KUKA.Gripper&SpotTech2.3 07.06.00 en

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SOFTWARE

KR C...

KUKA.Gripper-- and SpotTech 2.3

for KUKA System Software (KSS) 5.x, 7.0

Issued: 10 July 2006

Version: 00

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e

Copyright

2006

KUKA Roboter GmbH

This 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, in

the case of a replacement or service work.

We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies

cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a

regular basis, however, and necessary corrections will be incorporated in subsequent editions.

Subject to technical alterations without an effect on the function.

KUKA Interleaf

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Contents

1

General

6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Installation / uninstallation / update

7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

GripperTech

8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

Basic gripper functions

8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1

Type 1

2 outputs, 4 inputs, 2 switching states

8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.2

Type 2

2 outputs, 2 inputs, 3 switching states

8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.3

Type 3

2 outputs, 2 inputs, 3 switching states

8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.4

Type 4

3 outputs, 2 inputs, 3 switching states

8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.5

Type 5

2 outputs, 4 inputs, 2 switching states

9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.6

Freely programmable type

9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.6.1 Programming example

9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.7

Initialization and configuration examples

13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Manually operating a gripper

14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Programming gripper functions

15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1

Gripper

15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2

Check Gripper

18

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4

SpotTech

20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

Basic SpotTech user functions

20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1

Range of commands

20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.2

The functions SPOT and RETRACT

20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2

Programming and operation

21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1

General information on programming

21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1.1 Variables in input boxes of the inline forms

21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1.2 Overview of the inline forms

21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2

Spot welding (SPOT)

22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.3

Types of motion

22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.3.1 Point--to--point (PTP) motion

22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.3.2 Motion along a straight line (LIN)

22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.3.3 Motion along a circular path (CIRC)

22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.3.4 Activating/deactivating collision detection

22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.4

Programming a weld spot (SPOT)

23

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4.2.4.1 Menu

23

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.4.2 The inline form and the parameter lists for the welding command “SPOT”

24

. . . . . . . . . . . . .

4.2.4.3 Selecting the welding gun (Gun = n)

25

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.4.4 Retract stroke after the welding process (RETR OPN / CLO)

25

. . . . . . . . . . . . . . . . . . . . . . . .

4.2.4.5 Weld parameter list

25

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4.2.5

Opening/closing the welding gun retract stroke (RETRACT)

26

. . . . . . . . . . . . . . . . . . . . . . . . .

4.2.5.1 Types of motion

27

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.5.2 Programming the retract stroke (RETRACT)

27

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.6

Motion commands

29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.7

Reorientation of the welding gun

30

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4.3

Program example

31

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4.3.1

Creating a new program

31

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4.3.1.1 Welding the first spot sequence

35

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4.3.1.2 Welding the second spot sequence

36

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4.3.1.3 Moving from the end of the spot seam to the home position

36

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4.4

Altering existing programs

37

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4.4.1

Altering command lines

37

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4.4.2

Deleting command lines

37

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4.4.3

Adding commands to an existing program

38

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4.4.3.1 Description of the alteration

39

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4.4.3.2 Changing the position of the welding gun (point in space P10)

39

. . . . . . . . . . . . . . . . . . . . . . . .

4.4.3.3 Reorientation of the welding gun -- inserting the command “Motion” (P11)

39

. . . . . . . . . . . . . .

4.4.3.4 Moving to the point in space P12 -- inserting the command “Motion”

40

. . . . . . . . . . . . . . . . . . .

4.4.3.5 Welding spot P13 -- inserting the command “SPOT”

40

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.3.6 Moving to the weld spot P16 and welding

40

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4.4.3.7 Moving to the home position

40

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4.5

SpotTech configuration

41

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4.5.1

Program sequence

41

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4.5.2

Retract stroke (RETRACT) and working stroke (SPOT)

42

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.3

Early closing of the gun (PRESPOT)

42

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4.6

Components of the SpotTech package

44

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4.6.1

Program structure

44

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4.6.2

SPOT Tech--specific files

44

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7

Adaptation to the periphery, configurable options

45

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4.7.1

FOLD “SPOT” in the file “$CONFIG.DAT”

45

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4.7.2

The user--specific program “USERSPOT.SRC”

46

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.2.1 Schematic sequence diagram for SPOT (without RETRACT)

47

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4.7.2.2 Schematic sequence diagram for SPOT (with RETRACT)

48

. . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.2.3 Robot controller -- welding controller interface

49

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4.7.2.4 Program example for the file “USERSPOT.SRC”

49

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4.8

Program example

52

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4.9

Manual operation of the welding gun using the status keys

53

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4.9.1

Separate control of RETRACT and SPOT

53

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4.9.1.1 Definition of function type and assignment of physical outputs

53

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4.9.2

Manual control of RETRACT and SPOT in series

55

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1

General

The software packages GripperTech and SpotTech are supplied together on a Setup CD and

expand the scope of the basic KRC software.
-- The functions of the GripperTech technology package (gripper programming) enable the

robot system to control and monitor tools and devices in its work environment.

-- The SpotTech technology package is used for the convenient programming of spot welding

applications.

2

Installation / uninstallation / update

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2

Installation / uninstallation / update

From system software version 5.1 onwards, technology packages are offered exclusively as

add--on software modules. These are available on CD--ROM. Should you be interested in

purchasing further modules, please contact KUKA Support.
The installation procedure is the same for all technology packages and is described in a

separate documentation module.

The installation, uninstallation, reinstallation and update of technology packages

are described in detail in the documentation “Installation/Uninstallation/Update of

Tech Packages”.

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3

GripperTech

3.1

Basic gripper functions

The GripperTech technology package includes five basic types of gripper control, with whose

logic functions the majority of applications that occur are covered. If these basic types prove

to be insufficient at any time, any additional gripper functions can be freely programmed.
Each gripper must be assigned a function type. If a gripper is to be temporarily or

permanently excluded from use, it must be assigned gripper type “0”.

3.1.1

Type 1

2 outputs, 4 inputs, 2 switching states

e.g. a simple gripper with the functions OPEN and CLOSE;

State

OUT1

OUT2

IN1

IN2

IN3

IN4

A

TRUE FALSE TRUE FALSE TRUE FALSE

B

FALSE TRUE FALSE TRUE FALSE TRUE

3.1.2

Type 2

2 outputs, 2 inputs, 3 switching states

e.g. a slide with a center position;

State

OUT1

OUT2

IN1

IN2

A

TRUE FALSE TRUE FALSE

B

FALSE TRUE FALSE TRUE

C

FALSE FALSE FALSE FALSE

3.1.3

Type 3

2 outputs, 2 inputs, 3 switching states

e.g. a vacuum gripper with the functions VACUUM, BLOW and OFF;

State

OUT1

OUT2

IN1

IN2

A

TRUE FALSE TRUE FALSE

B

FALSE TRUE FALSE TRUE

C

FALSE FALSE FALSE FALSE

3.1.4

Type 4

3 outputs, 2 inputs, 3 switching states

The same as type 3 but with three control outputs (type 3 has two outputs);

State

OUT1

OUT2

OUT3

IN1

IN2

A

TRUE FALSE FALSE TRUE FALSE

B

FALSE TRUE

TRUE FALSE TRUE

C

FALSE TRUE FALSE FALSE FALSE

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3.1.5

Type 5

2 outputs, 4 inputs, 2 switching states

The same as type 1 but with a pulse signal instead of a continuous signal.

State

OUT1

OUT2

IN1

IN2

IN3

IN4

A

TRUE FALSE TRUE FALSE TRUE FALSE

B

FALSE TRUE FALSE TRUE FALSE TRUE

In contrast to gripper type 1, a continuous signal is not applied here, but a pulse of variable

duration is transmitted whenever the signal level changes. It is set by modifying the variable
GRP_PULSE_TI.

During controller operation, this variable can be altered by means of the “Modify” -- “Variable”

options in the “Monitor” menu.

More detailed information on how to modify the values of system variables during controller

operation can be found in the chapter “Monitor Functions”, section “Variables”.

3.1.6

Freely programmable type

A freely programmable gripper type has been integrated in order to cover all user require-

ments. Any number of completely freely definable grippers can be configured by means of

entries in the files $CONFIG.DAT, USERGRP.DAT and USER_GRP.SRC.

3.1.6.1 Programming example

Requirement

A welding gun is to switch between the positions OPEN -- RETRACT -- WORKING STROKE

-- RETRACT -- OPEN when the status key “Manual gripper operation” is pressed.

OPEN

RETRACT

WORKING STROKE

RETRACT

OPEN

Position “A”

Position “B”

Position “C”

Position “B”

Position “A”

This task requires the use of two double--acting pneumatic cylinders controlled via electro-

magnetically operated 4/2--way valves.

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Retract cylinder

Working stroke cylinder

Output 1

Output 2

Output 3

Output 4

State

Control

Out-

put1

Out-

put2

Out-

put3

Out-

put4

A

FALSE TRUE FALSE TRUE

B

TRUE FALSE FALSE TRUE

C

TRUE FALSE TRUE FALSE

Programming
In order to implement the example described, make the following changes or additions to the

data shown below.

Entries in the file “$CONFIG.DAT”
The freely programmable gripper is defined with the identification number “100”.

;==================================
; Definition of grippers
;==================================

DECL GRP_TYPES GRIPPER[8]

GRIPPER[1]={TYPE 100}

Entries in the file “$USER_GRP.DAT”:

&ACCESS

RP

&COMMENT USER GRIPPER package
DEFDAT

USER_GRP

...

