YASKAWA YRC1000 OPERATOR’S MANUAL FOR SPOT WELDING USING AIR GUN

YRC1000

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OPERATOR’S MANUAL

FOR SPOT WELDING USING AIR GUN

Upon receipt of the product and prior to initial operation, read these instructions below thoroughly, and retain for future reference.

MOTOMAN INSTRUCTIONS

MOTOMAN- INSTRUCTIONS YRC1000 INSTRUCTIONS YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC) YRC1000 MAINTENANCE MANUAL YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)

The YRC1000 operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual. The YRC1000 operator’s manual above consists of “GENERAL” and “SUBJECT SPECIFIC”. The YRC1000 alarm codes above consists of “MAJOR ALARMS” and “MINOR ALARMS”.

182902-1CD 0

MANUAL NO. RE-CSO-A055

DANGER

• This manual explains the various components of the YRC1000

CAUTION

NOTICE

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system and general operations. Read this manual carefully and be sure to understand its contents before handling the YRC1000.

• General items related to safety are listed in “Chapter 1.Safety” o the YRC1 op

eration, carefully read the YRC1000 Instructions before reading

this manual.

• In some drawings in this manual, the protective covers or shields are removed to show details. Make sure to install all the covers and shields in place before operating this product.

• YASKAWA is not responsible for incidents arisi un

authorized modification of its products. Unauthorized

modification voids the product warranty.

• The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product.

000 INSTRUCTIONS. To ensure correct and

ng from

safe

• YASKAWA may modify this model without notice du

e to product improvements, modifications, or changes in specifications. If such modification is made, the manual number also be revised.

•

If your copy of the manual is damaged or lost, contact a YASKAW re

presentative to order a new copy. The representatives are liste

the back cover. Be sure to tell the representative the manu nu

mber listed on the front cover.

when necessary

will

Notes for Safe Operation

DANGER

WARNING

CAUTION

NOTICE

NOTE

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Read this manual carefully before installation, operation, maintenance, or inspection of the YRC1000.

In this manual, the Notes for Safe Operation are classified as “DANGER”, “WARNING”, “CAUTION”, or “NOTICE”.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Safety Signs identified by the signal word DANGER should be used sparingly and only for those situations presenting the most serious hazards.

Indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury. Hazards identified by the signal word WARNING present a lesser degree of risk of injury or death than those identified by the signal word DANGER.

Indicates a hazardous situation, which if not avoided, could result in minor or moderate injury. It may also be used without the safety alert symbol as an alternative to “NOTICE”.

NOTICE is the preferred signal word to address practices not related to personal injury. The safety alert symbol should not be used with this signal word. As an alternative to “NOTICE”, the word “CAUTION” without the safety alert symbol may be used to indicate a message not related to personal injury.

Even items described as “CAUTION” may result in a serious accident in some situations. At any rate, be sure to follow these important items.

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as “DANGER”, “WARNING” and “CAUTION”.

iii

DANGER

• Before operating the manipulator, make sure the servo power is

TURN

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tur

ned OFF by performing the following operations. When the se

er is turned OFF, the SERVO ON LED on the

pow pe

ndant is turned OFF. – Press the emergency stop buttons on the front door of th

YRC1000, on the programming pendant, on the external control device, etc.

–

Disconnect the safety plug of the safety fence. (when in the play mode or in the remote mode).

If operation of the manipulator cannot be stopped in an emergency, personal injury and/or equipment damage may result.

Fig. : Emergency Stop Button

• Before releasing the emergency stop, make sure to remove the obstacle or error caused the emergency stop, if any, and then turn the servo power ON.

Failure to observe this instruction may cause unintended movement of the manipulator, which may result in personal injury.

Fig. : Release of Emergency Stop

programming

rvo

• Observe the following precautions when performing a teaching operation within the manipulator's operating range:

– Be sure to perform lockout by putting a lockout device on

fety fence when going into the area enclosed by the safe

nce. In addition, the operator of the teaching operation mu

fe display the sign tha

other person closes the safety fence. – View the manipulator from the front whenever possible. – Always follow the predetermined operating procedure. – Always keep in mind emergency response measures against the

manipulator’s unexpected movement toward a person. – Ensure a safe place to retreat in case of emergency.

Failure to observe this instruction may cause improper or unintended movement of the manipulator, which may result in personal injury.

• Confirm that no person is present in the manipulator's operating range and that the operator is in a safe location before:

– Turning ON the YRC1000 powe

Moving the manipulator by using the programming penda

– –

Running the system in the check mo Performing automatic operations

–

Personal injury may result if a person enters the manipulator's operating range during operation. Immediately press an emergency stop button whenever there is a problem. The emergency stop buttons are located on the front panel of the YRC1000 and on the right of the programming pendant.

