot motion and the switching on or off of the material or air flowin the adhesive application system. These delays must be taken into account whenconfiguring adhesive application tasks. Similarly affected are switching processes whichaffect the robot speed and/or material flow (i.e. the width of the bead) during an adhesiveapplication process.

These interactions are shown schematically in the following diagram:

Delay

Dispensingcontroller

Robot motion with offset

0

Uana[mV]

t [ms]

Offset

Delay time MaterialDelay

Start dispensingcontroller

Start robot

Vrob[mm/s]

Delay time MaterialDelay


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The following sketch illustrates the delays for a simple bead. The start point is the point fromwhich the robot begins its motion.

The “on” point represents the point where the command to turn on the adhesive gun is given.As can be seen, the adhesive flow actually only begins after a certain delay has elapsed.

The “off” point represents the point where the command to turn off the adhesive gun is given.The bead ends after the corresponding delay has elapsed.

The start point and end point must be taught by the user at the time of calibration. Duringthe calibration routine, mark the points “on”, “off” and “switch” on a suitable surface.See Section 4.3.3.

Start point End pointon off

DelayGunOffDelay

DelayGunOnDelay

Adhesive application

The following sketch shows the delays when switching the adhesive parameters within abead.

switch switch

DelayDelay


MaterialReactionNegOffsMaterialReactionPosOffs

Finally, this diagram illustrates the effect of the time delays in the overall system whenactivating or deactivating the analog output:


DelayMaterialDelayAirDelay


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4.3.2 Adapting the variable values using “GluetechData.exe

To adapt the variable values when configuring equipment–specific data, call the program“GluetechData.exe”. This is done using the menu function “Setup” � “GLUE Tech” � “Configure process data”.

When the “Timing” index tab is selected, the following screen will be shown:

More than one system (“System 2” in the example here) isonly shown if 2 or 3 dispensing controllers were specifiedunder “Settings”.See Section 4.1.3.


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4.3.3 Calibration with the aid of the KRL program “Calibrate_Equipment”

The calibration program “Calibrate_Equipment” makes available the following functions:

� Verifying the TCP of the calibrated tools.

� Calculating the delay when turning the adhesive gun on/off.

� Calculating the delay when turning the analog channels (material, air) on/off.

� Calculating the reaction time when a change is made in an analog channel.

This program is started using the menu function “Setup” � “GLUE Tech” � “Select calibration routine”.

After this selection is made, the KRL program is shown in the KCP program window.

The calibration procedure is described step by step below.

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4.3.3.1 Determining the CP velocity

Press the Start key on the KCP.

A query appears in the message window asking you whether the default velocity should beused for the calibration process.

If you press the “Yes” softkey, the CP velocity will be initialized as 0.4 m/s.

Pressing the “No” softkey removes the message previously displayed, and when the Startkey is pressed another dialog will open.

Pressing the corresponding softkey initializes the CP velocity as 0.1, 0.2, 0.4, 0.6 or 0.8 m/s.The “Default” softkey initializes the default CP velocity, i.e. 0.4 m/s.

4.3.3.2 Data used for calibration

When the Start key is pressed a query appears in the message window asking what datayou want to use for calibration.

The data which can be used are offered for selection in the softkey bar. The individualsoftkeys have the following functions here:

The internal variables of the calibration routine and the variables for Equipment 1 (EquipData[1]) are initialized with the value 0.0.

The internal variables of the calibration routine are initialized with the values of Equipment 1.

The internal variables of the calibration routine and the variables for Equipment 2 (EquipData[2]) are initialized with the value 0.0.

The internal variables of the calibration routine are initialized with the values of Equipment 2.

The internal variables of the calibration routine and the variables for Equipment 1 (EquipData[1]) and Equipment 2 (EquipData[2]) are initialized with the value 0.0.

The softkeys contained in the softkey bar depend on the number of dispensing controllersentered under “Settings”. See Section 4.1.3.


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4.3.3.3 Calibration variables

In order to achieve optimal adhesive application, it may be necessary to adjust the amountsdispensed before and after the switch. Adaptation can be carried out by changing theappropriate variable values using the variable modification function.

Variable Wert

dAnalogOffsetLow[x]= 0,2 (default)

dAnalogOffsetHigh[x]= 0,8 (default)

Additional variables are described in the “System variables” chapter.

4.3.3.4 Gun times

When the Start key is pressed a query appears in the message window asking what guntimes are to be used.

4.3.3.5 Verifying the setup data

The data listed in the following table are verified by the program.

Variable Value

$ANA_DEL_FLT <> #ON

$VEL_FLT_OFF <> TRUE

$ACC_MA.CP < 10.0

$ACC_MA.ORI1 < 1000

$ACC_MA.ORI2 < 1000

$RED_ACC_CPC > 3

If one of these conditions is fulfilled, the corresponding message will be displayed. Thismessage will specify the variable which must be changed and the file in which the variableis contained.

After verification has been carried out once, calling this program again will not verify thedata again unless the query shown in the following dialog is answered with “Yes”.

Answer this query by pressing the appropriate softkey.

If you press the “Yes” softkey, the machine data will be verified again.

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Pressing the “No” softkey means that the machine data will not be verified again.

4.3.3.6 Function selection

Pressing the Start key again causes the following query to appear in the message window:

The functions of the available softkeys are described below:

If the “All” softkey is pressed, all functions will be executed in sequence.

“Test TCP” checks the tool data by means of reorientation at the reference point in question.

“Gun On/Off” is used to calculate the delay times when switching the adhesive gun on andoff.


DelayGunOffDelay

DelayGunOnDelay


“Eq. Delay” is used to calculate the delay times when switching the analog output on and off.


DelayMaterialDelayAirDelay


“Ana. Switch” serves to calculate the reaction times when the voltage at the analog outputis changed abruptly.

switch switch

DelayDelay


MaterialReactionNegOffsMaterialReactionPosOffs


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Pressing the “End” softkey terminates the calibration routine.