ENUM GUN_STAT RET_OPN,RET_CLS,WRK_CLS,WRK_OPN

Data type, enumeration of gun states:

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STRUC MY_GUN INT RET_OPN,RET_CLS,WRK_OPN,WRK_CLS,GUN_STAT
STAT

Structure of the user--defined data type “MY_GUN”:

DECL MY_GUN MY_GUN1={RET_OPN 100,RET_CLS 101,WRK_OPN
102,WRK_CLS 103,STAT #RET_OPN}

Assignment of outputs for the welding gun “MY_GUN1” of type “MY_GUN”:

...
ENDDAT

Entries in the file ”USER_GRP.SRC”

DEF

GRP_MANUAL ( ) ;=================

;part for manual functions
;=====================================

SWITCH

GRIPPER[G_NO].TYPE ;switch type of gripper

;end of example for new gripper

CASE 100

$OUT[MY_GUN1.RET_OPN]=FALSE

Reset output

$OUT[MY_GUN1.RET_CLS]=FALSE

Reset output

$OUT[MY_GUN1.WRK_OPN]=FALSE

Reset output

$OUT[MY_GUN1.WRK_CLS]=FALSE

Reset output

SWITCH MY_GUN1.STAT

Start of the control structure

CASE #RET_OPN

If the state of the gun

MY_GUN1.STAT has the value

#RET_OPN (retract stroke

open)

PULSE($OUT[MY_GUN1.RET_CLS],TRUE,0.3) send a 0.3 second

pulse to the output

RET_CLS (retract stroke

closes)

MY_GUN1.STAT=#RET_CLS

set the state of the gun

MY_GUN1.STAT to

#RET_CLS (retract

stroke closed)

CASE #RET_CLS

If the state of the gun

MY_GUN1.STAT has the value

#RET_CLS (retract stroke

closed)

PULSE($OUT[MY_GUN1.WRK_CLS],TRUE,0.3) send a 0.3 second

pulse to the output

WRK_CLS (working

stroke closes)

MY_GUN1.STAT=#WRK_CLS

set the state of the gun

MY_GUN1.STAT

to #WRK_CLS (working

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stroke closed)

CASE #WRK_CLS

If the state of the gun

MY_GUN1.STAT has the value

WRK_CLS (working stroke

closed)

PULSE($OUT[MY_GUN1.WRK_OPN],TRUE,0.3) send a 0.3 second

pulse to the output

WRK_OPN (working

stroke opens)

MY_GUN1.STAT=#WRK_OPN

set the state of the gun

MY_GUN1.STAT to

#WRK_OPN (working

stroke open)

CASE #WRK_OPN

If the state of the gun

MY_GUN1.STAT has the value

#WRK_OPN (working stroke

open)

PULSE($OUT[MY_GUN1.RET_OPN],TRUE,0.3) send a 0.3 second

pulse to the output

RET_OPN (retract stroke

opens)

MY_GUN1.STAT=#RET_OPN

set the state of the gun

MY_GUN1.STAT to

#RET_OPN (retract

stroke open)

DEFAULT

If none of the states listed so

far appears, execute the

following instructions

ENDSWITCH

End of the control structure

...

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3.1.7

Initialization and configuration examples

On switching to state “A”

(Open), output 17 will be set

to TRUE and output 18

(inverted) also to TRUE.

When scanned, input 22

must have the state TRUE

and input 23 the state FALSE

so that the motion program

can continue.

On switching to state “B”

(Closed), output 17 will be

set to FALSE and output 18

(inverted) also to FALSE.

When scanned, input 22

must have the state FALSE

and input 23 the state TRUE

so that the motion program

can continue.

Not defined

17

--18
0
0

22

23
0
0

Example_1

On switching to state “A”

(Open), output 19 will be set

to TRUE and output 21 to

FALSE. When scanned,

input 22 must have the state

TRUE, input 23 (inverted)

the state TRUE, input 24 the

state TRUE and input 25

(inverted) also the state

TRUE so that the motion

program can continue.

On switching to state “B”

(Closed), output 19 will be

set to FALSE and output 21

to TRUE. When scanned,

input 22 must have the state

FALSE, input 23 (inverted)

also the state FALSE, input

24 the state FALSE and input

25 (inverted) also the state

FALSE so that the motion

program can continue.

Not defined

19

21
0
0

22

--23
24
--25

Example_2

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3.2

Manually operating a gripper

A configured gripper can only be operated in the modes:

G

TEST1 (reduced velocity) or

G

TEST2 (programmed velocity),

with an enabling switch being held down.
Use the top status key shown on the left to select from the configured grippers the one that

you would like to operate.

You can then switch between the gripper functions using the bottom status key shown on the

left.

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3.3

Programming gripper functions

Pay attention to the position of the edit

cursor. The next program line created

by you will be inserted as a new line

after the cursor.

3.3.1

Gripper

Open the menu using the menu key “Technology”. Then select “GRIPPERTech”. The follow-

ing submenu is displayed:

As a gripper function is to be programmed, confirm the offered selection “Gripper”.
An inline form for entering the parameters that are required for executing a gripper function

is opened in the programming window.

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the gripper function at any time by pressing the softkey

“Cmd Abort” or the ESC key. The command will not be saved in this case.
If the programming window is in focus, the various input windows can be selected using the

“↑” and “↓” arrow keys. The window that is currently selected is highlighted by a color back-

ground.
The programming window can be activated by repeatedly pressing the “Window selection”

key until the entire window is highlighted in color.
Move the cursor to the input box “SET”. The status key (at the bottom right of the display)

changes its assignment.
You can choose between the configured grippers using this status key.

Move the cursor to the input box “State”. The status key (at the bottom right of the display)

changes its assignment.
You can use this status key to choose between the functions that have been defined for the

selected gripper.

Move the cursor to the next input box on the right. The status key (at the bottom right of the

display) changes its assignment.

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The approximate positioning function can be switched on or off using this status key.

If you switch the approximation function off, a further input box, “GDATn”, appears on

the right, in this case GDAT1.

If the cursor is moved to this box with the “↓” arrow key, a status window is opened.

Data that more precisely characterize the gripper function must be entered here.
Activate this status window using the “Window selection” key.

Decide at this point whether any sensors that may be fitted on the gripper are to be

interrogated or whether a wait time is to be used to ensure that the functions that have been

programmed are fully executed.
Wait Time:
If “Check Gripper” is switched off because, for example, it is not possible to interrogate the

sensors, a wait time of up to ten seconds can be defined here.

Check Gripper:
Here you can specify whether the sensors on the gripper are to be interrogated before the

robot starts moving again (it is only possible to interrogate the sensors if approximate

positioning is switched off in this block). If the sensors do not return a status message, the

controller allows you to set the inputs so that execution of the program can continue

unhindered.

Only use this simulation if you are sure that it cannot result in any unexpected

situations!

If you switch the approximation function on, two further input boxes, “at” and “Delay”, appear

on the right.

Other than in the case of the gripper function without approximation, the robot does

not stop here after reaching the end point in order to activate the gripper.

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Motion block

1

End point

Execute gripper

function

Without approximate

positioning

The gripper function

is executed along

this line

Motion block

1

Motion block

2

Motion block

2

End point

End point

End point

With approximate

positioning

The parameters START, END and Delay are used to define the point at which the

gripper function is executed.

START

END

Delay

positive

Delay

negative

The reference point for activation of the gripper is determined using the status key (at

the bottom, to the right of the display).
Then move the cursor to the box “Delay”. You can enter a value here, using the

numeric keypad, or change the default value by increments of 1 ms using the status

key (at the bottom, to the right of the display).

Then press the softkey “Cmd Ok”. The gripper function is now fully programmed and saved.

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3.3.2

Check Gripper

This command is only executed if it is located before a motion instruction.

Any sensors fitted on the gripper can be interrogated using this command. If the conditions

defined by the function type and configuration of the gripper are not satisfied, the robot stops

moving. It does not continue the motion program until the conditions are met.
Now open the menu by means of the menu key “Technology”. Then select “GRIPPERTech”.

(The menu items contained in this menu depend on the specific software configuration.)

As a gripper sensor interrogation is to be programmed, select the option “Check Gripper”.

The inline form for entering the parameters that are required for executing a gripper sensor

interrogation is opened in the programming window.

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the gripper sensor interrogation at any time by pressing

the softkey “Cmd Abort” or the ESC key. The command will not be saved in this case.
If the programming window is in focus, the various input windows can be selected using the

“↑” and “↓” arrow keys. The window that is currently selected is highlighted by a color back-

ground.
The programming window can be activated by repeatedly pressing the “Window selection”

key until the entire window is highlighted in color.
Move the cursor to the input box “CHECK”. The status key (at the bottom right of the display)

changes its assignment.
You can choose between the configured grippers using this status key.

Move the cursor to the input box “State”. The status key (at the bottom right of the display)

changes its assignment.
You can use this status key to choose between the functions that have been defined for the

selected gripper.

Move the cursor to the input box “at”. The status key (at the bottom right of the display)

changes its assignment.

The reference point for the gripper interrogation is determined using this status key.

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Motion block

1

The gripper function

is executed along

this line

End point

End point

Motion block

2

The parameters START, END and Delay are used to define the point at which the gripper

function is executed.

START

END

Delay

positive

Delay

negative

Then move the cursor to the box “Delay”. You can enter a value here, using the numeric

keypad, or change the default value by increments of 1 ms using the status key (at the

bottom, to the right of the display).