Read and understand the Explanation of the Warning Labels before operating the manipulator.

t the operation is being performed so that no

the

WARNING

• Perform the following inspection procedures prior to conducting

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manipulator teaching. If there is any problem, immediately take necessary steps to solve it, such as maintenance and repair.

– Check for a problem in manipulator movement.

– Check for damage to insulation and sheathing of external wires.

• Always return the programming pendant to the hook on the YRC1000 cabinet after use.

If the programming pendant is left unattended on the manipulator, on a fixture, or on the floor, etc., the Enable Switch may be activated due to surface irregularities of where it is left, and the servo power may be turned ON. In addition, in case the operation of the manipulator starts, the manipulator or the tool may hit the programming pendant left unattended, which may result in personal injury and/or equipment damage.

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and supply cables.

In this manual, the equipment is designated as follows.

Equipment Manual Designation

YRC1000 Controller YRC1000

YRC1000 Programming Pendant Programming Pendant

Cable between the manipulator and the controller Manipulator cable

Descriptions of the programming pendant keys, buttons, and displays are

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shown as follows:

Equipment Manual Designation

Programming Pendant

Character Keys /Symbol Keys

Axis Keys /Numeric Keys

Keys pressed simultaneously

Displays The menu displayed in the programming

The keys which have characters or its symbol printed on them are denoted with [ ]. ex. [ENTER]

[Axis Key] and [Numeric Key] are generic names for the keys for axis operation and number input.

When two keys are to be pressed simultaneously, the keys are shown with a “+” sign between them, ex. [SHIFT]+[COORD]

pendant is denoted with { }. ex. {JOB}

Description of the Operation Procedure

In the explanation of the operation procedure, the expression “Select • • • “ means that the cursor is moved to the object item and [SELECT] is pressed, or that the item is directly selected by touching the screen.

Registered Trademark

In this manual, names of companies, corporations, or products are trademarks, registered trademarks, or brand names for each company or corporation. The indications of (R) and TM are omitted.

Contents

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1 Spot Welding Application Using an Air Gun.................................................................................... 1-1

1.1 System Overview of Spot Welding System Using an Air Gun ........................................... 1-1

1.2 Function Keys .................................................................................................................... 1-3

1.3 Teaching ............................................................................................................................ 1-5

1.3.1 Manual Spot Welding Function............................................................................. 1-5

1.3.1.1 Manual Dry Spotting................................................................................ 1-5

1.3.1.2 Stroke Switching ..................................................................................... 1-5

1.3.1.3 Welding On/Off........................................................................................ 1-6

1.3.1.4 Resetting Alarms ..................................................................................... 1-7

1.3.2 Registering Work Instructions............................................................................... 1-8

1.3.2.1 GUNCL Instruction .................................................................................. 1-9

1.3.2.2 SPOT Instruction ................................................................................... 1-11

1.3.2.3 STROKE Instruction .............................................................................. 1-14

1.3.2.4 STRWAIT Instruction............................................................................. 1-16

1.4 Setting Welding Conditions (for Air Gun)......................................................................... 1-17

1.4.1 Settings for Manual Spot Welding ...................................................................... 1-17

1.4.2 Spot Welder Condition Data Setting................................................................... 1-19

1.4.3 Spot Gun Condition Data File............................................................................. 1-22

1.5 Spot Welding Diagnosis................................................................................................... 1-25

1.5.1 Spot Welding Diagnosis Window........................................................................ 1-25

1.5.1.1 Setting Tolerance Value........................................................................ 1-25

1.5.1.2 Tip Hit Count Clear................................................................................ 1-26

1.6 Spot Gun Motion Control ................................................................................................. 1-27

1.6.1 Gun Motion Control ............................................................................................ 1-27

1.6.1.1 X Type Gun ........................................................................................... 1-27

1.6.1.2 C Type Gun ........................................................................................... 1-28

1.6.2 Process Timing................................................................................................... 1-30

