Miller LINE TRACKER TOUCH SENSOR Owners manual

Millerﬁ

September

1991

FORM:

OM-146

806

MODEL:

Line Touch

Tracker

Sensor

OWNERS

IMPORTANT:

special installing,

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operation

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AMIi.~Ud..Cw~y

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Ap~eton,

Tel.

ELECTRIC

~

1079

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414-734-9821

54912

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CONTENTS

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PARTS

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SECTION

3

4

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8

Millerﬁ

September

1991

FORM:

OM.146

806

SECTION

1



SAFETY

MODEL:

Line

Touch

Tracker

Sensor

IMPORTANT:

special installing,

instructions

operation

operate,

understand

emphasis

operating,ormaintaining

of

or

Read

for

are

robotic

maintain

these

understand

and

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on

use

only

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by

equipment.

this

unit.

instructions.

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material

persons

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persons

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to

install,

not

with

before

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safe

fully

MILLER

AMerGroupLtd.,Company

P.O.

Appleton,

Tel.

ELECTRIC

Box

1079

WI

414-734-9821

54912

USA

Mfg.

PRINTED

Co.

IN

U.S.A

TABLE

OF

CONTENTS

Section

1.1

1.2

1.3

1.4

1.5

1.6

1

.7

1.8

1.9

1.10

1.11

1.12

No

General

1.1.1

1.1.2

Safety

General

Safety

Operator

Safety

Safety Safety Safety

Safety

Information

General

Safety

Alert

Safety

Requirements

Safety

Procedures

Checks

Procedures

Adjustment,

Arc

Welding

And

Symbol

And

Requirements

For

Requirements

During

After

Entering

Before

During

At

End

During

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SECTION

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Installation

Teaching

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Procedures

1SAFETY

Words

(Programming)

Program

Operation Operation

Maintenance,

Page

1.1

1.2

1.3

1.4 1

1.4

1.5

1.6

1.7

No.

.4

1.1

GENERAL

INFORMATION

AND

SAFETY

1.1.1

Information

General

presented

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1.8

Millerﬁ

September

1991

FORM:

OM-146

806

SECTION

MODEL:

2

SPECIFICATIONS

Line

Touch

Tracker

Sensor

IMPORTANT:

special installing,

instructions

operation

operate,

understand

emphasis

operating,

of

or

Read

for

are

robotic

maintain

these

and

understand

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on

use

safety

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only

by

equipment.

this

unit.

instructions.

the

material

persons

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not

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entire

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equipment.

trained

allow

your

contents

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experienced

untrained

distributor

of

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persons

if

this

manual,

unit

you

manual,

and

in

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to

do

not

with

before

these

safe

Install,

fully

MILLER

AMllorGroupLtd.,

P.O.

Appleton

Tel.

ELECTRIC

Box

1079

WI

414-734-9821

Company

54912

USA

Mfg.

PRINTED

Co.

IN

U.S.A

SAFETY

GUIDELINES

A.

ROBOTIC

Read,

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1)

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TABLE

SECTION

OF

CONTENTS

-

SPECIFICATIONS

2

Section

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

No

Introduction

General

2.2.1

2.2.2

Safety

Line

Duty

Line

2.6.1

2.6.2

Site Precautions

Information

General

Safety

Alert

Tracker

Cycle

Tracker

General Touch

Selection

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Safety

And

Symbol

Signal

Components

Specifications

Sensing

And

For

Preventing

Specifications

Preparation

For

Noise

Words

Line

Interference

Tracker

Installation

Page

2.1

2.4

2.5

2.6

2.8

2.9

No.

2.1

INTRODUCTION

Section

This

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equipment

from

another,

at

right

robot.

radio

stabil

or

equip

greater

the

com

No.

using

for

2.9

Millerﬁ

September

1991

FORM:

OM-146

806

SECTION

MODEL:

3

INSTALLATION

Line

Touch

Tracker

Sensor

IMPORTANT:

special

installing,

Instructions

operation

operate,

understand

emphasis

operating,ormaintaining

of

or

Read

for

are

robotic

maintain

these

and

understand

the

on

use

safety

only

by

equipment.

this

unit.