Program execution is continued by pressing the Start key.

If the system was configured for two sets of adhesive application equipment, a query willappear asking which equipment is to be calibrated.

Press the appropriate softkey (“Equip. 1” or “Equip. 2”).

This description continues with the calculation of the delay times of the adhesive gun(Gun On/Off) for a configured set of adhesive application equipment.

Other parameters are calculated in a similar manner.

Depending on the configured application, other dialog messages may be generated, whichmust be answered accordingly.

4.3.3.7 Performing the selected function

Pressing the Start key again causes the following query to appear in the message window:

After confirming by means of the “OK” softkey, you must then teach the start point and endpoint.A corresponding message in the message window confirms that the current coordinateshave been saved.

The points must be in a straight line. The distance between the start point and the end point must be more than 400 mm.If the distance is too short, a corresponding message is generated.

When the Start key is pressed the robot moves over the path between the points. If thedistance between the points is great enough, then the program calculates the points in spacewhere the dispensing gun is switched on and off. The robot moves to these points.

Mark these points (e.g. with a felt–tip marker) on a suitable surface when told to do so in themessage window.

Mark position of dispense gun.

4.3.3.8 Verifying the switching points

The motions used to check the distance between points, to calculate the positions forswitching on and off, and motion to these points to allow marking, must be executed atreduced velocity. The operating mode “T2” is set; if necessary the routine will initialize theprogram override using the value 10.

For the calibration run itself, the override value must be set to 100. This is indicated by acorresponding message in the message window, which must be confirmed using the “OK”softkey.

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When the end point has been reached, the following message appears in the message window:

Mark position of dispense gun.

Does the position where the gun opens match with the marked position?

Press the “Yes” softkey to confirm that the adhesive gun was switched on at the markedposition.

Pressing the “No” softkey calls a routine which can be used to correct the switching point.

The “Repeat” softkey repeats the motion using the same switching actions.

4.3.3.9 Correcting the switching point

If you have answered with “No” the query as to whether or not the marked positioncorresponds to the point where the adhesive gun was switched on, the following queryappears in the message window:

Which direction do you want to shift?

If the switching action has to be carried out earlier, press the “Earlier” softkey.

If the switching action has to be carried out later, press the “Later” softkey.

In the next step you will specify the distance by which the switching point will be offset. Thefollowing dialog message appears in the message window:

Select by pressing a softkey the distance to shift the gun close position.

Press the appropriate softkey to select the distance the point will be offset. You have a choiceof 1, 2, 5, 10, 20, 25 and 50 millimeters.

To offset the point by a distance which lies between these fixed values, repeat this partof the procedure several times.

Example: The switching point must be shifted forwards 42 millimeters, i.e. the adhesivegun must be switched on “Earlier”. You can do it this way:

First offset: 20 mm

Second offset: 20 mm

Third offset: 2 mm

The robot moves over the test path again after each offset correction.For example, offsetting the point three times means that the robot will move over thespecified path three times.

When the switching position corresponds to the marked position, press the “Yes” softkey. Aquery appears in the message window asking you whether you want to save the gunswitch–on time that was calculated.

Repeat

Earlier

Later


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Do you want to save gun on delay time (–357ms)?

Pressing the “Yes” softkey saves this value; the “No” softkey discards the newly–calculatedvalue and retains the old value.

The same query is repeated for the gun switch–off time. Here, too, the “Yes” softkey savesthe new value and the “No” softkey discards it.

Then the prompt “Select calibration function” appears in the message window. Select thedesired function using the softkeys “All”, “Test TCP”, “Gun On/Off”, “Eq. Delay” or “Ana.Switch”.

The calibration program is terminated by means of the “End” softkey.

4.4 Configuring technology–specific dataThe program “GluetechData.exe” is opened via the menu function “Setup” � “GLUE Tech”� “Configure process data” or “Setup” � “GLUE Tech” � “I/O Configuration”.

Use the menu key to select the index tab “Bead”. The following user interface is shown onthe KCP:

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If “SWIRL” is set (see Section 4.5.1), then the value for “Air” � “Analog type” mustbe set to “SPEED_INDEP”.Larger changes should be made by switching the bead data “Offset[%]” or theparameter boards of the dispensing controller.

4.4.1 Technology–specific data – Description

The meanings and characteristics of technology–specific data are shown in the following table:

Technology–specific data

Variable Meaning Range of values, Comments

PrePressure Default value for pre–pressure 0, .., 100%

MaterialFactor Dynamic setpoint of material 0, .., 100%

MaterialOffset Static setpoint of material 0, .., 100%

AirFactor Dynamic setpoint of air 0, .., 100%

AirOffset Static setpoint of air 0, .., 100%

Speed Reference speed for analog output

This value must be > 0 and<=2000 mm/s.

FlowType Defines the reference variable of the analog output

#TCP_SPEED – Referencevariable is the actual velocity($VEL_ACT)#PROG_SPEED – Referencevariable is the programmedvelocity ($VEL.CP)#SPEED_INDEP – No dynamiccomponent, static only

Comment Remarks(name of the data set)

Freely selectable.The designation can consist ofletters and numbers.


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4.5 Configuring technology–specific options

The following program “GluetechData.exe” is opened via the menu function “Setup” �“GLUE Tech” � “Configure process data” or “Setup” � “GLUE Tech” � “I/O Configuration”.

Use the menu key to select the index tab “Settings”. The following user interface is shownon the KCP:

(System 2 System 3)

The appropriate check box must be selected depending on the number of dispensingcontrollers.

4.5.1 Technology–specific options – Description

The meanings and characteristics of the technology–specific options are shown in thefollowing table:

Technology–specific options

Variable Meaning Range of values, Comments

GlueType Definition of the type of applica-tion.

GLUE_1KDefault adhesive bondingapplication.

GLUE_2K2–component application

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BeadShaping Definition of the bead shaping. NONEAir is not switched on.AIR Air is switched on.SWIRLSwirling is switched on.

iNumberOfDoser

Number of dispensers.