1.6.2.1 OPERATION MODE = 0

(SINGLE GUN, OPEN → WELDING → OPEN).................................... 1-30

1.6.3 OPERATION MODE = 1

(SHORT OPEN → WELDING → SHORT OPEN).............................................. 1-31

1.6.3.1 OPERATION MODE = 2

(SHORT OPEN → WELDING → FULL OPEN) .................................... 1-32

1.6.3.2 OPERATION MODE = 3

1.6.3.3 OPERATION MODE = 4

(FULL OPEN → WELDING → SHORT OPEN) .................................... 1-33

(FULL OPEN → WELDING → FULL OPEN) ........................................ 1-34

1.6.4 Stroke Change Control Method .......................................................................... 1-35

1.6.4.1 Single Gun, C Double Gun, X Double Cylinder Gun ............................. 1-35

1.6.4.2 X Double Mechanical Stopper Type...................................................... 1-35

1.6.5 I/O Allocation ...................................................................................................... 1-37

1.6.5.1 Input Allocation Window ........................................................................ 1-37

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Contents

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1.6.5.2 Output Allocation Window ..................................................................... 1-38

1.6.5.3 Pseudo Input Signal Window................................................................. 1-39

1.6.6 Allocation Signal Meanings................................................................................. 1-40

1.6.7 Monitor Function for Spot Welding Equipment ................................................... 1-42

1.6.8 Spot Welding Exclusive Signal Allocation List .................................................... 1-43

1.7 Instruction List.................................................................................................................. 1-47

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1 Spot Welding Application Using an Air Gun

Robot Controller

Welder

WELD COND (8 bits max)

Welding Gun

WELD REQUEST

WELD COMPLETION

WELD ERROR

WELD ERROR RESET

WELD ON/OFF

GUN PRESSURE

STROKE CHANGE

DOUBLE STROKE GUN FULL-OPEN DETECTION

(Single Solenoid / Double Solenoid)

DOUBLE STROKE GUN SHORT-OPEN DETECTION

128 64 32 16 8 4 2 1 (8) (7) (6) (5) (4) (3) (2) (1)

8-bit

* Values in parentheses are for discrete.

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1.1 System Overview of Spot Welding System Using an Air Gun

1 Spot Welding Application Using an Air Gun

1.1 System Overview of Spot Welding System Using an Air Gun

An I/O signal diagram of a typical spot welding system is shown below.

Fig. 1-1: I/O Signal Diagram for Spot Welding System

• WELD COND (level signal)

• Sets the welding conditions for the welder.

• The output format can be set as binary or discrete.

• Can handle up to 255 conditions (for binary).

• WELD REQUEST (level/pulse)

Outputs the start instruction to the welder.

• WELD ERROR RESET (level)

Resets the welding alarm status of the welder.

• GUN PRESSURE (level)

Outputs gun pressure instruction to the welding gun.

1-1

1 Spot Welding Application Using an Air Gun

SUPPLE-

MENT

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1.1 System Overview of Spot Welding System Using an Air Gun

• STROKE CHANGE (level)

Select the stroke of the gun.

• In case of single solenoid: Change by 1 signal

• In case of double solenoid: Change by 2 signal

For details on signal contents, refer to chapter 1.6 Spot Gun Motion Control.

For details on I/O allocation, refer to chapter 1.6.5 "I/O Allocation".

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1 Spot Welding Application Using an Air Gun

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1.2 Function Keys

Each function used for spot welding is allocated on [Numeric Key]s of the programming pendant. These keys become available when the WORK HOME POSITION is on the display.

Displays the MANUAL SPOT window.

Displays the WORK HOME POSITION window.

[FWD] + [TASK ORIGIN] With the WORK HOME POSITION window in the teach mode, press these keys to move the manipulator to the work home position.

Displays the SPOT instruction in the input buffer to register welding operations.

[INTERLOCK] + [SPOT] With the MANUAL SPOT window displayed, press these keys to perform manual welding.

Displays the GUNCL instruction in the input buffer to register dry spot welding operations.

[INTERLOCK] + [GUN CLOSE] With the MANUAL SPOT window displayed, press these keys to perform manual dry spot welding.

[INTERLOCK] + [WELD ON/OFF] Press these keys to turn on or off the welding ON/OFF signal.

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1 Spot Welding Application Using an Air Gun

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1.2 Function Keys

Instruction to change the stroke to the short open position when using a double stroke gun: Displays the STROKE SHORT instruction in the input buffer.

The SHORT OPEN POSITION SETTING window appears the first time the key is pressed. The selection No. for the short open position appears from the second time the key is pressed.

[INTERLOCK] + [SHORT OPEN] The movable side electrode moves to the selected short open position.

Instruction to change the stroke to the full open position when using a double stroke gun: Displays the STROKE LONG instruction in the input buffer.

The FULL OPEN POSITION SETTING window appears the first time the key is pressed. The selection number for the full open position appears from the second time the key is pressed.

[INTERLOCK] + [FULL OPEN] The movable side electrode moves to the selected full open position.