Then press the softkey “Cmd Ok”. The gripper interrogation function is now fully programmed

and saved.

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4

SpotTech

4.1

Basic SpotTech user functions

Once the technology package has been correctly installed, additional commands are

available in the SpotTech package for spot welding applications.

4.1.1

Range of commands

An initialization command and two program commands, which are used to control the

welding equipment, are basically available for spot welding. These are:

G

INI

This initialization command is automatically entered at the beginning of each new

program that is to be created (skeleton program). This sets the basic parameters for the

robot and the application program and initializes the welding and motion commands and

approximate positioning.

G

SPOT

The command “SPOT” controls the robot motion to a weld spot, and the welding process.

The opening and closing of the welding gun retract stroke after the welding process can

also be programmed by means of this command.

Collision detection can also deactivated here.

G

RETRACT

The command “RETRACT” controls the robot motion to any point, and the opening and

closing of the welding gun retract stroke after reaching the end point. This function is

required, for example, if access to weld spots or auxiliary points with the retract stroke

of the welding gun fully open or closed is impeded by obstructing contours.

Collision detection can also deactivated here.

Motions that do not include a welding operation and do not change the state of the welding

gun retract stroke or which are used for reorientating the welding gun are programmed by

means of a command belonging to the group “Motion”.

4.1.2

The functions SPOT and RETRACT

The SpotTech basic functions “SPOT” and “RETRACT” are shown in the following sketch.

Welding gun

Component

R

etr

ac

ts

tr

ok

e

Wo

rk

in

g

st

ro

ke

Retract stroke open

“RETR OPN”

Retract stroke closed

“RETR CLO”

Welding process

“SPOT”

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4.2

Programming and operation

This section describes how to create spot welding programs and how to program welding

and motion commands. It also contains information on everything that has to be taken into

account when setting individual parameters.
SpotTech has a universal basic structure and each of the programming possibilities given

here is dependent on the welding equipment and user--specific subprograms that are used.

4.2.1

General information on programming

4.2.1.1 Variables in input boxes of the inline forms

The inline forms contain a series of input boxes, whose designations are freely selectable.

This applies to the boxes
P1 ...

Designation of the end point

PDAT1 ..., CPDAT1 ...

Designation of the “Movement parameters” data set

SDAT1 ...

Designation of the “Weld parameters” data set

The following must always be observed:

-- The designation can consist of letters and numbers. Special characters apart from the

underscore “_” cannot be used.

-- The first character of a designation must always be a letter.
-- The designation is entered unchanged as a pure character string into all of the

subsequent program lines.

-- If the last character is a number, the value of this number is automatically incremented

(n+1), e.g. “SDAT1”, “SDAT2” ... “SDATn” or “SEAM_FRONT1”, “SEAM_FRONT2”

... “SEAM_FRONT99”, in the subsequent commands.

If a number is entered at the end of the designation -- this number being incremented (n+1)

in each subsequent command -- please remember that the number of characters increases

by 1 when going from 9 to 10.

4.2.1.2 Overview of the inline forms

The following sections contain screenshots of the inline forms assigned to each of the

“SpotTech” commands, showing both the input boxes and the parameter lists that can be

opened in the status window if the cursor is moved to the appropriate box in the inline form.
The operator control elements and symbols that are used here are explained below:
If the inline form is active, the desired input box can be selected by means of the arrow keys.

The selected box is displayed in white lettering on a blue background.
The operator control elements shown below the inline form are intended to be an additional

aid to familiarize you with the possibilities of making entries in inline forms and parameter

lists. These have the meanings described below:

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If the cursor is positioned in the appropriate box of the inline form, the bottom right status key

can be used to alter the parameters or to select data sets that have already been defined.

It is possible to both enter and alter commands and parameters by means of the keypad (by

pressing the initial letter of the command/parameter).
This symbol indicates that a parameter list (movement or weld parameters) is assigned to

the input box in the inline form. The status window together with the appropriate parameter

list is activated when the “Window selection” key on the graphical user interface is pressed.
This softkey (which is only available when a parameter list is active in the status window) is

used to exit the status window and activate the corresponding input box in the inline form.

4.2.2

Spot welding (SPOT)

The command “SPOT” controls the robot motion to a weld spot, and the welding process.

It can also be used to control the opening and closing of the welding gun retract stroke

(RETRACT) after the welding process.
This command primarily contains the type of motion (PTP, LIN, CIRC), the designation of the

weld spot (Pn), the movement parameters (PDATn or CDATn), the weld parameters

(SDATn) and the designation of the welding gun (Gun= n) and the activation of collision

detection.

4.2.3

Types of motion

Three types of motion can be selected for the command “SPOT”: “PTP”, “LIN” and “CIRC”.

Since the robot must be exactly positioned to each weld spot, the “approximate positioning”

function is not included.

4.2.3.1 Point--to--point (PTP) motion

PTP (point--to--point) motion allows the robot to be moved to the end position at the highest

possible velocity. This motion is the most efficient. For spot welding seams, most robot

motions between the individual weld spots are generally executed as PTP motions.

However, it must be remembered that:

The path cannot be predicted exactly for PTP motions! The motion characteristics

of the robot with greater distances between points and near obstacles should

therefore be checked in a test run.

4.2.3.2 Motion along a straight line (LIN)

LIN (linear) motions are used whenever the robot has to follow an exact path to the end point.

4.2.3.3 Motion along a circular path (CIRC)

In the case of CIRC motions, the welding gun is moved along a circular path. This type of

motion is selected whenever the gun cannot be positioned to the end point using a linear

motion.

4.2.3.4 Activating/deactivating collision detection

Irrespective of the type of motion, collision detection can be activated or deactivated for the

weld gun. If detection is activated, the necessary KRL program lines are integrated into the

fold block.

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4.2.4

Programming a weld spot (SPOT)

4.2.4.1 Menu

After selecting the relevant option (“SPOT Tech -- SPOT -- PTP” in this example) by means

of the menu key “Technology”, the inline form described in the next section is opened.

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4.2.4.2 The inline form and the parameter lists for the welding command “SPOT”

Frames

Ext. TCP
“True” or “False”

LIN/CIRC

PTP

Softkey bar when the inline form is active

Softkey bar when a parameter list is active

Tool coordinate
system

Base coordinate
system

Example of a
weld parameter list

Early closing of
the welding gun

Timer program for
the 1st gun pair

Pressure for
the 1st gun pair

LIN/CIRC
motion

PTP motion

Velocity
(0.001 to 2 m/s)

Acceleration
(1 to 100 %)

Velocity
(1 to 100 %)

Acceleration
(1 to 100 %)

Collision detection
“True” or “False”

You can switch to the commands “RETRACT” or “Motion” and change the motion type

(PTP, LIN or CIRC) at any time during programming, until this is concluded using “Cmd Ok”.

Brief description of the input boxes of the inline form (from left to right), their functions and

their range of values where applicable:

Box

Function

Range of values, Comments

PTP

Type of motion

PTP, LIN, CIRC
Change using bottom right status

key, softkey or keypad.

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P2

Designation of the end point;

with CIRC motions, a further

input box is available for the

auxiliary point.

Freely selectable
Change the designation Pn by

using the keypad or the bottom

right status key.

PDAT2

Designation of the movement

parameters

Freely selectable (see Section

4.2.1.1).

SPOT Gun= 1

Designation of the welding gun

Select from up to 5 guns.

RETR OPN

Retract stroke after the welding

process (RETRACT)

CLO = retract stroke closed

OPN = retract stroke open

SDAT1

Designation of the weld parame-

ters

Freely selectable (see Section

4.2.1.1).

4.2.4.3 Selecting the welding gun (Gun = n)

It is possible to select from up to 5 welding guns. This is dependent on the welding equipment

that is used.

4.2.4.4 Retract stroke after the welding process (RETR OPN / CLO)

In this input box, you define whether the welding gun retract stroke is to be open or closed

after the welding process.

Welding gun

Component

R

etr

ac

ts

tr

ok

e

Wo

rk

in

g

st

ro

ke

Retract

stroke open

“RETR OPN”

Retract stroke closed

“RETR CLO”

You can switch between “Retract stroke open” (RETR OPN) and “Retract stroke closed”

(RETR CLO) by pressing the bottom right status key. This status key has a toggle function

in this instance. The pulldown menu will be opened and closed automatically after a short

time. Alternatively, the respective initial letter (“O” = OPN = open; “C” = CLO = closed) can

be entered by means of the keypad. The cursor must be positioned in the input box next to

“RETR” in this case.

4.2.4.5 Weld parameter list

Due to the universal basic structure of the spot welding technology, the parameters for the

welding data can be adapted individually to the requirements of both the user and the welding

equipment that is used.
The option of closing the welding gun early is described below on the basis of a spot welding

application.

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Early closing of the welding gun

(early closing time)

-- 1000 to 0 milliseconds

Pn

Start of early

closing of gun

Weld spot

position Pn

reached

Gun closed

Ea

rly

cl

osi

ng

time

Working stroke

Early closing

distance

The point of closing the gun early (early closing time) is to optimize the time taken to execute

the spot welding process. Whilst the welding gun is still moving to the weld spot, the closing

operation is already starting. In this instance, it must be ensured that the gun is not closed

completely until just after the end position Pn is reached.

Variations in air pressure, the position of the gun and other factors may produce different

opening and closing times for the gun. The closing time of the welding gun must therefore

be checked in a test run. Closing the gun too early while the robot is still moving results in

the weld spot being incorrectly positioned and may cause the component and the tool to

be damaged!