Instructions.

the

material

persons

Do

not

Contact

entire

throughout

this

equipment.

trained

allow

your

contents

and

experienced

untrained

distributor

of

this

the

This

persons

if

manua,

manual,

unit

do

you

before

and

in

the

to

Install,

not

with

these

safe

fully

MILLER

AMillerGroupLtd.,

Appleton,

Tel.

ELECTRIC

Box

1079

WI

414-734-9821

Company

54912

USA

Mfg.

PRINTED

Co.

IN

U.S.A

SAFETY

GUIDELINES

A.

ROBOTIC

Read,

addition

understand,

1)

2)

3)

4)

5)

6)

SAFETY

and

the

to

KEEP

STAY

KEEP

HAVE

robot.

UNDERSTAND

unique

cause

UNPREDICTABLE of

following

OUT

ALERT

INFORMED

AN

EMERGENCY

industrial

of

their

operation.

comply

before

of

robot

when

AND

devices

movements.

with

beginning

work

robot.

near

about

ROBOT

BE

status

STOP

FAMILIAR

and

all

safety

robotic

envelope

of

BUTTON

can

present

MOTION

rules

when

robot

WITH

can

the

at

beginning

procedures

main

power

and

general

IN

HAND

ROBOTIC

unexpected

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Section

or

operations.

is

on.

working

whenever

MOVEMENTS.

hazards

the

best



1

Safety

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7)

8)

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Read,

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NEVER

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used.

THOROUGHLY

TEST

cell

TURN

AND

are

OFF

velope.

Provide

bot

Control

WELDING

understand,

in

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stand

place

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yourself

VERIFY

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and

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between

TRAIN

that

ALL

properly.

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Program

following

Module.

with

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before

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PERSONNEL

safety

power

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devices

source

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rules

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1)

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rays;

hot

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5)

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power

heat,

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TABLE

OF

CONTENTS

Section

3.1

3.2

3.3

3.4

3.5

No

Introduction

General

3.2.1

3.2.2

Safety

Installation

Line

3.5.1

3.5.2

3.5.3

3.5.4

3.5.5

Information

General

Safety

Alert

Tracker

Fiber

Weld

Line

Weld

Line

Touch

Input

SECTION

Symbol

Touch

Of

Connections

Optic

Cable

Tracker

Cable

Tracker

Power

And

Safety

And

Signal

Sensing

Cable

Connections

Cable

Connections

INSTALLATION

3

Words

Warning

To

Wire

To

Welding

Connections

Labels

Drive

Assembly

Power

Source

And

Page

3.1

3.2

3.3

3.5

3.6

3.7

3.9

No.

3.1

INTRODUCTION

This

Section

which

arc

plete

attempting

protection

installation.

Safety

robot

application.

be

must

References

vide

additional

GENERAL

3.2

3.2.1

Information

pertains

which

ment.

must

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and

the

is

followed

General

to

should

be

to

equipment

provides

followed

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most

important

Although

throughout

to

Sectionsofthis

other

information

INFORMATION

presented

be

read,

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installation

in

detail

system.

robot

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design,

to

prepare

Proper

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control

consideration

the

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AND

this

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information

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site

selection

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devices

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and

unit

that

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to

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on

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labels,

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tags,

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3.3

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attention

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1

Owners

and

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SYMBOL

alert

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maintenance,

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other

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and

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ANSI/RIA

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WORDS

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3.4

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Table

3.1

Line

TI~I~eF

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MPG1

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Millerﬁ

September

1991

FORM:

OM-146

806

SECTION

MODEL:

TEACHING

4

OPERATION

&

Line

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IMPORTANT:

special installing,

Instructions

operation

operate,

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for

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instructions.

the

material

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allow

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equipment.

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experienced

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persons

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do

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install,

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with

before

these

safe

fully

MILLER

AMIerGroupLtd.

Appleton,

Tel.

414.734-9821

ELECTRIC

Company

1079

WI

54912

USA

Mfg.

PRINTED

Co.

IN

U.S.A

SAFETY

GUIDELINES

A.

ROBOTIC

Read,

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Section

No.

SECTION

-

TABLE

4-

OF

CONTENTS

TEACHING

OPERATION

&

Page

No.