QuitFault Type of fault acknowledgement ALLAcknowledge all.SINGLEAcknowledge individually.PLCAcknowledge via PLC.

MirrorPgno Program number mirroring (re-transmission) by the dispensingcontroller

FALSEThe dispensing controller doesnot mirror the program numbersthat were transferred.

TRUEThe dispensing controller doesmirror the program numbers thatwere transferred; the robotcontroller waits for the programnumber to be correctly mirrored.

iPGNOLength Program number/parameter setnumber length in bits

bSingleFault-ToPLC

The PLC is informed in the eventof a single fault.

FALSEOutput is not setTRUEOutput is set

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5 ProgrammingThis section describes the creation of new programs and the programming of adhesiveapplication and motion instructions. Also included are instructions on how to set parametersusing the inline forms.

To ensure satisfactory operation, the “GLUE Tech“ package must be configured properly.Information on this can be found in Section 4 of this documentation.

5.1 Program example

5.1.1 Standard program

1 INI2 Initialize And Start System 1 With BeadData 1 Set Program

Number 2 Param Number 13 Check Purge System 1 Time 10 min System 2 Time 10 min System

3 Time 10 min4 PTP HOME Vel= 100 % DEFAULT5 PTP P1 CONT Vel= 100 % PDAT1 Tool[1] Base[0]6 Set High Motion Parameter ON PATH 10 % ORIENTATION 25 %7 LIN P3 CONT Vel= 0.5 m/s CPDAT2 Tool[1] Base[0]8 LIN P4 CONT Vel= 0.5 m/s CPDAT3 GlueOn Distance –10 mm Gun 1

Tool[1] Base[0]9 LIN P5 CONT Vel= 0.5 m/s CPDAT4 Tool[1] Base[0]10 LIN P6 CONT Vel= 0.5 m/s CPDAT5 Glue BeadDATA 1 Distance 0 mm

Set Param Number 4 Tool[1] Base[0]11 LIN P7 CONT Vel= 0.5 m/s CPDAT6 Tool[1] Base[0]12 LIN P8 CONT Vel= 0.5 m/s CPDAT7 GlueOff Distance –5 mm End

Measurement Yes Change Doser No Tool[1] Base[0]13 LIN P9 CONT Vel= 0.5 m/s CPDAT8 Tool[1] Base[0]14 Set High Motion Parameter OFF15 PTP P10 CONT Vel= 100 % PDAT2 Tool[1] Base[0]16 Process Complete17 PTP HOME Vel= 100 % DEFAULT18 Error Check

5.1.2 Main program

1 INI2 Initialize And Start System 1 With BeadData 1 Set Program

Number 2 Param Number 13 Check Purge System 1 Time 10 min System 2 Time 10 min System

3 Time 10 min4 PTP HOME Vel= 100 % DEFAULT56 ;Rear wheel arch7 Example_01 () ;Adhesive bonding program89 ;Sill10 Example_02 () ;Adhesive bonding program1112 Process Complete13 PTP HOME Vel= 100 % DEFAULT14 Error Check

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5.1.3 Subprogram

12 PTP P1 CONT Vel= 100 % PDAT1 Tool[1] Base[0]3 Set High Motion Parameter ON PATH 10 % ORIENTATION 25 %4 LIN P3 CONT Vel= 0.5 m/s CPDAT2 Tool[1] Base[0]5 LIN P4 CONT Vel= 0.5 m/s CPDAT3 GlueOn Distance –10 mm Gun 1

Tool[1] Base[0]6 LIN P5 CONT Vel= 0.5 m/s CPDAT4 Tool[1] Base[0]7 Lin P6 CONT Vel= 0.5 m/s CPDAT5 Glue BeadData 1 Distance 0 mm

Set Param Number 4 Tool[1] Base[0]8 LIN P7 CONT Vel= 0.5 m/s CPDAT6 Tool[1] Base[0]9 LIN P8 CONT Vel= 0.5 m/s CPDAT7 GlueOff Distance –5 mm End

Measurement Yes Change Doser Yes Tool[1] Base[0]10 LIN P9 CONT Vel= 0.5 m/s CPDAT8 Tool[1] Base[0]11 Set High Motion Parameter OFF12 PTP P10 CONT Vel= 100% PDAT2 Tool[1] Base[0]

5.2 Creating an adhesive application task

To create an adhesive application task, use the general template “Module”.

To do this, press the “New” softkey and use the arrow key to select the line “Module” in theleft “Template selection” window.

Module Module

Then press the “OK” softkey and in the input box “Name” enter a file name for the adhesiveapplication task. Entering remarks in the “Comment” input box is optional. You can get thereusing the arrow key.

Once the entry has been made, press the softkey “OK” or the Enter key.

Now select the newly–created skeleton program using the “Open” or “Select” softkey. It isopened in the KCP program window.

1 INI2 PTP HOME Vel= 100 % DEFAULT345 PTP HOME Vel= 100 % DEFAULT

5.3 Entering commands

Commands are entered using the menu function “Technology” � “GLUE Tech”. (The type and number of technology packages displayed depend on your softwareconfiguration.)

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To select the appropriate menu item, use the arrow keys on the KCP and then press the Enterkey. The corresponding inline form is then opened in the program window.

The softkey bar is altered at the same time. The following softkeys are available here:

Pressing the “Cmd Ok” softkey saves the program command and all its parameters. Theinline form is closed.

The “Cmd Abort” softkey rejects the program command and closes the inline form. Theentries made will not be saved.

Additional softkeys are available for individual menu commands. These softkeys aredescribed under the corresponding commands.

5.3.1 Motion instructions

Technology motions are programmed with the aid of inline forms. These are called using themenu function “Technology” � “GLUE Tech” � “Gluing motion”.Note: The type and number of technology packages displayed depend on your softwareconfiguration!