4.2.5

Opening/closing the welding gun retract stroke (RETRACT)

The command “RETRACT” controls the robot motion to any point, and the opening and

closing of the welding gun retract stroke. This function is required, for example, if access to

weld spots or auxiliary points with the gun fully open or closed as far as the working stroke,

is impeded by obstructing contours.

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In addition to the type of motion (PTP, LIN, CIRC), the name of the end point (Pn), the

movement parameters (PDATn or CDATn) and the designation of the welding gun (Gun= n),

this command also contains an instruction specifying whether the gun retract stroke is to be

open (OPN) or closed (CLO) after the end point has been reached.
Irrespective of the type of motion, collision detection can be activated or deactivated.

4.2.5.1 Types of motion

Three types of motion can be selected for the command “RETRACT”: “PTP”, “LIN” and

“CIRC”. Approximate positioning is not possible; the robot is exactly positioned to each point.

Further details on this are given in Section 4.2.3.

4.2.5.2 Programming the retract stroke (RETRACT)

Menu (The menu items contained depend on the specific software configuration.)

After selecting the relevant option by means of the menu key “Technology” (“SPOT Tech --

RETRACT -- PTP” in this example), the inline form described in the next section is opened.

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The inline form and the parameter lists for the command “RETRACT”

Frames

LIN/CIRC

PTP

Tool coordinate
system
Base coordinate
system

LIN/CIRC
motion

Velocity
(0.001 to 2 m/s)

Acceleration
(1 to 100 %)

PTP motion

Velocity
(1 to 100 %)

Acceleration
(1 to 100 %)

Softkey bar when the inline form is active

Softkey bar when a parameter list is active

Ext. TCP
“True” or “False”

Collision detection

“True” or “False”

You can switch to the commands “SPOT” or “Motion” and change the motion type (PTP,

LIN or CIRC) at any time during programming, until this is concluded using “Cmd Ok”.

Brief description of the input boxes of the inline form (from left to right), their functions and

their range of values where applicable:

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Box

Function

Range of values, Comments

PTP

Type of motion

PTP, LIN, CIRC
Change using bottom right status

key, softkey or keypad

P1

Designation of the end point;

with CIRC motions, a further

input box is included for the

auxiliary point.

Freely selectable
Change the designation Pn by

using the keypad or the bottom

right status key.

PDAT1

Designation of the movement

parameters.

Freely selectable

RETR OPN

Retract stroke after reaching the

end point.

OPN = retract stroke open
CLO = retract stroke closed

SPOT Gun= 1

Designation of the welding gun

Select from up to 5 guns.

Retract stroke after reaching the end point (RETR OPN / CLO)
In this box, you define whether the welding gun retract stroke is to be open or closed after

the end point has been reached.

Welding gun

Component

R

etr

ac

ts

tr

ok

e

Wo

rk

in

g

st

ro

ke

Retract

stroke open

“RETR OPN”

Retract stroke closed

“RETR CLO”

You can switch between “Retract stroke open” (RETR OPN) and “Retract stroke closed”

(RETR CLO) by pressing the bottom right status key. This status key has a toggle function

in this instance. The pulldown menu will be opened and closed automatically after a short

time. Alternatively, the respective initial letter (“O” = OPN = open; “C” = CLO = closed) can

be entered by means of the keypad. The cursor must be positioned in the input box next to

“RETR” in this case.

4.2.6

Motion commands

Motions of the tool which do not feature a welding operation and which do not change the

welding gun retract stroke can be programmed by means of the command “Motion” from the

“Commands” menu.

A corresponding inline form is opened by means of the softkey “Motion”, with the motion type

(PTP, LIN or CIRC) that was predefined with the last command being displayed; this must

be changed, if necessary.

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4.2.7

Reorientation of the welding gun

Pn

(P2)

Pn

(P3)

P4

P1

P3

P2

Reorientation of the

welding gun by 90°

If the spot welding plane changes -- as shown in the sketch above -- the welding gun must

be reorientated. To do so, the gun must first be moved into a position (P2) where there is no

risk of it colliding with the component or with other obstructing contours during reorientation.
The reorientation (point in space P2 to P3) is carried out using the command “Motion -- LIN”

or -- if the gun retract stroke (RETRACT) is to be changed during the same operation -- “SPOT

Tech” -- “RETRACT” -- “LIN” (see Section 4.2.5). The gun can subsequently be positioned

to the next weld spot (P4).

Depending on the position of the robot axes, it may also be possible to select a PTP motion.

As PTP motions cannot be predicted exactly, a test run should be carried out.

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4.3

Program example

In this section, the use of the basic commands of the spot welding technology will be

described step by step on the basis of a simple program example. The assembly shown

below, consisting of three individual parts, is to be fabricated by means of spot welding.

Home

position

4.3.1

Creating a new program

To create a new program, press the softkey “New” and enter a program name (e.g. “Test”)

in the input box.
Now press the softkey “Select”. The following skeleton program is displayed in the program-

ming window:

Pay attention to the position of the edit cursor. The following program line created by you will

be inserted as a new line after the cursor.
Alternatively, you can program in edit mode by means of the softkey “Edit”. The syntax will

not be checked, however.

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The first weld spot

Home

position

When moving the welding gun from the home position to the first weld spot, it must be

ensured that no obstructing contours (e.g. those of the component) can cause a collision.

For example, the path of the PTP motion cannot be exactly predicted! The motion

characteristics of the robot near obstacles should therefore always be checked in a test

run.

The diagram given below shows a collision situation on the left. As can be seen in the

situation on the right, you can ensure that the welding gun is positioned safely to the first weld

spot (P2) by inserting an additional point in space (P1).

Home

position

Home

position

PTP

motion

Risk of a colli-

sion with the

component!

End

position

Positioning the welding gun

directly to the end point

Component

Component

Point in space P1

1st weld
spot P2

Inserting an additional point

in space

If the motion between the point in space P1 and the first weld spot (P2) is executed as a

PTP motion, the distance between these two points should not be too great. The robot can

use approximate positioning for moving from the home position to P2 via P1 because exact

positioning is not required until the welding gun moves to the position of the weld spot.

Moving from the home position to the point in space P1 -- “RETRACT”
The welding gun is moved from the home position to the point in space P1 by means of a

PTP motion. During the same operation, you ensure that the retract stroke is open after the

point has been reached.
Press the menu key “Technology” and select the options shown below (menu items in white

lettering on a blue background):

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After selecting the command “SPOT Tech -- RETRACT -- PTP”, the following inline form is

opened on the screen:

If the programming window is active, the input boxes can be selected by means of the arrow

keys. The selected box appears in white lettering on a blue background.

At the same time that the inline form given above is opened, the assignment of the softkey

bar changes to that shown below:

You can also correct your original selection (“SPOT”, “Motion” and type of motion) by means

of this softkey. The inline form changes accordingly when a selection is made. The command

can be aborted by means of the softkey “Cmd Abort” or the ESC key. This will close the inline

form.

The welding gun retract stroke must be open after the point in space P1 has been reached.

This is set in the input box “RETR”. In the example given above, “OPN” (open) is already

entered; otherwise, “CLO” (closed) appears here.

To change the setting, move the cursor to the input box “RETR”. You can

switch between “RETR CLO” and “RETR OPN” by means of the bottom right

status key. This status key has a toggle function. Alternatively, the letter “C”

(=closed) or “O” (=open) can be entered by means of the keypad. In this case,

enter “O”.

For the purpose of positioning the welding gun, move it to the position P1 by means of the

Space Mouse or the traversing keys. Information on controlling motions of the robot manually

can be found in the chapter [Manual traversing of the robot].

You can now press the softkey “Touch Up”. In this case, press the softkey “Yes” to confirm

the query “Touchup (Y/N)?” that is displayed in the message window. Alternatively, press the

softkey “Cmd Ok” or the Enter key. The current robot coordinates are automatically saved.

The command is ended by pressing the softkey “Cmd Ok” or the Enter key. If the point P1

has not yet been touched up, the current robot coordinates are now automatically saved. The

information message “Point P1 created automatically” is displayed in the message window.

The inline form is closed and the generated program line is inserted into the program form

afterwards. The numbers of the following program lines are automatically updated.

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Setting the first weld spot (SPOT)
A PTP motion is used to move the welding gun from the point in space P1 to the weld spot

P2. The gun is exactly positioned to point P2 where the welding process will then be

executed. Since a sequence of further spot welds follows P2, the retract stroke can remain

closed.
Press the menu key “Technology” and select the options shown below (menu items in white

lettering on a blue background):

After selecting the command “SPOT Tech” -- “SPOT” -- “PTP”, the following inline form

appears on the display.

Alternatively, you can also press the softkey “Last Cmd”. If you had last entered a

“RETRACT” command, an inline form for the command “RETRACT” is displayed. “SPOT”

can then be called by means of the softkey “SPOT”. The same inline form is thus available.
As can be seen, the names for the end point (P2) and the data set (PDAT2) have been

adapted. A further box is also displayed: the designation of the weld parameter set (SDAT1).
The welding gun retract stroke can be left closed (“RETR CLO”) in this program example.

If the first command to be entered was “RETR OPN” (retract stroke open), this has been used

as a default setting in the input box of the new inline form.
To change the setting, move the cursor to the input box “RETR”. Press the bottom right status

key or enter the letter “C” by means of the keypad. “CLO” (=closed) subsequently appears

in the input box of the inline form.