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

4.10

4.11

4.12

Introduction

General

4.2.1

4.2.2

Safety

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4.5.1

4.5.2

Wire

4.6.1

4.6.2

Information

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4.7.1

4.7.2

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4.8.1

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4.8.2

Conditions

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4.8.3

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4.8.4 Pattern

4.9.1

4.9.2

4.9.3

4.9.4

4.9.5

System

Fail-Safe

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4.12.1

4.12.2

4.12.3

4.12.4

4.12.5

4.12.6

4.12.7

4.12.8

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4

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4.2

4.3

4.6

4.7

....

4.8

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4.9

4.10

4.11

4.14

4.15

4.16

4.20

4.22

.

..

.

4.23

4.24

..

.

4.29

..

.

4.35

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.

4.41

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4.48

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.

4.54

4.62

4.63

4.64

4.65

4.66

4.68

4.72

4.73

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Section

4.6).

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gun/torch

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that

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point

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4)

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the

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the

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is

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the

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the

welding

4.17)

the

program,

key,

using

sequence

SF3

SF2

using

and

the

after

command

P100

gun/torch

Axis

the

and

enter

the

display

P100

P

deviation

after

the

function

the

using

S046

that

so

the

will

Enter

desired

appear

keys.

S047

data

stored

movement

data

(approximately

the

appropriate

the

in

data

of

tip

movement

automatic

shown:

as

the

SF2

(P,

Cal.

M4

the

M4

60

command,

or

Q,

0.25

INPUT

welding

data

(P,

moving

enter

L),

in.

(6

number

wire

or

Q,

speed.

enter

a

mm)

is

at

L)

short

dis

(see

a

The tered

SF2

in

command

the

program.

for

search

pattern

number

4.40

is

3

complete

and

the

sequences

are

en

4.9.4

Teaching

Pattern

Search

Function

(SF2)

For

Pattern

Number

4

Pattern

that

seam

stated

horizontally,

number

have

thickness

a

requires

previously,

oratan

3.

IMPORTANT:

determine

command

The

pattern

and

P3),

shown

at

an

Point

P0

_

to

number4search

determines

in

Figure

inclineordecline

A

Point

P5 P6

4

is

designed

horizontal

a

pattern

incline

Before

the

which

4.18

Point

Figure

to

range

of

fillet

number

decline

or

entering

wire

extension

uses

seam

determinesifthe

the

to

ﬁ

searching

Point

P1ﬁP2

-

P~int

4.18

Searching

locate

approximately

weld.

sequence

the

seam

14

If

the

conditionsatthe

4

can

to

be

used

the

searching

data

(stick-out)

four

searching

locationatPoint

workpiece

start

point.

Dummy

Point

P9

Point

-

-

Point

P3

Operation

for

ga.

when

search

at

moves

P4.

For

a

lap

to

7/16

the

start

the

to

The

deviates

- -

gun/torch

the

Pattern

pattern

contact

-~-

IMPORTANT:

weld

formed

joint

in.

mm

(2

weld

joint

workpiece

rather

point

number

tube

find

four

points

searching

vertically,

indicates

welding

direction

searching

command

detects

sensing

Indicates

welding

position

MACRO

path

directionisfrom

seam

the

to

paper

Number

thin

by

10

to

mm),

remain

deviates

than

using

enter

4,

Section

(see

(P5,

operation

horizontally,

straight

gun/torch

assigned

motion until

workpiece

voltage.

straight

gun/torch

by

command.

Arrows

of

surface

movement

weiding

movement

indicate

movement

4

metal

plates

and

constant

the

vertically,

pattern

the

SF0

4.6).

wire

touch

data

welding

when

back

paper.

and

of

in

the

of

S-0571

P6, P1,

appears

In

the

by

in

MACRO

by

to

assigned

the

of

the

as

or

The

MACRO

1)

2)

3)

commands

S00005

MOOll

M0914000

000

for

pattern

Searching

perpendicular

vertical

Welding

original

Welding

1/4

only

number

down

4

for

the

directiontothe

motion,

gun/torch

approach

gun/torch

of

the

distance

4.41

search

function

workpiece

find

to

movement

Point

P0.

movement

between

are

begins

at

workpiece

searching

to

return

to

position

line

follows:

as

approach

surface,

Point

tip

POP9.

of

tip

of

P5.

welding

Point

using

P0

wire

in

a

to

4)

S00006

Searching

the

workpiece

searching

for

Point

the

workpiece

surface,

P6.

using

in

a

perpendicular

vertical

a

down

direction

motion,

to

find

5)

6)

7)

8)

9)

10)

Si

5611

M5611

S00003

L04

R4

M311

002

2020

tip

down

from

P1

tip

the

weld

this

location

of

welding

Points

command.

direction

motion,

Point

P2

to

Point

for

positioning

of

welding

P2

to

joint

as

wire

P5

and

find

to

Point

to

wire

to

tip

at

in

horizontal

-

locate

Point

the

P1.