The following types of motion are available:

GLUE ON LIN Gun on – linear motion

GLUE SWITCH LIN Switching gluing parameters – linear motion

GLUE OFF LIN Gun off – linear motion

GLUE ON CIRC Gun on – circular motion

GLUE SWITCH CIRC Switching gluing parameters – circular motion

GLUE OFF CIRC Gun off – circular motion

GLUE ON PTP Gun on – PTP motion

GLUE OFF PTP Gun off – PTP motion

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5.3.1.1 Gun on – GLUE ON LIN

Inline form for turning the adhesive gun on at the end of a LIN block.

The menu function “Technology” � “GLUE Tech” � “Gluing motion” � “GLUE ON LIN”opens the following inline form:

The input boxes of this inline form have the following functions and ranges of values:

GLUE ON LIN

Box Function Range of values, Comments

LIN Type of motion LIN, CIRC, PTPCan be changed by means of thebottom right status key or by switching between LIN, CIRC andPTP using the softkeys.

P(1) Designation of the end point (End). Freely selectable. The designationPn can be changed using the key-pad or the bottom right status key.

CONT Switch approximate positioning on.

Vel= Velocity of the TCP. 0.001 ... 2.0 [m/s]Change using keypad or bottomright status key.

CPDAT Designation for the “Motion parame-ters” data set.

Freely selectable.The designation for CPDAT n canconsist of letters and numbers.

Distance Offset of the switch–on point. –200 ... 200 [mm]Change using keypad or bottomright status key.

Gun Designation of the adhesive gun. 1 ... 3.Change using keypad or bottomright status key (Gun#).

Check Pre-Pressure

Determines whether a check is car-ried out to see if the dispenser hasreached pre–pressure before thegun is opened.

“YES” or “No”Change using keypad or bottomright status key.

5.3.1.2 Switching gluing parameters – GLUE SWITCH LIN

Inline form for switching the gluing parameters at the end of a LIN block.

The gluing parameters are switched at the end of a LIN block.

The menu function “Technology” � “GLUE Tech” � “Gluing motion” � “GLUE SWITCH LIN”opens the following inline form:


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The input boxes of this inline form have the following functions and ranges of values.

GLUE SWITCH LIN


LIN Type of motion LIN, CIRCCan be changed by means of thebottom right status key or by switching between LIN and CIRCusing the softkeys.




CPDAT Designation for the “Motion param-eters” data set.


BeadData Select data set to be switched to. 1 ... 20Default setting: 1Increment: 1

Distance Offset of the switching point. –200 ... 200 [mm]Change using keypad or bottomright status key.

Set ParamNumber

Selection of the parameter number. 0 ... 31

5.3.1.3 Gun off – GLUE OFF LIN

Inline form for turning the adhesive gun off at the end of a LIN block.

The menu function “Technology” � “GLUE Tech” � “Gluing motion” � “GLUE OFF LIN”opens the following inline form:


GLUE OFF LIN


LIN Type of motion LIN, CIRC, PTPCan be changed by means of thebottom right status key or by switching between LIN, CIRC andPTP using the softkeys.




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Distance Offset of the switch–off point. –200 ... 200 [mm]Change using keypad or bottomright status key.

End Mea-surement

Selection of whether to end themeasurement.


ChangeDoser

Change the dispenser “YES” or “No”Change using keypad or bottomright status key.

5.3.1.4 Gun on – GLUE ON CIRC

Inline form for turning the adhesive gun on at the end of a CIRC block.

The menu function “Technology” � “GLUE Tech” � “Gluing motion” � “GLUE ON CIRC”opens the following inline form:


GLUE ON CIRC


CIRC Type of motion LIN, CIRC, PTPCan be changed by means of thebottom right status key or by switching between LIN, CIRC andPTP using the softkeys.

P(2)

P(3)

Designation of the end point (End).

Designation of the auxiliary point(Aux).

Freely selectable. The designationPn can be changed using the key-pad or the bottom right status key.



CPDAT Designation for the “Motion param-eters” data set.



Gun Designation of the adhesive gun. 1 ... 3.Change using keypad or bottomright status key (Gun#).


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5.3.1.5 Switching the bonding parameters – GLUE SWITCH CIRC

Inline form for switching the gluing parameters at the end of a CIRC block.

The menu function “Technology” � “GLUE Tech” � “Gluing motion” � “GLUE SWITCHCIRC” opens the following inline form:


GLUE SWITCH CIRC


CIRC Type of motion LIN, CIRCCan be changed by means of thebottom right status key or by switching between LIN and CIRCusing the softkeys.

P(5)

P(6)



Freely selectable. The designa-tion Pn can be changed usingthe keypad or the bottom rightstatus key.




Freely selectable.The designation for CPDAT ncan consist of letters and num-bers.


Distance Offset of the switching point. –200 ... 200 [mm]Change using keypad or bottomright status key.

Set ParamNumber

Selection of the parameter number. 0 ... 31

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5.3.1.6 Gun off – GLUE OFF CIRC

Inline form for turning the adhesive gun off at the end of a CIRC block.

The menu function “Technology” � “GLUE Tech” � “Gluing motion” � “GLUE OFF CIRC”opens the following inline form:


GLUE OFF CIRC


CIRC Type of motion LIN, CIRC, PTPCan be changed by means of thebottom right status key or by switching between LIN, CIRC andPTP using the softkeys.

P(1)

P(2)



Freely selectable. The designationPn can be changed using the key-pad or the bottom right status key.






End Mea-surement

Selection of whether to end themeasurement.


ChangeDoser

Change the dispenser “YES” or “No”Change using keypad or bottomright status key.


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5.3.1.7 Gun on – GLUE ON PTP

Inline form for turning the adhesive gun on at a PTP point.

The menu function “Technology” � “GLUE Tech” � “Gluing motion” � “GLUE ON PTP”opens the following inline form:


GLUE ON PTP


PTP Type of motion PTP, LIN, CIRCCan be changed by means of thebottom right status key or by switching between LIN, CIRC andPTP using the softkeys.