Enter the movement and weld parameters into both the inline form and the parameter lists

and move the welding gun to the desired position P2.
If your welding system has been configured appropriately, the functioning of the gun can be

checked at this point by means of the gun status keys. For information on this, see Section

4.9 and the chapter [SPOT Tech © -- Expert Programming].

After entering all of the parameters, press the softkey “Cmd Ok”. The current robot

coordinates are saved and the program form is updated accordingly.

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4.3.1.1 Welding the first spot sequence

P2

P3

P4

P5

RETR CLO

RETR OPN

The further points (P3 to P5) can be programmed using the procedure described in the last

section. In this case, leave the welding gun retract stroke closed (RETR CLO) for P3 and P4.
As the welding gun is to be positioned to the first weld spot (P6) of the second welding

sequence (see the sketch at the beginning of Section 4) after P5, the retract stroke must be

opened at P5. To do so, select the option “RETR OPN” when programming P5.
After all of the entries for the first spot sequence have been made, the program form appears

as follows:

As can be seen, the numeric values for the designation of the movement parameters

(PDATn) have each been increased by 1 in command lines 4 to 7. The numeric values for

the designation of the weld parameters (SDATn) have likewise been increased. The parame-

ters entered in “SDAT1” have automatically been entered in “SDAT2” .... “SDAT4”.

For spot sequences that are to be welded with the same welding tool and the same weld

parameters, programming can be simplified if each weld spot is not programmed

individually but by using the procedure described below:

G

Program the first weld spot of the sequence.

G

Determine the number of spots that are to be welded after the first spot.

G

Press the softkey “Last Cmd” and then the softkey “Cmd Ok”.

Repeat this according to the number of weld spots.

G

To save the robot coordinates, subsequently move the edit cursor (vertical line) to the

appropriate line of the program form in sequence. Position the robot manually to the

respective point, press the softkey “Touch Up” and confirm the request for confirmation

to save the coordinates. The current robot coordinates are saved for the point that is

currently selected.

With the motion type “CIRC”, the coordinates for the required auxiliary point must always

be touched up manually.

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4.3.1.2 Welding the second spot sequence

The second spot sequence begins at P6. A PTP motion can be used between the weld spots

P5 and P6 as the distance between them is small and the welding gun retract stroke is open.
The weld spot P6 can be programmed in the program example given above.
Now program the weld spots P7 to P9 following the description given in the previous section.

Select the option “RETR OPN” again for the last weld spot (P9) to open the welding gun

retract stroke after P9 has been welded.

4.3.1.3 Moving from the end of the spot seam to the home position

To move the welding gun back to the home position, a further point in space outside the

component is required so that a collision is safely avoided. This is P10 in this program

example, where it is assumed that there are no obstacles between P10 and the home

position.
The path between the weld spot P9 and the point in space P10 is executed as a “PTP” motion.
Press the softkey “Motion”. An inline form is opened:

After entering the parameters, press the key “Cmd Ok”.
Alternatively, this motion can also be programmed by means of the command “SPOT Tech”

-- “RETRACT” -- “PTP”.
The motion from P10 to the home position (“PTP -- HOME”) is already included in the

skeleton program. Programming of this program example is thus completed.

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4.4

Altering existing programs

It is possible to alter commands and/or parameters and to delete command lines in an

existing program at any time. Two examples are given below.

4.4.1

Altering command lines

The procedure for altering command lines is demonstrated below by using a different type

of motion for the command “SPOT -- RETRACT” to the point in space P1 to that used in the

above program example. The parameter “PTP” for P1 is to be changed to “LIN”.

Move the edit cursor to line 3 by means of the arrow keys.
Press the softkey “Change”. The inline form for this command line is opened. Move the cursor

to the first input box on the left.
Press the bottom right status key until “LIN” appears in the input box.

Then press the softkey “Cmd Ok”. The inline form is closed and the program form is updated

accordingly.

4.4.2

Deleting command lines

The motion command that appears in line 13 of the program form given below (P11) is to be

deleted. To do so, move the edit cursor to line 13.

Press the menu key “Program”

and select “Delete” by means of the arrow key. Then press the Enter key. The key “1” in the

numeric keypad can also be pressed (do not press Enter).

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Line 13 has been deleted and the original line 14 is now line 13.

4.4.3

Adding commands to an existing program

The procedure for adding commands to an existing program is given below. A further part

is added to the welded assembly described in Section 4.3:

Home

position

Reorientation of

the welding gun

by 90°

The new part is welded to the two brackets by means of two spots (P13 and P16 in the

diagram). As the welding gun has to be reorientated by 90° to weld these two spots in relation

to welding the spot sequences P2 to P5 and P6 to P9, it is advisable to weld them before

welding spot sequences P2 to P9.
In this example, these two spots are to be welded after weld spot P9. This requires the follow-

ing changes to be made to the program:

-- Alter the command “Motion” (P10)
-- Insert the command “Motion” (P11) to reorientate the welding gun
-- Insert the command “Motion” (P12)
-- Insert the command “SPOT -- SPOT” (P13)
-- Insert the command “Motion” (P14)
-- Insert the command “Motion” (P15)
-- Insert the command “SPOT -- SPOT” (P16)
-- Insert the command “RETRACT” (P17)

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-- Insert the command “Motion” (P18)

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4.4.3.1 Description of the alteration

Open the program form from the previous section.

4.4.3.2 Changing the position of the welding gun (point in space P10)

Move the edit cursor to line 12. Position the welding gun to the point in space P10. When

doing so, ensure that it cannot collide with the component or with other obstructing contours

during the following reorientation to P11. Press the softkey “Touch Up” to save the new robot

coordinates.

4.4.3.3 Reorientation of the welding gun -- inserting the command “Motion” (P11)

P10

P11

Ensure that the edit cursor is positioned in line 12 (P10). An inline form is opened by pressing

the softkey “Motion”.

Select the motion type “LIN”. Use the traversing keys or the Space Mouse to align the welding

gun accordingly (rotate by 90°). Save the current robot coordinates (Touch Up) and press

the softkey “Cmd Ok” after entering all the parameters.

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4.4.3.4 Moving to the point in space P12 -- inserting the command “Motion”

Now insert the command “Motion -- PTP” to move the welding gun to the point in space P12,

which is located above the weld spot P13.

4.4.3.5 Welding spot P13 -- inserting the command “SPOT”

Select “SPOT Tech” -- “SPOT” -- “PTP”. Select the option “RETR OPN” in the inline form,

enter the required parameters and close the inline form with “Cmd Ok”.

4.4.3.6 Moving to the weld spot P16 and welding

The welding gun is moved to the weld spot P16 via the points in space P14 and P15. Two

PTP motions are programmed from P13 to P14 and from P14 to P15. The appropriate inline

forms are shown below:

This is followed by the welding command “SPOT Tech” -- “SPOT” -- “PTP”:

4.4.3.7 Moving to the home position

The welding gun is moved to the home position via the points in space P17 and P18. The

motions from P16 to P17 and from P17 to P18 are to be programmed. The motion to “PTP

-- HOME” is already included in the skeleton program.
Alteration of the program is now completed.

The altered line 12 (P10) and the new lines 13 to 20 (P11 to P18) are indicated by the white

line on the left in the diagram.

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4.5

SpotTech configuration

Configuration of the SpotTech software package is only possible in expert mode.

4.5.1

Program sequence

The following diagram shows the basic sequence of a spot welding program between two

weld spots.

P

(n--1)

P

n

t

t

t

t

Weld spot

Trigger

PRESPOT

Trigger

SPOT

Weld spot

or starting point

Robot

motion

ADVSPOT

PRESPOT

SPOT

Weld

duration

(weld start --

weld complete)

Gun closing time

Weld complete

WLD_CMP

Communication with the

welding controller

(e.g.

setting program parameters)

Weld start

WLD_STRT

ADVSPOT

Time t

Working

stroke open

Retract open

(if programmed)

RETRACT

The usable functions depend on the type of welding gun used as well as its controller. The

individual functions:

Name

Description

Retract stroke

RETRACT

Retract stroke of the welding gun. Completely opens the gun, for

example, to approach weld spots over component edges.

Working stroke

Working stroke of the welding gun. The working stroke is generally

sufficient for spot sequences along even surfaces.

ADVSPOT

Advance communication with the welding controller (during gun

movement) so that all required weld data are available when the end

point is reached.

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PRESPOT

Early closing of the gun; programmable in the parameter list “Selec-

tion”. The closing operation already starts while the welding gun is

still moving to the weld spot.

SPOT

The actual welding process, initiated with the “Weld start” command

(WLD_STRT) to the welding periphery until the arrival of the “Weld

complete” signal (WLD_CMP).

4.5.2

Retract stroke (RETRACT) and working stroke (SPOT)

The basic SpotTech functions “SPOT” and “RETRACT” are shown schematically in the

following sketch.

R

etr

ac

ts

tr

ok

e

Welding gun

Component

Wo

rk

in

g

st

ro

ke

Retract stroke open

“RETR OPN”

Retract stroke closed

“RETR CLO”

Working stroke closed

“SPOT”

4.5.3

Early closing of the gun (PRESPOT)

The “PRESPOT” function allows the gun to close while the welding gun is moving to the end

point.