Welding

Searching

the

same

P6

that

Searching

the

workpiece

searching

Calculation

P3

plus

determine

Calculation

of

welding

Welding

the

center

a

of

edge

gun/torch

distance

was

performed

for

the

movement

as

the

workpiece

surface,

Point

horizontal

locationofPoint

gun/torch

for

to

wire

of

P3.

vertical

correct

Point

at

P1

line

distance

movement

seam

the

wire

P3.

direction

movement

in

Step

using

down

extension

P4.

and

in

distance

from

P4.

toward

designate

to

position

between

MACRO

3

a

perpendicular

vertical

a

Point

length

to

position

a

review

To

press

display.

the

commands

FORW.

Precautions

M4411

11)

E

12)

WARNING:

cause

can



Turn

metal

SENSOR

the

Press

robot

will

key

Use

1)

welding

the

020

off

parts

MACRO

the

perform

by

pressing

for

each

that

a

searching

accurate

ELECTRIC

injury.

robot

controller

in

contact

key

RECORD

the

command

should

wire

during

location

Welding

Point

End

SHOCK

BEFORE

with

commands

when

the

key,

the

designated

and

holding

to

observed

be

speed

slower

Step

Point

of

gun/torch

P4.

MACRO

FROM

the

welding

during

SF2

command

first

MACRO

operation.

the

End

the

during

than

MACRO

5

P1.

movement

command.

INTERMITTENT

touching

wire.

block

Continue

TEACH

(E).

teaching

12

ipm

command

to

the

welding

operation

are

(30

which

as

block

as

cm/mm.)

appears command

ENABLE

position

ROBOT

wire,

after

teaching

the

current

wilt

appear

operation

and

key

follows:

would

of

tip

SENSING

drive

sequence

on

pressing

to

prevent

result

welding

rolls,

program

the

of

the

wire

VOLTAGE

gun,

data,

on

display,

MACRO

BLOCK

the

bending

in

misdetecting

or

the

and

the

at

any

4.42

Useaslow

2)

speed

MACRO

10

welding

P0

errors,

MACRO

gun/torch

and

dummy

moving

especially

command.

command

speed

angle

Point

for

when

An

alternative

is

to

that

P9.

the

positioning

the

welding

to

prevent

begin

remains

the

search

the

MACRO

gun/torch

a

large

at

same

between

commands

angle

change

approach

teaching

to

changes

in

torch

Point

P0

prevent

in

Step

with

in

a

angle

approach

over-

10

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slight

Point

Teach

3)

movement

4)

Dummy point.

The

5)

regard

Points

6)

Points distance

workpiece points

the

When

7)

quence

stopped,

ditions,

start

the

Point

distance

Point

to

P0, P6,

P0

and

apart

must

weld

start

dummy

data.

at

be

Point

P9

must

be

between

P1

P1,

P9

to

the

weld

Points

the

as

and

P2,

too

are

prevent

start

repositioned

the

on

point

using

taught

center

P9

close

the

point;

searchingisinterrupted

operation

the

dummy

point.

welding

continues

Point

gun/torch

P9

is

Position

in

P0

and

between

all

are

together,

welding

likewise,

an

equal

seam.

the

by

from

may

used

(P),

line

with

and

P1,

Points

set

as

equal

both

wire

if

distance

fail

safe

approach

contact

as

positioning

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approach

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lengths

points

from

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must

bending

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closer

function

point

the

workpiece.

movement

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Point

P1

and

pg.

in

the

be

due

and

P9

together

(see

P0

or

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or

(0),

P0

and

the

weld

P9

must

be

equal

search

operation.

repositioned

to

contact

to

are

Section

where

To

data

far

to

prevent

4.11),

robot

prevent

before

apart,

these

(L)

start

with

an

equal

with

the

both

missing

and

se

motion

con

the

weld

tf

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8)

searching

movement

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gun/torch

distance

pendicular

lished,

tacting

ation.