[INTERLOCK] + [WELD ALM RESET] A Power Source alarm reset signal is output to the Power Source only while these keys are held down.

The welding conditions, gun pressure and weld request are reset with this function.

However, the following two keys are for the function keys for spot welding with motor gun and not for spot welding with air gun.

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1 Spot Welding Application Using an Air Gun

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1.3 Teaching

In order to use the air gun function, first perform teaching as described below.

1.3.1 Manual Spot Welding Function

To perform manual spot welding, carry out the following operation.

1. Press [0/MANUAL SPOT] of [Numeric Key]s.

2. Press [INTERLOCK] + [SPOT] simultaneously.

To perform manual spot welding, press these keys simultaneously while the MANUAL SPOT window is called up.

The conditions displayed in the MANUAL SPOT window are used for manual spot welding.

Regarding the condition setting, refer to chapter 1.4.1 "Settings for Manual Spot Welding".

When registering the welding instruction [SPOT], the values set in the MANUAL SPOT window are used as the initial data.

1.3.1.1 Manual Dry Spotting

1.3.1.2 Stroke Switching

To perform manual dry spotting, carry out the following operation.

1. Press [0/MANUAL SPOT] of [Numeric Key]s

2. Press [INTERLOCK] + [GUN CLOSE] simultaneously.

To perform manual dry spotting, press these keys simultaneously while the MANUAL SPOT window is called up.

The conditions displayed in the MANUAL SPOT window are used for manual dry spotting.

Note that the numbers specified in the MANUAL SPOT window are used as the initial values for the gun number of the gun to be operated and the gun number used when registering the dry spot instruction GUNCL.

While the key is being pressed, the dry spotting motion is performed. When the key is released, the operation stops.

• Press [INTERLOCK] and [FULL OPEN] simultaneously to switch to the full open position.

• Press [INTERLOCK] and [SHORT OPEN] simultaneously to switch to the short open position.

Note that the numbers specified in the MANUAL SPOT window are used as the initial values for the gun number of the gun to be operated and the gun number used when registering the stroke switching instruction STROKE.

AP parameter specifies whether the stroke signal should be set ON or OFF to make the stroke full open. (The initial setting is OFF.)

1-5

1.3.1.3 Welding On/Off

SUPPLE-

MENT

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1 Spot Welding Application Using an Air Gun

1.3 Teaching

Press [INTERLOCK] and [WELD ON/OFF] simultaneously in the teach mode to turn on or off the welding ON/OFF signal to all connected welders.

A user message appears when the welding ON/OFF signal is turned ON in the teach mode.

During manual spot welding, the welding current flows only when this message appears.

The output destination must be allocated in the spot input/output allocation information window before this function is used.

For information on the signal allocation method, see chapter 1.6.5 "I/O Allocation".

1-6

1.3.1.4 Resetting Alarms

SUPPLE-

MENT

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1 Spot Welding Application Using an Air Gun

1.3 Teaching

The alarm reset signal to all connected welders remains ON while [INTERLOCK] and [WELD ALM RESET] are being pressed simultaneously. The welding conditions, gun pressure and weld request are reset with this function.

The output destination must be allocated in the spot input/output allocation information window before this function is used.

For information on signal allocation method, see chapter 1.6.5 "I/O Allocation".

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1 Spot Welding Application Using an Air Gun

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1.3 Teaching

1.3.2 Registering Work Instructions

The function keys [GUNCL](GUNCL instruction), [SPOT](SPOT instruction), [SHORT OPEN]/[FULL OPEN](STROKE instruction) can be used for registering the work instructions.

The STRWAIT instruction is registered using [INSTRUCTION LIST].

Table 1-1: Registering Work Instructions

Specific Keys Instructions

[GUN CLOSE] GUNCL instruction

[SPOT] SPOT instruction

[SHORT OPEN] [FULL OPEN]

Instructions are registered during the teach mode when the cursor is in the address area of the job content window.

1. Select {JOB} under the main menu.

2. Select {JOB CONTENT}.

STROKE instruction

– The JOB CONTENT window is displayed.

3. Move the cursor to the address area.

1-8

1.3.2.1 GUNCL Instruction

NOTE

GUNCL

GUN#(X)

GUN NO.

X: 1 to 8

X: 0.01 to 655.35 sec.

T=X

GUN PRESSURE TIME

ATT=X

ANTICIPATION CONDITION

X: 0 to 655.35 sec.

(1) (2) (3)

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 Additional Items

1 Spot Welding Application Using an Air Gun

1.3 Teaching

This is the dry spotting instruction. It performs dry spotting for the specified time. The gun performs dry spotting then returns to the start position after the time-up timer counts out. Use this instruction when spotting is required, such as after automatic tip dressing or automatic tip replacement.