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Weld spot

position Pn

reached

Welding gun

closed

Early closing

distance

Working stroke

Pn

Ea

rly

cl

osi

ng

time

Trigger for early gun

closing (PRESPOT)
TRIGGER WHEN DISTANCE=1

DELAY=SSDAT1.CLO_TM DO
USERSPOT(#PRESPOT,S_ACT)

PRIO= -1

Trigger for weld start

TRIGGER WHEN DISTANCE=1

DELAY=0.0 DO USERSPOT

(#SPOT,S_ACT) PRIO= -1

The point of closing the gun early (PRESPOT) is to optimize the time taken to execute the

spot welding process. The closing operation already starts while the welding gun is still

moving towards the weld spot. In this instance, it must be ensured that the gun is not closed

completely until just after the end position Pn is reached.

Variations in air pressure, the orientation of the gun and other factors may produce different

gun opening and closing times. The closing time of the welding gun must therefore be

checked in a test run. Closing the gun too early while the robot is still moving results in the

weld spot being incorrectly positioned and may cause the component and the tool to be

damaged!

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4.6

Components of the SpotTech package

4.6.1

Program structure

The interface to the welding controller is implemented in the form of a configurable

“handshake”. The settings and assignments of the physical inputs and outputs are defined

in the file “$CONFIG.DAT”.
In the following block diagram the program structure of the KR C1 robot controller is shown

in the “Spot welding robot” configuration.

BAS(...)

H50(...)

USERSPOT

*.SRC

*.DAT

H50.SRC

BAS.SRC

P00.SRC

CELL.SRC

SPS.SUB

BAS(...)

H50(...)

USERSPOT

*.SRC

*.DAT

BAS(...)

H50(...)

USERSPOT

*.SRC

*.DAT

. . .

DEF SPS()

CWRITE (..”.RUN

/R1/CELL()”)

LOOP

...

ENDLOOP

USERSPOT.SRC

IR_STOPM.SRC

$CONFIG.DAT

USERSPOT

PACKAGE

Technology--

specific

organization

program

Part 1

Part 2

Part n

Functions

for gripper

control

Functions

for robot

motion

Functions

for spot

welding

Functions

for

Automatic

External

Routines for

handling

faults

KR C1 program structure

4.6.2

SPOT Tech--specific files

The following files, which are included in the “SPOT Tech” package, are required for

executing spot welding applications. You will always see the symbols shown on the left with

the file names throughout this document whenever the corresponding file or parts of it are

described.
$CONFIG.DAT

Contains data specific to SPOT Tech within the Fold

“USERSPOT”.

USERSPOT.SRC

This file is supplied as a skeleton program. This is where you enter

data for your own spot welding programs, e.g. for initializing, for

RETRACT, ADVSPOT, SPOT, etc.

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4.7

Adaptation to the periphery, configurable options

This section describes the SpotTech peripheral interfaces with an example illustrating the

assignment of the digital outputs and inputs. The Fold “USERSPOT” contained in the file

“$CONFIG.DAT” as well as the file “USERSPOT.SRC” are described.

4.7.1

FOLD “SPOT” in the file “$CONFIG.DAT”

The Fold “SPOT” from the file “$CONFIG.DAT” is shown below.
;FOLD SPOT GLOBALS;
;==================================
; Structures:
;==================================
ENUM S_COMMAND SPOT,RETR,PRESPOT,INIT,ADVSPOT

Branch

“SWITCH CMD”

in file

“USERSPOT.SRC”C”

ENUM S_PAIR_SLCT FIRST,SECOND,BOTH

Gun--specific

parameters

STRUC SPOT_SUGG_T CHAR GUN[24],RETR_CMD[24],CHOISE[24],CLO_TM[24],

PGNO1[24],PRESS1[24],PGNO2[24],PRESS2[24],SPOT_PARAMS[24]

STRUC SPOT_TYPE INT GUN,S_PAIR_SLCT PAIR,COMMAND RETR,INT CLO_TM,

INT PGNO1,REAL PRESS1,INT PGNO2,REAL PRESS2

;==============================
; External declarations:
;==============================
EXT

USERSPOT (S_COMMAND

:IN,SPOT_TYPE

:IN )

;==============================
; Variables:
;==============================
DECL SPOT_TYPE SDEFAULT={GUN 1,PAIR

Default data set

#FIRST,RETR #OPN,CLO_TM 0,PGNO1 1,

for SPOT

PRESS1 0.0,PGNO2 0,PRESS2 0.0}
DECL SPOT_TYPE S_ACT

Global variables

DECL INT S_ACT_DELAY

that are used in

DECL BOOL S_READY

the robot program.

INT BOSCHCMD_OK=534
INT BOSCHSTAT_OK=528

;==============================
; all for Bosch-Serial-Interface
;==============================
EXT

BOSCH (INT

:IN,INT

:IN,INT

:OUT )

; BOSCH-OUTWORD 1 (513-528) param
SIGNAL BOSCHPAR $OUT[513]

TO $OUT[528]

; BOSCH-OUTWORD 2 (529-544) command
SIGNAL BOSCHCMD $OUT[529]

TO $OUT[533]

; BOSCH-INWORD 1 (513-528) status+validbit
SIGNAL BOSCHSTAT $IN[513]

TO $IN[527]

;ENDFOLD

If adaptation to the peripheral hardware used is required, please consult the corresponding

documentation.

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4.7.2

The user--specific program “USERSPOT.SRC”

The skeleton program “USERSPOT.SRC” provided in the SpotTech technology package

serves as the framework for applications individually tailored to the welding equipment being

used. In the following sections, you will find examples of the configuration options available.
&COMMENT USERSPOT package
DEF

USERSPOT (CMD :IN,S :IN )

;********************************
; USERSPOT - Package KR C1
; R2.2.x
; Date: 23.03.98
;
;********************************
DECL S_COMMAND CMD
DECL SPOT_TYPE S
SWITCH

CMD

CASE #INIT

Initialization (contained in INI FOLD)

INIT ( )
CASE #ADVSPOT

Call during advance run

ADVSPOT (CMD,S )
CASE #PRESPOT

Triggering of early closing of

PRESPOT (CMD,S )

the welding gun

CASE #SPOT

Triggering “Weld start” at

SPOT (CMD,S )

weld spot position

S_READY=TRUE

Enable for further program execution

CASE #RETR

Gun retract stroke (RETRACT)

RETRACT (CMD,S )
S_READY=TRUE
ENDSWITCH
END ; END OF MAIN
;*****************************
DEF

ADVSPOT (CMD :IN,S :IN )

User data for “ADVSPOT”

DECL S_COMMAND CMD
DECL SPOT_TYPE S
END ;(ADVSPOT)
;*****************************
DEF

PRESPOT (CMD :IN,S :IN )

User data for “PRESPOT”

DECL S_COMMAND CMD
DECL SPOT_TYPE S
END ;(PRESPOT)
;*****************************
DEF

SPOT (CMD :IN,S :IN )

User data for “SPOT”

DECL S_COMMAND CMD
DECL SPOT_TYPE S
END ;(SPOT)
;*****************************
DEF

RETRACT (CMD :IN,S :IN )

User data for “RETRACT”

DECL S_COMMAND CMD
DECL SPOT_TYPE S
END ;(RETR)
;*****************************
DEF

INIT ( )

User data for “INIT”

END ;(INIT)

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4.7.2.1 Schematic sequence diagram for SPOT (without RETRACT)

The following diagram shows the basic program sequence of the command “SPOT”. The

options “PRESPOT” (early closing of the gun) and “RETRACT” (open/close retract stroke

of the gun) are not shown.

Weld parameter

designation

0

t

t

t

t

t

t

Robot

motion

GUN_WRK

Working stroke

activation

(output)

WRK_STAT

Working stroke

status

(input)

WLD_STRT

Weld start

(output)

WLD_CMP

Weld

complete

(input)

PNUM

Program

number

(output)

OPEN

CLOSE

OPEN

CLOSE

TRUE

FALSE

TRUE

FALSE

S01

S02

(Auxiliary point)

ADVSPOT

S.PGN01

After welding the spot “S01” the weld complete signal (WLD_CMP=TRUE) triggers, with its

falling edge (WLD_CMP=FALSE), the instruction for opening the working stroke of the

welding gun (GUN_WRK=G_OPN). At the same time the weld start signal

“WLD_STRT=FALSE” as well as the program number “PNUM=0” are set.
The robot controller now waits for the status message “WRK_STAT==G_OPN” indicating

that the working stroke of the gun is open. This signal enables robot movement to the next

weld spot.
To ensure that all the data required for welding are available at the end point (in this example

point “S02”), the welding program number, for example “PNUM=S.PGN01”, is already output

during the actual movement, provided this has been configured in the section “ADVSPOT”

of the file “USERSPOT.SRC”.
At the end point (in this example point “S02”), the control instruction is given to close the

working stroke (GUN_WRK=W_CLO). The status message from the welding controller that

the working stroke is closed (WRK_STAT=W_CLO) triggers the weld start

(WLD_STRT=TRUE).
At the conclusion of the welding process, the instruction is given once again, by means of

the falling edge of the weld complete signal (WLD_CMP=FALSE), to open the working stroke

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of the gun (GUN_WRK=G_OPN) as well as to set the weld start signal “WLD_STRT” to

FALSE and the program number “PNUM” to ZERO.