Vel= Velocity of the axes. 1 ... 100 [%] of maximum valueChange using keypad or bottomright status key.

PDAT Designation for the “Motion param-eters” data set.

Freely selectable.The designation for PDAT n canconsist of letters and numbers.

Gun Designation of the adhesive gun. 1 ... 3.Change using keypad or bottomright status key.

Delay Switch–on point delay. –1.0 ... 1.0 [sec]Default setting: 0.0Increment: 0.1

Period Period 0 ... 5.0 [sec]Default setting: 0.5Increment: 0.1

Pressure Pressure 0 ... 100 [%]Default setting: 50Increment: 1

Period

– PTP with approximate positioning: The value is not taken into account, since the adhesiveapplication begins and ends with a single point.

– PTP without approximate positioning: The programmed value corresponds to the durationof the adhesive application.

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5.3.1.8 Gun off – GLUE OFF PTP

Inline form for turning the adhesive gun off at a PTP point.

The menu function “Technology” � “GLUE Tech” � “Gluing motion” � “GLUE OFF PTP”opens the following inline form:


GLUE OFF PTP


PTP Type of motion PTP, LIN, CIRCCan be changed by means of thebottom right status key or by switching between LIN, CIRC andPTP using the softkeys.



Vel= Velocity of the axes. 1 ... 100 [%] of maximum valueChange using keypad or bottomright status key.

Delay Switch–off point delay. –1.0 ... 1.0 [sec]Default setting: 0.0Increment: 0.1


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5.3.2 Gluing instructions

Gluing instructions are also programmed with the aid of inline forms. These are called usingthe menu function “Technology” � “GLUE Tech” � “Gluing instruction”.

The following instructions are available:

– Init system

– Set program number

– Set motion parameter

– Dispense complete

– Reload doser

– Error check

– Purge gun

– Monitoring purge gun

– Enable purge

The assignments of the softkey bar vary depending on the specific inline form which isopen.

Some of these assignments are described briefly below:

Cmd Ok The inline form is closed and the command is saved.

Cmd. Abort The inline form is closed, and the command is not saved.

INIT Opens the inline form “Set Program Number”.

SET PGNO Opens the inline form “Set Program Number”.

CP PARAM Opens the inline form “Set High Motion Parameter”.

END Opens the inline form “Process Complete”.

RELOAD Opens the inline form “Reload”.

CHECK Opens the inline form “Error Check”.

PURGE Opens the inline form “Purge”.

PURGEMON Opens the inline form “Check Purge System”.

==> Changes the assignment of the softkey bar.

<== Reverts to previous assignment of the softkey bar.

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5.3.2.1 Initialize system

The function “Init system” ...

� ... calculates the factor, offset and delay of the analog output from the transmitted dataset (BeadData x),

� ... sets the output “START APPLICATION CYCLE” for the selected dispensingcontroller (System x) and prepressurizes the system,

� ... polls the input “ENABLE EXTERNAL” (if this input has not been set, a correspondingmessage will be generated),

� ... polls the input “METER FULL” (if this input has not been set and the option “WITHDOSER” has been configured, then the routine for filling the doser is called),

� ... starts the cyclical analog output function.

� ... sets the program number for the dispensing controller,

� ... waits for the program number that was output to be correctly mirrored by thedispensing controller, assuming that the option PROGRAM NUMBER MIRRORINGhas been configured.

� ... waits for the subprogram “Move to Purge” to be executed or the input “Purgerequest”. The subprogram can call the inline form “Initialize And Start System” whena timer elapses (Check Purge System) or by means of the input “Purge request”.

The menu function “Technology” � “GLUE Tech” � “Gluing instruction” � “Init system”opens the following inline form:


Init system


InitializeAnd StartSystem

Selecting the adhesive applicationsystem.

1, 2 or 3Change using keypad or bottomright status key.

With BeadData

Selecting the technology data set.

1 ... 20Change using keypad or bottomright status key.

Set ProgramNumber

Selecting the program number forthe dispensing controller.

0 ... 31 Change using keypad or bottomright status key.

Param Number

Selecting the parameter board ofthe dispensing controller.

0 ... 31 Change using keypad or bottomright status key.


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5.3.2.2 Set program number

The function “Set program number” ...

� ... sets the program number for the dispensing controller,

� ... waits for the program number that was output to be correctly mirrored by thedispensing controller, assuming that the option PROGRAM NUMBER MIRRORINGhas been configured.

The menu function “Technology” � “Gluing instruction” � “Set program number” opens thefollowing inline form:

The input box of this inline form has the following functions and range of values:

Set program number


Set ProgramNumber

Selecting the program number forthe dispensing controller.


Param Number

Selecting the parameter board ofthe dispensing controller.



5.3.2.3 Set motion parameter

The function “Set motion parameter” ...

� ... initializes the user variables for CP and orientation acceleration and orientationvelocity to the required values,

� ... initializes the system variables for CP and orientation acceleration and orientationvelocity to the values required for adhesive application tasks,

The menu function “Technology” � “GLUE Tech” � “Gluing instruction” � “Set motionparameter” opens the following inline form:


Set motion parameter


Set HighMotion Pa-rameter

Setting/resetting parameters ONVariables for CP and orientationacceleration are initialized withhigher values.OFFVariables for CP and orientationacceleration are initialized withthe default values.

PATH Definition of the maximum path ac-celeration for CP blocks.

1 ... 100 [%]Change using keypad or bottomright status key.

ORIENTA-TION

Definition of the maximum orienta-tion acceleration for CP blocks.

1 ... 100 [%]Change using keypad or bottomright status key.

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5.3.2.4 Reset motion parameter

The function “Reset motion parameter” reinitializes the user variables for CP and orientationacceleration using the default values.