Be sure to use this instruction in the short open status with a double stroke gun other than X double stroke mechanical stopper type gun. The instruction controls only one gun at one time. Two guns cannot perform dry spotting simultaneously. When GUNCL instruction is executed, it takes a time for the stroke action and dry spotting time is shortened.

(1) Gun# (X)

Specifies a gun to be pressed.

(2) T = X

Specifies the time when the gun is closed.

(3) ATT = X

Starts execution of GUNCL X second(s) before reaching the move instruction located immediately before it. However, it is necessary to specify “NWAIT” to the move instruction immediately before the GUNCL instruction.

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1 Spot Welding Application Using an Air Gun

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1.3 Teaching

 Operation Procedure

1. Move the cursor to the line before the place where the GUNCL instruction is to be registered.

2. Press [2/GUN CLOSE] or [INSTRUCTION LIST].

3. Select the {GUNCL} instruction.

– When [2/GUN CLOSE] is pressed, the “GUNCL” instruction appears

in the input buffer line.

– When [INSTRUCTION LIST] is pressed, the instruction list dialog

appears. Select “GUNCL” from the list.

4. Move the cursor to the address area.

5. Add items and modify the number data.

6. Press [ADD], then press [ENTER].

– The GUNCL instruction is registered.

 Example

The gun pressure signal is turned ON 0.5 seconds before the manipulator reaches the step 5 position and then turns OFF after 2 seconds (1.5 seconds after reaching there) and moves to the execution of step 6.

1-10

1.3.2.2 SPOT Instruction

SUPPLE-

MENT

SPOT

GUN#(X)

GUN1 NO.

X: 1 to 8

X: 0 to 4

MODE=X

GUN1 ACTION MODE

WTM=X

GUN1 WELD CONDITION

X: 1 to 255

ATT=X

ANTICIPATION CONDITION

X: 0 to 655.35 sec.

GUN#(X)

GUN2 NO.

X: 1 to 8

X: 0 to 4

GUN2 ACTION MODE

MODE=X

WTM=X

GUN2 WELD CONDITION

X: 1 to 255

(1) (2) (3)

(4) (5) (6)

(7)



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 Additional Items

1 Spot Welding Application Using an Air Gun

1.3 Teaching

This instruction starts the spot welding sequence. It outputs the gun pressure signal then executes the welding sequence appropriate for the gun type. The function key [SPOT] can be used for its registration.

The condition number used for the registration of the spot instruction is a value set on the manual spot condition window.

Two guns can be controlled simultaneously.

Under two-gun control, this instruction is completed when the gun with the slower welding sequence completes welding. See chapter 1.6 Spot Gun Motion Control for information on the welding sequence executed by this instruction.

(1) GUN #(X)

(2) MODE = X

Setting Data Before Welding After Welding

0Single Gun

1 Short Open Short Open

2 Short Open Full Open

3 Full Open Short Open

4 Full Open Full Open

(3) WTM=X

(4) GUN#(X)

(5) MODE=X

Specifies the number of welding condition set to the welder.

Specifies the gun move operation mode. In the case of double stroke, specifies the open status before and after the welding.

Specifies the number of welding conditions set to the welder.

Specifies the second gun at two-gun control. Cannot be omitted at simultaneous two-gun control. Do not set when only one gun is used.

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1 Spot Welding Application Using an Air Gun

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1.3 Teaching

Specifies the operation mode of the second gun at two-gun control. Specifies the open status before and after welding in the case of double stroke. Do not set when only one gun is used. Setting data is the same as shown in the table in (2).

(6) WTM=X

Specifies the number of the welding conditions set to the second welder at two-gun control. Do not set when only one gun is used.

(7) ATT=X

Starts execution of SPOT X second(s) before reaching the move instruction immediately before it. However, it is necessary to specify “NWAIT” to the move instruction immediately before the SPOT instruction. By omitting this item, the SPOT instruction is executed as usual after reaching the move instruction.

 Operation Procedure

1. Move the cursor to the line before the place where the SPOT instruction is to be registered.

2. Press [./SPOT] or [INSTRUCTION LIST].

– When [./SPOT] is pressed, the “SPOT” instruction appears in the

input buffer line.

– When [INSTRUCTION LIST] is pressed, the instruction list dialog

appears. Select {SPOT} from the list.

3. Add items and modify the number data.

4. Press [ADD], then press [ENTER].

– The SPOT instruction is registered.