4.7.2.2 Schematic sequence diagram for SPOT (with RETRACT)

0

t

t

t

t

t

t

t

t

t

t

t

With PRESPOT

GUN_RET

Retract stroke

activation

(output)

RET_STAT

Retract stroke

status

(input)

GUN_WRK

Working stroke

activation

(output)

WRK_STAT

Working stroke

status

(input)

WLD_STRT

Weld start

(output)

WLD_CMP

Weld

complete

(input)

PNUM

Program

number

(output)

Robot

motion

S01

S02

(Auxiliary point)

OPEN

CLOSE

OPEN

CLOSE

OPEN

CLOSE

OPEN

CLOSE

TRUE

FALSE

TRUE

FALSE

TRUE

FALSE

ADVSPOT

S.PGN01

If “RETR OPN”

selected

If “RETR CLO”

selected

After welding the spot “S01” the weld complete signal (WLD_CMP=TRUE) triggers, with its

falling edge (WLD_CMP=FALSE), the instruction for opening the working stroke of the

welding gun (GUN_WRK=G_OPN). At the same time the weld start signal

“WLD_STRT=FALSE” as well as the program number “PNUM=0” are set.
When the status message “WRK_STAT==G_OPN” is given, indicating that the working

stroke of the gun is open, movement is initiated to the next weld spot, provided the option

“RETR CLO” (gun retract stroke remains closed) has been programmed with the SPOT

command.
If the option “RETR OPN” has been programmed (the gun retract stroke is opened after the

spot has been welded), the command “GUN_RET=G_OPN” is executed. In this case,

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movement to the next weld spot is not enabled until the status signal “RET_STAT=OPEN”

is set. During this movement, the welding program number (PNUM) is output if this has been

configured in the section “ADVSPOT” of the file “USERSPOT.SRC”.
At the end point (in this example point “S02”), the control instruction is given to close the

working stroke (GUN_WRK=CLOSE). The welding program number (PNUM) is output at the

same time. If the retract stroke at point “S02” is open (RET_STAT=OPEN), the

corresponding close instruction (GUN_RET=CLOSE) is given first of course.
The status message from the welding controller that the working stroke is closed

(WRK_STAT=W_CLO) triggers the weld start (WLD_STRT=TRUE). At the conclusion of the

welding process, an instruction is given once again by means of the weld complete signal

(WLD_CMP) to open the working stroke of the gun (GUN_WRK=G_OPN).

4.7.2.3 Robot controller -- welding controller interface

The following table provides an overview of the configurable physical inputs and outputs. The

addresses refer to the extension of the file “USERSPOT.SRC” shown in Section 4.7.2.4.

Name

Description, signal states

Output / Input

(example)

PNUM

Welding program no. (max. 255 characters)

Output 1 ... 8

WLD_STRT

Weld start

Output 15

WLD_CMP

Weld complete signal (from welding controller)

Input 15

Working stroke control (SPOT)

GUN WRK

Close stroke

Open stroke

GUN_WRK

TRUE

FALSE

Output 10

FALSE

TRUE

Output 11

Working stroke status message (SPOT)

WRK STAT

Stroke closed

Stroke open

WRK_STAT

TRUE

FALSE

Input 10

FALSE

TRUE

Input 11

Retract stroke control (RETRACT)

GUN RET

Close stroke

Open stroke

GUN_RET

TRUE

FALSE

Output 12

FALSE

TRUE

Output 13

Retract stroke status message (RETRACT)

RET STAT

Stroke closed

Stroke open

RET_STAT

TRUE

FALSE

Input 12

FALSE

TRUE

Input 13

4.7.2.4 Program example for the file “USERSPOT.SRC”

&COMMENT USERSPOT package
DEF

USERSPOT (CMD :IN,S :IN )

;********************************
; USERSPOT - Package KR C1
; R2.2.x

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; Date: 23.03.98
; Example No 1
; SPOT / RETRACT
;********************************
DECL S_COMMAND CMD
DECL SPOT_TYPE S

Assignment of inputs/outputs

;Program No.
SIGNAL PNUM $OUT[1] TO $OUT[8]

Program number, outputs 1...8

;GUN-RETRACT
SIGNAL GUN_RET $OUT[10] TO $OUT[11]

Retract stroke (RETRACT),

outputs 10, 11

;State RETRACT
SIGNAL RET_STAT $IN[10] TO $IN[11]

Retract stroke status, inputs 10, 11

;GUN work (SPOT)
SIGNAL GUN_WRK $OUT[12] TO $OUT[13]

Working stroke (SPOT),

outputs 12, 13

;State SPOT
SIGNAL WRK_STAT $IN[12] TO $IN[13]

Working stroke status, inputs 12, 13

;Weld Start
SIGNAL WLD_STRT $OUT[15]

Weld start, output 15

;Weld done
SIGNAL WLD_CMP $IN[15]

Weld complete signal, input 15

;=================================
;GROUP Definitions
INT R_CLO,R_OPN,W_CLO,W_OPN

Retract stroke / working stroke states

R_CLO=’B0001’
R_OPN=’B0010’
W_CLO=’B0001’
W_OPN=’B0010’
;=================================
SWITCH

CMD

CASE #INIT
INIT ( )
CASE #ADVSPOT
ADVSPOT (CMD,S )
CASE #PRESPOT
PRESPOT (CMD,S )
CASE #SPOT
SPOT (CMD,S )
S_READY=TRUE
CASE #RETR
RETRACT (CMD,S )
S_READY=TRUE
ENDSWITCH
END ; END OF MAIN

;*********************************

DEF

ADVSPOT (CMD :IN,S :IN )

WLD_STRT=FALSE

Reset weld start

PNUM=S.PGNO1

Issue program number

END ;(ADVSPOT)

;*****************************

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DEF

PRESPOT (CMD :IN,S :IN )

GUN_RET=R_CLO

Close retract stroke (RETRACT)

WAIT FOR

RET_STAT==R_CLO

Waiting for “Retract closed”

GUN_WRK=W_CLO

Close working stroke

END ;(PRESPOT)

;*****************************

DEF

SPOT ( )

WAIT FOR

WRK_STAT==W_CLO

Waiting for “Working stroke closed”

WLD_STRT=TRUE

Set weld start

WAIT FOR

WLD_CMP

Waiting for weld complete

signal (TRUE)

PNUM=0

Set program number to ZERO

WAIT FOR

NOT (WLD_CMP)

Waiting for weld complete

signal (FALSE)

WLD_STRT=FALSE

Reset weld start (FALSE)

GUN_WRK=W_OPN

Open working stroke

WAIT FOR

WRK_STAT==W_OPN

Waiting for “Working stroke open”

SWITCH

S.RETR

If “RETR OPN” programmed

CASE #OPN

after weld spot:

GUN_RET=R_OPN

open retract stroke (RETRACT)

WAIT FOR

RET_STAT==R_OPN

Waiting for “Retract stroke open”

ENDSWITCH

END ;(SPOT)

;*****************************

DEF

RETRACT ( )

SWITCH

S.RETR

Retract stroke (RETRACT)

CASE #OPN

If “RETR OPN” programmed:

GUN_RET=R_OPN

open retract stroke (RETRACT)

WAIT FOR

RET_STAT==R_OPN

Waiting for “Retract stroke open”

CASE #CLO

If “RETR CLO” programmed:

GUN_RET=R_CLO

close retract stroke

WAIT FOR

RET_STAT==R_CLO

Waiting for “Retract stroke closed”

ENDSWITCH

END ;(RETR)

;*****************************

DEF

INIT ( )

PNUM=0

Set program number to ZERO

WLD_STRT=FALSE

Reset weld start

GUN_WRK=W_OPN

Open working stroke (SPOT)

WAIT FOR

WRK_STAT==W_OPN

Waiting for “Working stroke open”

GUN_RET=R_OPN

Open retract stroke (RETRACT)

WAIT FOR

RET_STAT==R_OPN

Waiting for “Retract stroke open”

S_READY=TRUE

Enable for further program execution

END ;(INIT)

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4.8

Program example

A simple demonstration program (for example, DEMO01.SRC) for welding a single spot is

described in the following. Add the command “SPOT Tech”--“SPOT”--“PTP” to a skeleton

program as shown in program line 4 below.

Now move the edit cursor to line 4 and select “FOLD” -- “Act FOLD op/cl” with the menu

function “Program” (to do so you must be within the user group “Expert”). You will now see

the complete program listing for the entered command.

File “DEMO01.SRC”

PTP P1 PDAT1 SPOT Gun= 1 RETR OPN SDAT

PDAT_ACT=PPDAT1

⎫

BAS (#PTP_DAT )

⎥

FDAT_ACT=FP1

⎬

Motion parameters

BAS (#FRAMES )

⎥

BAS (#VEL_PTP,PPDAT1.VEL )

⎭

Ref. to data set (for

precalculation)

S_ACT.GUN=1

Selection of welding gun (1...5)

S_ACT.PAIR=SDEFAULT.PAIR

Selection of gun pair

S_ACT.RETR=#OPN

Retract stroke open

S_ACT.CLO_TM=SSDAT1.CLO_TM
S_ACT.PGNO1=SSDAT1.PGNO1

Welding program number

S_ACT.PGNO2=SDEFAULT.PGNO2
S_ACT.PRESS1=SSDAT1.PRESS1
S_ACT.PRESS2=SDEFAULT.PRESS2
S_READY=FALSE
USERSPOT (#ADVSPOT,S_ACT )
TRIGGER

WHEN DISTANCE=1

Trigger for gun closing

DELAY=SSDAT1.CLO_TM DO USERSPOT

(working stroke)

(#PRESPOT,S_ACT ) PRIO= -1

Trigger for early gun closing

(PRESPOT)

TRIGGER

WHEN DISTANCE=1

Trigger for weld start (SS)

DELAY=0.0 DO USERSPOT
(#SPOT,S_ACT) PRIO= -1
PTP

XP1

WAIT FOR

S_READY

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4.9

Manual operation of the welding gun using the status keys

When carrying out tests, it is useful to be able to test the retract stroke (RETRACT) and

working stroke (SPOT) functions of the gun in addition to the gun movement, without actually

welding.