piece

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9)

the

termines

dummy

for

returns

2

MACRO

in

between

direction

searching

the

workpiece

Therefore,

surface

position

dummy

Point

the

point

the

command,

the

direction

the

to

determine

movement

proper

helps

weld

the

Points

continues

P9,

to

seam.

tip

of

to

the

surface

distance

data

so

teaching

direction

determine

During

of

the

welding

and

Step

dummy

P0

and

workpiece

in

the

to

determine

between

the

weld

after

just

of

this

initial

the

3

Point

from

P9

to

directionofPoint

PointsP5and

seam

the

dummy

searching

4.43

workpiece

searching

wiretothe

MACRO

P9.

This

which

find

Point

inclineordecline

any

position.

SF2

sequence

point

pattern.

and

position

operation,

original

command

position

welding

approach

will

move

direction

the

is

exactly

Point

searchingisperformed

Once

P6.

P9

with

Point

the

P6

welding

workpiece

P6

must

in

remain

is

always

the

appropriate

on

considered

location

of

gun/torch

in

P0

welding

the

1/4

in

a

per

is

estab

wire

con

devi

the

work

as

de

teach

To follows:

pattern

search

function

(SF2)

sequence

data

for

pattern

number

4,

proceed

as

IMPORTANT:

touch be

The gram

the

mately

sensing

set

to

following

relatestothe

seam

14

workpiece

point.

IMPORTANT:

workpiece

position

regard

torch

angle

just

that

to

angle

should

before

Before

function

YES

(1)

to

example

conditions

for

a

lap

joint

to

ga.

7/16

deviates

vertically,

Conductivity

surface

is

and

perpendicular

searching

to

searching

in

be

a

following

beginning

data,

provide

for

entering

formed

in.

mm

(2

the

shown

by

to

any

TOUCH

touch

thin

10

horizontally,

should

the

electrode

the

to

direction

perpendicular

SF2

during

direction

position

command.

teaching

VOLT

sensing

Figure

metal

the

wire.

search

plates

or

good

The

pattern

in

mm),

provide

searching

the

SF0

for

a

following

to

operations

selection

voltage

function

4.18

when

that

seam

at

requires

incline

an

metal-to-metal

workpiece

direction.

operation

SF1

the

reference

for

(item

(see

a

program

15)

Section

(SF2)

in

sequence

that

System

4.10).

searchingisperformed

have

thickness

a

horizontalfillet

a

decline

or

to

range

the

searching

continuity

surface

The

welding

should

operation.

point

should

be

the

The

during

be

gun/torch

same

welding

the

SF0

will

contain

Data

7

in

data

to

of

approxi

weld,

and

between

located

angle

welding

gun/torch

operation

must

a

pro

locate

the

start

the

in

a

with

gun/

1)

2)

3)

Teach

function

Teach Position

the

approach

welding

direction

Press

the

wire

extension

(SF2)

(P),

sequence

Point

Continuous

gun/torch

the

to

weld

P

(SENSOR)

either

joint.

key,

search

data

P0

Motion

at

function

(see

location

a

(Q),

Section

or

perpendicular

A

typical

display

P100

P

and

the

display

(SF0)

where

Linear

the

to

will

before

4.6).

searching

movement

(L)

workpiece

P

using

data

S045

appear

entering

the

motion

data,

orata

will

appear

M4

60

shown:

as

pattern

will

begin

and

slight

angle

as

search

using

in

shown:

the the

position

4.44

4)

Press

time

the

forward

is

key

DISPLAY

pressed

as

SELECT

shown:

key

twice,

and

the

display

will

change

each

5)

To

change

selection

number

INC.

the

SF1

SF2

Press

the

or

press

appears

DEC.

or

the

RECORD

pattern

the

(if

key,

D

1

e

P

A

key,

PATTERN

number,

Increase

QUICK

changing

INCREASE-DECREASE

I

R

T

I

and

press

(INC.)

of

the

P

100

.

P

E

the

SEARCH

1

00

R

N

display

P100

the

appropriate

Decrease

or

data

is

S04

SEAR

will

appear

S045

numerical

(DEC.)

key

performed

5

CH

shown:

as

NO.04

keys

until

key

is

pressed

rapidly).