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1 Spot Welding Application Using an Air Gun

NOTE

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1.3 Teaching

 Examples

The sequence of the SPOT instruction is started from the short open 0.5 seconds before the manipulator reaches the position of step 5. After completion of the sequence, the status becomes full open to move to the execution of step 6.

If the manipulator starts moving before the gun opens when gun open status is not verified, adjust the timing with the TIMER instruction as shown below.

Do not use the “ATT” unless it is indispensable. As the gun will be closed during the robot move operation by the use of ATT, the robot might possibly move with its gun closed.

Set the ATT value after setting the ATT minimum value (0.01 seconds) and execute a confirmatory operation.

1-13

1.3.2.3 STROKE Instruction

SUPPLE-

MENT

NOTE

STROKE

GUN#(X)

GUN NO.

X: 1 to 8

LONG/SHORT

GUN STROKE

(1) (2)

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1 Spot Welding Application Using an Air Gun

1.3 Teaching

This is an instruction to alternate short open and full open of a double stroke gun at any time other than welding.

It executes the stroke changes sequence with an X double stroke mechanical stopper type gun, and with the other double stroke guns, it changes the change signal to full open or to short open status.

This instruction can control only one gun at a time. Two guns cannot be pressed at the same time.

For details on the stroke change sequence of an X double stroke mechanical stopper type gun to be executed by this instruction, see chapter 1.6 Spot Gun Motion Control.

When using an X double stroke mechanical stopper type gun, stroke change is enabled only at pressing. With an execution of this instruction, the gun performs dry spotting: the stroke can be changed while the dry spotting is executed. (In case of the other types of guns, this instruction only turns the stroke change signal ON/OFF.)

 Additional Items

(1) GUN# (X)

Specifies a gun characteristic file number of stroke to be changed.

(2) LONG or SHORT

Specifies the stroke status by alternating LONG and SHORT.

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1 Spot Welding Application Using an Air Gun

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1.3 Teaching

 Operation Procedure

1. Move the cursor to the line before the place where the STROKE instruction is to be registered.

2. Press [-/SHORT OPEN], [3/FULL OPEN], or [INSTRUCTION LIST].

– The “STROKE GUN#(1) SHORT” instruction appears in the input

buffer line when [-/SHORT OPEN] is pressed; the “STROKE GUN#(1) LONG” instruction appears in the input buffer line when the key [3/FULL OPEN] is pressed.

– When [INSTRUCTION LIST] is pressed, the instruction list dialog

appears. Select {STROKE} from the list.

3. Add items and modify the number data.

4. Press [ADD], then press [ENTER].

– The STROKE instruction is registered.

 Example

Stroke is fully opened in order to avoid interference when the manipulator reaches the position of step 5. Then the manipulator moves to step 6 to avoid interference.

1-15

1.3.2.4 STRWAIT Instruction

STRWAIT

GUN#(X)

GUN NO.

X: 1 to 8

LONG/SHORT

GUN STROKE

(1) (2)

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 Additional Items

1 Spot Welding Application Using an Air Gun

1.3 Teaching

This is an instruction to verify the double stroke gun status short open or full open, at any time other than welding. It waits until a signal to verify full open or short open is turned ON.

This instruction can control only one gun at a time; it cannot control two guns simultaneously.

(1) GUN# (X)

Specified a gun characteristic file number of which stroke is verified.

(2) LONG or SHORT

Specifies the stroke status to be verified by alternating LONG and SHORT.

 Operation Procedure

1. Move the cursor to the line before the place where the STRWAIT instruction is to be registered.

2. Select the {STRWAIT} from the instruction list.

3. Add items and modify the number data.

4. Press [ADD], then press [ENTER].

– The STRWAIT instruction is registered.

 Example

Stroke is fully opened in order to avoid interference when the manipulator reaches the position of step 5. Then the STRWAIT instruction verifies that the stroke has become full open status and the manipulator moves to step 6 to avoid interference.

1-16

1 Spot Welding Application Using an Air Gun

A B C D

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1.4 Setting Welding Conditions (for Air Gun)

1.4.1 Settings for Manual Spot Welding

 Manual Spot Window

A. TWO GUN CONTROL

Specifies whether the simultaneous control is turned ON or OFF when using two guns.

B. GUN NO.

Specifies the gun number of the gun to be used for manual spot welding.

C. WELDING COND (WTM)

Specifies the manual spot welding condition number to be used for welding.

D. ACTION MODE

Specifies the gun operation mode. Shows the gun open status before and after the welding.