The menu function “Technology” � “GLUE Tech” � “Gluing instruction” � “Set motionparameter” opens the inline form described in Section 5.3.2.3. Pressing the “Off” softkeylocated in the middle of the softkey bar causes the inline form to appear as follows:

There are no further input boxes here.

5.3.2.5 Dispense complete

The function “Dispense complete” ...

� ... resets the output “START APPLICATION CYCLE”,

� ... resets the output for opening the adhesive gun,

� ... switches off the cyclical analog outputs.

The menu function “Technology” � “GLUE Tech” � “Gluing instruction” � “Dispensecomplete” opens the following inline form:

This inline form does not have any input boxes.

5.3.2.6 Reload doser

The function “Reload doser” ...

� ... sets the output “RELOAD DOSER”,

� ... waits for the input “METER FULL” or the programmed time interval.

The menu function “Technology” � “GLUE Tech” � “Gluing instruction” � “Reload doser”opens the following inline form:

You can switch between “Reload TIME” and “Reload FULL” by means of an additionalsoftkey in the middle of the softkey bar. The designation of this softkey automatically changeseach time it is pressed.


Reload doser


Reload Termination condition for the filling operation.

TIME Termination after the pro-grammed time has elapsed.FULLTermination when the input METER FULL is detected.

[TIME] Duration of the filling operation.(Only if “TIME” has beenselected.)

0.1 ... 5.0 [s]

Wait for Doser Full Waits until the dispenser is full. TRUEFunction activatedFALSEFunction deactivated


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5.3.2.7 Error check

The function “Error check” ...

� ... checks whether one of the inputs “FAULT, APPLICATION”, “MATERIAL HIGH”,“MATERIAL LOW”, “ERROR MIXTURE THRESHOLD HIGH” or “ERROR MIXTURETHRESHOLD low” is not set,

� ... generates a message if one of these inputs is set,

� ... sets the output “FAULT MESSAGE TO PLC”, if this option has been configured.

� ... waits for the input to be reset.

The menu function “Technology” � “GLUE Tech” � “Gluing instruction” �“Error check”opens the following inline form:

This inline form does not have any input boxes.

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5.3.2.8 Purge gun

The function “Purge gun” ...

� ... sets the output “PURGE”,

� ... waits for the programmed time interval (Purge TIME) or the input “Purge COMPLETE”.

The menu function “Technology” � “GLUE Tech” � “Gluing instruction” � “Purge gun”opens the following inline form:

You can switch between “Purge TIME” and “Purge COMPLETE” by means of an additionalsoftkey in the middle of the softkey bar. The designation of this softkey automatically changeseach time it is pressed.


Purge gun


Purge Specifies whether the purgingoperation is carried out for aparticular duration, or until the gun ispurged completely.

TIMETermination after the programmedtime has elapsed.COMPLETETermination when the input “Purge COMPLETE” is detected.

TIME Duration of the purging operation.(Only if “TIME” has been selected.)

0 ... 10 [s]Change using keypad or bottomright status key.

System Specifies the system to be purged(dispensing controller).

1, 3Change using keypad or bottomright status key.

With Air Selection: with or without clearingwith compressed air.

NOwithout clearing;YESwith clearing.

Component Selection of the component to bepurged.

A, B or A+B

Gun Designation of the adhesive gun. 1...3Change using keypad or bottomright status key (Gun#).


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5.3.2.9 Monitoring purge gun

The function “Monitoring purge gun” starts a timer which monitors the pauses between twopurging operations.

The menu function “Technology” � “GLUE Tech” � “Gluing instruction” � “Monitoring purgegun” opens the following inline form:

The input boxes of this inline form have the following functions and ranges of values.

Monitoring purge gun


Check PurgeSystem 1 Time

Specifies the maximum time intervalbetween two purging operations forthe first dispensing controller.

0 ... 10 [min]Change using keypad or bottomright status key.

System 2 Time Specifies the maximum time intervalbetween two purging operations forthe second dispensing controller.


System 3 Time Specifies the maximum time intervalbetween two purging operations forthe second dispensing controller.


5.3.2.10 Teaching the purging position

The timer described above, or the input “Purge request”, is polled in each dispensingapplication. Once this timer has elapsed or the input “Purge request” has been set, theprogram “MoveToPurge” is called in the gluing instruction “Init system”.

The motion to the purging position must be taught in this program.

Ensure that the correct adhesive application system is selected (Case branch).

5.3.2.11 Enable for purging

This instruction sets the enable signal for purging.

Enable for purging


Enable Purge Determines the enable signal for thepurging operation.

YESEnable for purging, robot islocated in the purging positionNOEnable for purging is reset

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6 Variables

This chapter contains an overview of all the variables used in the GlueTech technologypackage.

6.1 I/O interface variables

The variables listed here are for the first set of adhesive application equipment. The variablesfor the second and third sets of adhesive application equipment are not listed separatelyhere, as they only differ by “xxSL2xx” and “xxSL3xx”.

I/O interface variables

Signal name Meaning Input/output

aoSL1MatFlow Specified value for material $ANOUT[1]

aoSL1BeadShp Specified value for air spray $ANOUT[2]

doSL1StartSys Start $OUT[999]

doSL1Gun1On Gun on $OUT[999]

doSL1ReloadMeter Fill dispenser $OUT[999]

doSL1AirOn Enable air / Swirl $OUT[999]

doSL1AutoExternal Automatic external $OUT[999]

doSL1PrePurge Pre–purge $OUT[999]

doSL1Purge Purge $OUT[999]

doSL1SystemReady Enable operation $OUT[999]

doSL1ProgNo Program number bit 0 $OUT[999] TO$OUT[999]

doSL1FinishMeasure End of measuring $OUT[999]

doSL1PurgeEnable Enable purge $OUT[999]

doSL1FaultAckn Acknowledge fault $OUT[999]

doSL1WithoutMaterial Without material $OUT[999]

doSL1ParamNo Parameter set bit 0 $OUT[999] TO$OUT[999]

doSL1PistSelect1 Select gun 1 $OUT[999]

doSL1PistSelect2 Select gun 2 $OUT[999]

doSL1DoserChange Change dispenser $OUT[999]

doSL1HeatingUnitOn System / heating on $OUT[999]

doSL1HeatingUnitReset Reset heating $OUT[999]

doSL1PumpReset Reset pump $OUT[999]

doSL1FaultPeripheryAckn Acknowledge fault $OUT[999]

doSL1FaultToPLC Fault message to PLC $OUT[999]

doSL1PurgeA Purge component A $OUT[999]

doSL1PurgeB Purge component B $OUT[999]