M4

to

the

at

enter

desired

the

same

the

desired

pattern

time

as

When

6)

pattern

key,

IMPORTANT:

however,

data;

CPU

memory.

Cal.

The

Press

the

set

change

OUTPUT

the

Cal.

the

Normally,

for

storing

number,

call

to

and

deviation

the

number

and

Ca

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if

the

numerical

OUTPUT

Cal.

OUTPUT

see

deviation

the

data

storing

deviation

desired

the

display

I

.

SF2

command

Cal.

selection

1

key

to

data

information

stored

pattern

4

should

will

OUTPUT

must

to

set

NO

(N),

setting.

data

is

necessary,

during

number

be

appear

the

P

selection

selected

as

100

provides

selection

set

to

OUTPUT

press

the

necessaryforan

follow

endofthese

SF2

an

the

at

be

Cal.

or

not

the

pattern

shown:

Y

the

capability

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set

to

numerical

to

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the

instructions

pattern

appears

S04

1

:

NO

1,

YES

(INC.)

SF2

search

on

number),

5

N

:

store

to

deviation

(0),

YES

(Y)

(Y),

press

or

command;

for

operation.

the

display

press

M4

0 0

touch

Decrease

to

the

sensing

data

store

numerical

however,

setting

the

sequences

(in

the

RECORD

is

not

deviation

(DEC.)

if

Cal.

a

this

case,

deviation

stored

data.

0

key

the

need

OUTPUT

required

in

to

4.45

7)

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the

forward

DISPLAY

SELECT

key,

and

the

display

will

appear

as

shown:

IMPORTANT:

tion

Output

last

If

the

selection

Calibration

desired

pressed

entered

data

Cal.

in

Calibration

at

ly).

Press

8)

Cal

number

OUTPUT

Step Output

the

same

REVERSE

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will

6

the

.OUTPUT

are

is

selected

be

present

selection

YES

was

number

Output

time

forward

Calibration

100

in

(1),

or

press

number

the

as

DISPLAY

that

in

Step

press

INC.

P100

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had

previously

that

Calibration

6

was

the

appropriate

the

Increase

appears

DEC.

or

SELECT

P100

NO

(if

(0),

the

key,

Y

S045

NO.00

number

been

selections

used

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number.

proceedtoStep

numerica

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and

or

INCREASE-DECREASE

of

the

display

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changing

S045

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N

to

store

8.

keys

the

data

will

0 0

:

M4

(0to99).

deviation

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the

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to

select

(DEC.)

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performed

appear

M4

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the

key

as

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data,

OUTPUT

desired

until

key

rapid

shown:

the

is

REVERSE

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movement

reversing

prevent

Press

key

(DEC.)

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piece

ipm

SEARCH

same

missing

the

to

set

keytochange

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9)

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using

cm/mm.)

(2.5

time

selection

the

for

the

path

the

numerical

REVERSE

the

SEARCH

SPEED

touch

SPEED SPEED

the

as

provides

search

of

function

welding

workpiece

1

to

key

selection

REVERSE

the

forward

DISPLAY

applies

or

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the

(if

DEC.

sensing.

increments.

or

press

appears

INC.

the

pattern.

gun/torch

for

certain

the

set

REVERSE

SPEED

robot

to

search

Press

Increase

the

QUICK

key,

to

SELECT

the

changing

capability

Most

to

search

movement,

weld

joint

selection

NO

(N),

or

setting.

key,

P

1

0

moves

speed

during

range

appropriate

(INC.)

or

INCREASE-DECREASE

of

the

reverse

pattern

except

conditions.

to

and

the

press

S04

the

pattern

to

isO

numerical

Decrease

data

the

path

operations

for

search

YES

(Y),

Increase

display

5

20

search

39

ipm

keys

(DEC.)

is

performed

of

welding

pattern

press

(INC.)

will

appear

the

gun/torch

do

not

number

numerical

Decrease

or

as

M4

Im

to

locate

to

100

select

until

cm/mm.)

the

(0

to

key

keyispressed

rapidly).

require

shown:

the

work-

desired

at

3

in

the

to

0

1

SEARCH

P

SPEED

1

4.46

0

S04

5

1

6

M4

i

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