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1 Spot Welding Application Using an Air Gun

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1.4 Setting Welding Conditions (for Air Gun)

 Operation Procedure

1. Press [0/MANUAL SPOT] of [Numeric Key]s.

2. Select the desired mode.

3. Select the item to be set.

1-18

1 Spot Welding Application Using an Air Gun

A B C D E F G

PULSE

PRESSURE COMMAND

WELDING CONDITION

WELDING COMMAND

WELD COMPLETE

WELD COND OUTPUT TIME

LEVEL

PRESSURE COMMAND

WELDING CONDITION

WELDING COMMAND

WELD COMPLETE

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1.4 Setting Welding Conditions (for Air Gun)

1.4.2 Spot Welder Condition Data Setting

The spot welder condition data file makes the welder-related settings using the welding sequence I/O signal control method.

 Welder Condition Window

A. WELDER NO.

Welder (system) numbers are specified.

B. WELD INST OUTPUT TYPE

Specifies welder output start timing. In the start timing, there are “PULSE”, “LEVEL”, and “START SIGNAL”.

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1 Spot Welding Application Using an Air Gun

START SIGNAL

PRESSURE COMMAND

WELDING CONDITION

WELDING COMMAND

WELD COMPLETE

WELD COND OUTPUT TIME

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1.4 Setting Welding Conditions (for Air Gun)

C. WELD INST OUTPUT TIME

When “WELD INST OUTPUT TYPE” is specified as “PULSE” or “START SIGNAL”, set the welder condition signal to the pulse output time. When “WELD INST OUTPUT TYPE” is specified as “LEVEL”, the time cannot be set.

D. WELD COND OUTPUT TYPE

Specifies welding condition output form. There are two output forms: “BINARY” and “DISCRETE”.

E. WELD COND MAX NUM

Specifies the number of welding conditions that can be set. When “WELD COND OUTPUT TYPE” is “DISCRETE”, the number of welding conditions cannot be set.

F. WELD END WAIT TIME

Specifies how many seconds to monitor the welding complete signal after the welding command is output from the SPOT instruction execution. An alarm occurs if the welding complete signal is not received within the set time.

G. STICK DETECT DELAY TIME

Once the welding end signal has been input, set the length of wait time that the wire sticking signal should be observed. After this wait time has elapsed, if a wire sticking signal has been input, an alarm occurs.

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1.4 Setting Welding Conditions (for Air Gun)

 Operation Procedure

1. Select {SPOT WELDING} under the main menu.

2. Select {WELDER CONDITION}.

3. Select the item to be set.

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A B C D E F G H

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1.4 Setting Welding Conditions (for Air Gun)

1.4.3 Spot Gun Condition Data File

Set the type of a gun, the number of the welder to be used, etc. for welding gun numbers 1 to 8.

 Gun Condition Window

A. GUN NO.

Sets the gun condition file number.

B. GUN TYPE

Specifies the type of the welding gun. The sequence to be executed is specified by this value. Four gun-types are available:

• Single Gun

• C double stroke cylinder type gun

• X double stroke mechanical stopper type gun

• X double stroke cylinder type gun

When the gun type other than the single gun is set, the new setting items are displayed.

C. WELDER NO.

Specifies the welder to which the gun is connected.

D. OPEN MONITOR

Specifies whether the short-open status is verified or not at welding sequence execution.

E. GUN OPEN/CLOSE SET AT STOP

Specifies the gun open/close setting for when a hold, emergency stop, or alarm occurs during welding instruction execution.

• ON: welding instruction, welding condition, and pressure instruction are turned off.

• OFF: welding instruction, welding condition are turned off.

F. FULL OPEN MONITOR

Specifies whether the full-open status is verified or not at welding sequence execution.

G. CHANGE TIME (OPEN -> FULL-OPEN)

Sets the time from when the welding completion signal is received to when the manipulator actually starts moving after becoming the shortopen status or the full-open status. Valid when the full open monitor is OFF.

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1.4 Setting Welding Conditions (for Air Gun)

H. OPEN STROKE OUT DELAY TIME

Specifies the timing to change the stroke change signal to the shortopen status after the gun pressure instruction is output (ON) when a mechanical stopper type gun is used. (Used when changing from the full-open status to the short-open status.) This function can be used when the LS pressure is not set.

I. FULL OPEN STROKE OUT DELAY TIME

Specifies the timing to change the stroke change signal to the full-open status after the gun pressure instruction is output (ON) when a mechanical stopper type gun is used. (Used when changing from the short-open status to the full-open status.) This function can be used when the LS pressure is not set.

J. STROKE CHANGE OUTPUT TIME

Sets the time to output the stroke change signal when a mechanical stopper type gun is used.