6 Variables (continued)

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doSL1Purge2K Purge 2–component $OUT[999]

doSL1ComponentBOff Component B off $OUT[999]

diSL1Fault Group fault $IN[1026]

diSL1MatHigh Upper limit value fault $IN[1026]

diSL1MatLow Lower limit value fault $IN[1026]

diSL1Fault1 Fault 1, system fault $IN[1026]

diSL1Fault2 Fault 2, material fault $IN[1026]

diSL1Ready Ready for operation $IN[1026]

diSL1MeterFull Dispenser full $IN[1026]

diSL1PurgePassed Purge ready $IN[1026]

diSL1ProgRecieved Acknowledge program numberbit 0

$IN[1026]

diSL1MeasurePassed Measurement ready $IN[1026]

diSL1DispOk Dispensing OK $IN[1026]

diSL1DoserNearlyEmpty Dispenser nearly empty $IN[1026]

diSL1PrePressOk Feed pressure OK $IN[1026]

diSL1ParamRecieved Acknowledge parameter set bit 0 $IN[1026]

diSL1DoserSingleMode Dispenser in single mode $IN[1026]

diSL1DoserChangeAckn Acknowledge dispenser change $IN[1026]

diSL1PurgeRequest Request purging $IN[1026]

diSL1PrePurgeRequest Request pre–purging $IN[1026]

diSL1Automatic Automatic $IN[1026]

diSL1PumpIsOn Pump on $IN[1026]

diSL1HydraulicIsOn Hydraulic system on $IN[1026]

diSL1HeatingIsOn Heating on $IN[1026]

diSL1HeatingReady Heating ready $IN[1026]

diSL1BarrelPreWarning Drum pre–warning $IN[1026]

diSL1FaultPeriphery Fault $IN[1026]

diSL1DryByPLC With/without material underexternal control

$IN[1026]

diSL1MixtureUndefined Mixture undefined $IN[1026]

diSL1FaultMixture Mixture fault $IN[1026]

diSL11KMode Single–component mode $IN[1026]

diSL11KInMixer 1 component in mixer $IN[1026]

diSL12KInMixer 2 components in mixer $IN[1026]

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6.2 Variables in $Config.dat

The following variables are defined in the file “C:\KRC\Roboter\Krc\System\$Config.dat”.

Variables in $Config.dat

Variable name Meaning

dBlowTime Duration of the clearing time after purging.

Default value: 2.0

GlueSetupMode Wait/do not wait for the program number to be mirrored.

Default value: FALSE

eGlueRestartMode Program resumption following a fault ($STOPMESS).

Default value: #GLUE_OFF

– #GLUE_OFF: Gun no longer opened.– #GLUE_CONT: Gun reopened.– #GLUE_USER: User–defined (calls

GLUE_UserRestart).

bWithSpeed SPEED component of the Bead data set is/is not taken intoconsideration when calculating the cyclical analog outputfactor.

Default value: FALSE

6.3 Variables in Glue.dat

The following variables are defined in the file “C:\KRC\Roboter\Krc\R1\TP\GLUETECH\Glue.dat”.

Variables in Glue.dat

Variable name Meaning

iTimerGlueTech Specifies the timer (timer 16) for actions that are to be carriedout for a programmed duration (Reload TIME, Purge Time,PTP Glue)

iTimerSystem1 Specifies the timer (timer 15) for monitoring the length of timebetween purge cycles in system 1 (Check Purge)



NOTE

Timers 13 to 16 are preset during installation of GlueTech. If the user is already usingthese timers, they can be changed by means of the variable modification function.

7 Messages

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7 MessagesThis section describes a range of messages which are displayed in the KUKA Control Panelmessage window in conjunction with the GlueTech application. Please also refer to the current online help function.

Message text Description, causeSystem 1 (or 2 or 3) not ready Cause:

Input “Ready” of system 1 (or 2 or 3) not set orincorrectly configured.Monitor:During program execution in operating mode<> #T1 if program execution with material hasbeen selected.Effect:Program execution is stopped.Remedy:– check configuration (input number, I/O range);– simulate missing input (softkey).

Doser system 1 (or 2 or 3) is beingfilled(message is only displayed duringthe filling operation.)

Cause:Input “Meter full” of system 1 (or 2 or 3) not setor incorrectly configured.Monitor:During program execution in operating mode<> #T1 if “With doser” has been configuredand “Program execution with material” hasbeen selected.Effect:Output for filling the doser is set, controllerwaits for input “Meter full”.Remedy:Check configuration (input number, I/O range).

No signal PREPRESSURE OK bysystem 1 (or 2 or 3)

Cause:Input “Prepressure ok” of system 1 (or 2 or 3)not set or incorrectly configured.Monitor:During program execution in operating mode<> #T1 if program execution with material hasbeen selected.Effect:Program execution is stopped.Remedy:– check configuration (input number, I/O range);– simulate missing input (softkey).