4.9.1

Separate control of RETRACT and SPOT

The configuration described below allows separate manual control of the gun retract stroke

(RETRACT) and working stroke (SPOT).
Using the “Gripper selection” status key, you can choose from the following:

-- Retract stroke (RETRACT)

--

(“Gripper”) no. 1 and

-- Working stroke (SPOT)

--

(“Gripper”) no. 2

The retract stroke (1) or the working stroke (2) can be controlled corresponding to the

selection you make with the status key for manual gripper operation.

Working stroke (SPOT)

Retract stroke (RETRACT)

GUN_WRK

OPEN

CLOSE

OPEN

GUN_RET

OPEN

CLOSE

OPEN

Operation of retract stroke

Operation of working stroke

Retract/working stroke selection

4.9.1.1 Definition of function type and assignment of physical outputs

The “GRIPPER Tech” package provides a number of gripper function types. Two function

types are available for implementing the above configuration:
Function type 1

static outputs

(for static valves)

Function type 5

pulse outputs

(for pulse valves)

Logic table for function types 1 and 5:

State

OUT1

OUT2

A

TRUE

FALSE

B

FALSE

TRUE

The changes required in the file “$CONFIG.DAT” for manual gun operation are described

below.

Static outputs
Entries in the file “$CONFIG.DAT” when using gripper function type 1:
; Definition of grippers
;==================================
INT MAXGRIPPER=8

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DECL GRP_TYPES GRIPPER[8]

GRIPPER[1]={TYPE 1,OUT1 10,OUT2 11,

Retract stroke (RETRACT)

OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0,

Definition of function type (1) and

IN4 0,GRP_OLD 1}

assignment of the physical outputs

(in this example 10 and 11)

GRIPPER[2]={TYPE 1,OUT1 12,OUT2 13,

Working stroke (SPOT)

OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0,

Definition of function type (1) and

IN4 0,GRP_OLD 1}

assignment of the physical outputs

(in this example 12 and 13)

Pulse outputs
Entries in the file “$CONFIG.DAT” when using gripper function type 5:
; Definition of grippers
;==================================
INT MAXGRIPPER=8

DECL GRP_TYPES GRIPPER[8]

GRIPPER[1]={TYPE 5,OUT1 10,OUT2 11,

Retract stroke (RETRACT)

OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0,

Definition of function type (5) and

IN4 0,GRP_OLD 1}

assignment of the physical outputs

(in this example 10 and 11)

GRIPPER[2]={TYPE 5,OUT1 12,OUT2 13,

Working stroke (SPOT)

OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0,

Definition of function type (5) and

IN4 0,GRP_OLD 1}

assignment of the physical outputs

(in this example 12 and 13)

The pulse duration for function type 5 is preset to 0.5 seconds. It is possible to make a change

at the end of the block “Definition of grippers” in the file “$CONFIG.DAT”.
REAL GRP_PULSE_TI=0.5 ; pulse time for gripper type 5
Corresponding entry using the menu function “Monitor -- Variable -- Modify”:

Variable

Default (sec.)

GRP_PULSE_TI

0.500

The inputs (IN1 ... IN4) are not polled in these examples because the mechanical gun

function can be checked visually. For this reason the configuration and addressing of the

physical inputs are irrelevant for the manual gun control function.

In the examples above, the retract stroke control for gripper no. 1 and working stroke

control for gripper no. 2 were assigned. You can also assign other numbers if these

numbers are reserved for other applications, for example.

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The assignment of gripper no. 8, for example, requires the following entry in the file

“$CONFIG.DAT”:
GRIPPER[8]={TYPE 1,OUT1 10,OUT2 11, ...

Note that the value of the variable “MAXGRIPPER” must be at least as high as the

configured gripper number. “MAXGRIPPER=8” is the default setting.

4.9.2

Manual control of RETRACT and SPOT in series

The following example describes how the retract stroke and working stroke of guns with

4--way valves can be manually controlled. Switching between the following states should be

possible using the status key for manual gripper control:

-- Retract stroke (RETRACT) open, working stroke (SPOT) open
-- Retract stroke closed, working stroke closed
-- Retract stroke closed, working stroke open

GUN_RET
GUN_WRK

OPEN
OPEN

CLOSE
CLOSE

CLOSE
OPEN

Operation

Selection of welding gun 1 / 2

OPEN
OPEN

Definition of function type and assignment of physical outputs
For implementation of the above configuration, the “GRIPPER Tech H50” package provides

function type 4, with only the outputs 2 and 3 being used.
Logic table of function type 4, outputs 2 and 3:

State

OUT2

OUT3

A

FALSE

FALSE

B

TRUE

TRUE

C

TRUE

FALSE

The changes required in the file “$CONFIG.DAT” for manual gun operation are described

below.
; Definition of grippers
;==================================
INT MAXGRIPPER=8

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DECL GRP_TYPES GRIPPER[8]

GRIPPER[1]={TYPE 4,OUT1 10,OUT2 12,

Retract (OUT 10) and working stroke

OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0,

(OUT 12), definition of the function

IN4 0,GRP_OLD 1}

type (4) and assignment of the

physical outputs (e.g. 10 and 11)

1

Index

Index -- i

Zeichen

$CONFIG.DAT, 9, 10, 44, 45, 53

Zahlen

4/2--way valves, 9

A

Adding commands, 38
ADVSPOT, 41, 47, 48
Altering existing programs, 37
Approximation function, 16
Arrow keys, 15
Assignment of inputs/outputs, 50
at, 16, 18

B

Basic functions, 42
BLOW, 8

C

Call during advance run, 46
CASE #ADVSPOT, 46
CASE #INIT, 46
CASE #PRESPOT, 46
CASE #SPOT, 46
CHECK, 18
Check Gripper, 16, 18
CIRC, 22
Cmd Ok, 17
Continuous signal, 9
Creating a new program, 31

D

Default data set, 45
Delay, 16, 17, 19
Deleting command lines, 37
Designation of the welding gun, 22

E

Early closing of the welding gun, 26
Early closing time, 26
Early gun closing, 42
Enabling switch, 14

END, 17, 19
Exclusion from use, 8

F

FOLD, 52
Function type, 8

G

GDAT, 16
Gripper sensor interrogation, 18
GRIPPERTech, 15, 18
GRP_PULSE_TI, 9
Gun, 22
Gun opening and closing times, 43

I

Identification number, 10
INI, 20
Initialization command, 20
Initialization and configuration examples, 13
Inline form, 15, 18, 21, 23
Inline form RETRACT, 28
Inline form SPOT, 24
Inputs, 45
Issue program number, 50

L

LIN, 22

M

Manual control of RETRACT and SPOT in se-

ries, 55
Manual gripper operation, 9
Manual operation of the welding gun, 53
Manually operating a gripper, 14
Monitor, 9

O

OFF, 8
Outputs, 45

P

P1, 21
Parameter lists RETRACT, 28

Index

Index -- ii

Parameter lists SPOT, 24
PDAT, 21, 25
Peripheral interfaces, 45
Pneumatic cylinders, 9
PRESPOT, 42
Program example, 31, 49, 52
Program number output, 50
Program sequence, 41
Program structure, 44
Programmed velocity, 14
Programming a weld spot, 23
Programming gripper functions, 15
Programming the retract stroke, 27
PTP, 22
Pulse, 9
Pulse outputs, 54

R

Reduced velocity, 14
Reorientation of the welding gun, 20, 30, 38,

39
Reset weld start, 50
RETR CLO, 20, 25, 29, 48
RETR OPN, 20, 25, 29, 48
RETRACT, 9, 20, 26, 41
Retract stroke, 20, 41, 42, 50
Retract stroke after the welding process, 25
Robot motion to a weld spot, 22

S

S_READY, 46, 52
SDAT, 21, 25
Selecting the welding gun, 25
Sensor interrogation, 16
Sensors, 16
Sequence diagram for SPOT (with RETRACT),

48
Sequence diagram for SPOT (without RE-

TRACT), 47
SET, 15
Set program number to ZERO, 51
Simulation, 16
Softkey bar, 15
SPOT, 20, 22, 23, 42, 47
SPOT Gun=, 25
Spot welding, 22

START, 17, 19
State, 15, 18
Static outputs, 53
Status key, 14
System variables, 9

T

TEST1, 14
TEST2, 14
Time optimization, 43
Trigger for early gun closing, 43, 52
Trigger for weld start, 43, 52
Types of motion, 22, 27

U

USER_GRP.DAT, 10
USER_GRP.SRC, 9, 11
USERGRP.DAT, 9
USERSPOT, 45
USERSPOT.SRC, 44, 45, 46, 47, 49

V

VACUUM, 8
Vacuum gripper, 8
Variables, 9, 45

W

Wait Time, 16
Weld complete signal, 47, 48, 49, 50
Weld parameters, 22, 25
Weld start, 49, 50
Welding gun, 9
Welding gun retract stroke, 22
Welding process, 20
Welding program number, 47, 49
WORKING STROKE, 9
Working stroke, 26, 41, 42, 50
Working stroke status, 50