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Fault controller system 1 (or 2 or 3) Cause:– Input “Fault, application” or– Input “Fault material high” or– Input “Fault material low” or– Input “Mixture threshold high” or– Input “Mixture threshold low”of system 1 (or 2 or 3) not set or incorrectlyconfigured.Monitor:During execution of the instruction “Errorcheck” and when program execution withmaterial has been selected.Effect:Program execution is stopped.Remedy:Check configuration (input number, I/O range).Acknowledge fault on the dispensing controller

System 1 (or 2 or 3): fault materialhigh

Cause:Input “Fault material high” of system 1 (or 2 or3) not set or incorrectly configured.Monitor:During execution of the instruction “Errorcheck” and when program execution withmaterial has been selected.Effect:Program execution is stopped.Remedy:Check configuration (input number, I/O range).Acknowledge fault on the dispensing controller

System 1 (or 2 or 3): fault materiallow

Cause:Input “Fault material low” of system 1 (or 2 or3) not set or incorrectly configured.Monitor:During execution of the instruction “Errorcheck” and when program execution withmaterial has been selected.Effect:Program execution is stopped.Remedy:Check configuration (input number, I/O range).Acknowledge fault on the dispensing controller

System 1 (or 2 or 3): mixturethreshold high

Cause:Input “Error mixture threshold high” of system1 (or 2 or 3) not set or incorrectly configured.Monitor:During execution of the instruction “Errorcheck” and when program execution withmaterial has been selected.Effect:Program execution is stopped.Remedy:Check configuration (input number, I/O range).Acknowledge fault on the dispensing controller

7 Messages (continued)

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System 1 (or 2 or 3): mixturethreshold low

Cause:Input “Error mixture threshold low” of system 1(or 2 or 3) not set or incorrectly configured.Monitor:During execution of the instruction “Errorcheck” and when program execution withmaterial has been selected.Effect:Program execution is stopped.Remedy:Check configuration (input number, I/O range).Acknowledge fault on the dispensing controller

Component SPEED of theselected data set (BeadData) hasnot yet been configured

Cause:The component is still initialized with thedefault value 0.Monitor:During program execution when processingthe instruction “Initialize and start system”.Effect:Program execution is stopped.Remedy:Use the offline tool to initialize the componentwith an appropriate value.

Component MATERIALFACTOR ofthe selected data set (BeadData)has not yet been configured

Cause:The component is still initialized with thedefault value 0.Monitor:During program execution when processingthe instruction “Initialize and start system”.Effect:Program execution is stopped.Remedy:Use the offline tool to initialize the componentwith an appropriate value.

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Submit interpreter stopped ordeselected

Cause:The Submit interpreter is not active.Monitor:During program execution when processingthe instruction “Initialize and start system”.Effect:Program execution waits for active Submitinterpreter.Remedy:Start/select Submit interpreter.

Group fault controller system 1(or 2 or 3)

Cause:The input FAULT has been set by the activedispensing controller.Monitor:During execution of the instruction “Errorcheck” and when program execution withmaterial has been selected.Effect:Program execution remains in a loop until theinput is reset.Remedy:Check whether the input has been configuredcorrectly.If the input is correctly configured, thedispensing controller has set the inputbecause of a fault. Acknowledge dispensingcontroller fault.If the input is not correctly configured, carryout the configuration using the configurationprogram.

1

Index

Index – i

Symbols

$ACC_MA.CP, 23

$ACC_MA.ORI1, 23$ACC_MA.ORI2, 23

$ANA_DEL_FLT, 23

dAnalogOffsetHigh[x], 23$Config.dat, 16

dAnalogOffsetLow[x], 23

$RED_ACC_CPC, 23$VEL_FLT_OFF, 23

A

Adapting the variable values, 20Additional menus, 9

Adhesive application task, 32AirDelay, 18

AirFactor, 28

AirOffDelay, 18AirOffset, 28

AirOnDelay, 18

AirReactionNegOffs, 18AirReactionPosOffs, 18

Analog voltages, 16Application with more than one dispensing con-troller, 15

B

BeadShaping, 30

bSingleFaultToPLC, 30

C

Calibrate_Equipment, 21

Calibration, 21, 22Calibration variables, 23

Characteristics, 5

Commands, 32Configuration, 12

Configuration program, 12

Configuring equipment–specific data, 18Configuring technology–specific data, 27

Configuring the inputs and outputs, 16CP velocity, 22

Creating an adhesive application task, 32

D

Default value for pre–pressure, 28

Dispense complete, 44Dynamic setpoint of air, 28

Dynamic setpoint of material, 28

E

Enable for purging, 47

Entering commands, 32

Equipment–specific data – Description, 18Error check, 45

F

Fill dispenser, 44

FlowType, 28

G

GLUE GLOBALS, 16

GLUE OFF CIRC, 38GLUE OFF LIN, 35

GLUE OFF PTP, 40

GLUE ON CIRC, 36GLUE ON LIN, 34

GLUE ON PTP, 39

GLUE SWITCH CIRC, 37GLUE SWITCH LIN, 34

GLUETECH APPLICATION IO, 16GluetechData.exe, 12, 20

GlueType, 29

Gluing instructions, 41Gun off, 35, 38, 40

Gun on, 34, 36, 39

Gun times, 23GunOffDelay, 18

GunOnDelay, 18

H

Hardware (short description), 6

I

I/O interface, 16

Init system, 42iNumberOfDoser, 30

iPGNOLength, 30

L

Linear characteristic, 16

Index

Index – ii

M

MaterialDelay, 18

MaterialFactor, 28MaterialOffset, 28MaterialReactionNegOffs, 18MaterialReactionPosOffs, 18

Menu keys, 13Menus for GlueTech, 9MirrorPgno, 30Monitoring purge gun, 47

Motion instructions, 33

P

PrePressure, 28

Programming, 31Purge gun, 46

Q

QuitByPLC, 30

R

Reset motion parameter, 44

S

Set motion parameter, 43

Set program number, 43Softkeys, 14Speed, 28Start–up, 12

Static setpoint of air, 28Static setpoint of material, 28Status keys, 9Swirl spraying method, 7

Switching gluing parameters – GLUE SWITCHCIRC, 37Switching gluing parameters – GLUE SWITCHLIN, 34System requirements, 5

T

Teaching the purging position, 47Technology–specific data, 27, 28

Documents

Gluetech 30 En