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1.4 Setting Welding Conditions (for Air Gun)

 Operation Procedure

1. Select {SPOT WELDING} under the main menu.

2. Select {GUN CONDITION}.

– The GUN CONDITION window is displayed.

3. Select the item to be set.

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1.5 Spot Welding Diagnosis

1.5.1 Spot Welding Diagnosis Window

This window shows the maintenance information for tip replacement.

It shows the set number of welds to tip replacement and the number currently completed.

1.5.1.1 Setting Tolerance Value

1. Select {SPOT WELDING} under the main menu.

2. Select {WELD DIAGNOSIS}.

– The SPOT WELD DIAGNOSIS window is displayed.

3. Select “GUN NO.”

– Enter the desired gun number, and press [ENTER].

4. Select “TOLERANCE”.

– Input the desired tip replacement value, and press [ENTER].

IT COUNT

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1.5.1.2 Tip Hit Count Clear

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1.5 Spot Welding Diagnosis

1. Select {SPOT WELDING} under the main menu.

2. Select {WELD DIAGNOSIS}.

– The SPOT WELD DIAGNOSIS window appears.

3. Select {CLEAR CURRENT POS} from {DATA}.

4. Select “YES”.

– The confirmation dialog appears.

– The current tip hit count is cleared.

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1.6 Spot Gun Motion Control

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1.6.1 Gun Motion Control

1.6.1.1 X Type Gun

 Single stroke

1 Spot Welding Application Using an Air Gun

1.6 Spot Gun Motion Control

As regards to the guns for each stroke methods, the motion control described in chapter 1.6.1 "Gun Motion Control" can be executed.

The following gun types are available:

• X, C types single stroke method

• X type double stroke method

• C type double stroke method

The ways to control the gun motions are shown on the following pages.

SHORT OPEN WELD SHORT OPEN

 Double stroke

SHORT OPEN WELD SHORT OPEN

FULL OPEN WELD SHORT OPEN

SHORT OPEN WELD FULL OPEN

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1.6 Spot Gun Motion Control

FULL OPEN WELD FULL OPEN

 Stroke change

FULL OPEN WELD

1.6.1.2 C Type Gun

 Single stroke

SHORT OPEN WELD SHORT OPEN

 Double stroke

SHORT OPEN WELD SHORT OPEN

FULL OPEN WELD SHORT OPEN

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1.6 Spot Gun Motion Control

SHORT OPEN WELD FULL OPEN

FULL OPEN WELD FULL OPEN

 Stroke change

FULL OPEN SHORT OPEN

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Signal Control Order

Manipulator Movement

Welding Instruction

(Output)

Welding Conditions

(Output)

Pressure Instruction

(Output)

Welding Completion

(Input)

Gun Short Open Detection (Input)

Manipulator starts moving by welding completion (Input) signal when "GUN OPEN" is not

specified in spot input allocation information display.

Turns ON/OFF welding instruction, welding condition and pressure instruction simultaniously.

However, strictly speaking, output welding instruction follows immediately after welding

condition output.

In case if the "GUN OPEN" is OFF, manipulator starts moving immediately after the OFF of the signal .

Anticipater Designation

NOTE

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1.6 Spot Gun Motion Control

1.6.2 Process Timing

1.6.2.1 OPERATION MODE = 0 (SINGLE GUN, OPEN → WELDING → OPEN)

 Gun Motion Control (With X gun, C gun, single type)

Connect “OPEN DETECTION” signal for “GUN OPEN” signal in case of using a single gun.

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1 Spot Welding Application Using an Air Gun

Stroke Change 1

(Output)

Gun Short Open

Detection (Input)

Stroke Change (Output) characteristic can be changed by parameter (Figure shows on setting at

FULL OPEN).

Short Open (OFF)

Signal Control Order

Manipulator Movement

Welding Instruction

(Output)

Welding Conditions (Output)

Pressure Instruction

(Output)

Complete of Welding

(Input)

Manipulator starts moving by welding completion (Input) signal when "GUN OPEN" is not specified in spot input allocation information display.

Turns ON/OFF welding instruction, welding condition and pressure instruction simultaniously. However, strictly saying, output welding instruction

immediately after welding condition output.

Anticipater Designation

Gun Full Open

Detection (Input)

In case if the "GUN OPEN" is OFF, manipulator starts moving immediately after the OFF of the signal .

Stroke Change 1 (Output)

X Mechanical Stopper Type

Gun Short Open Detection (Input)

Stroke change is of a double solenoid method (Stroke Change 1, 2) when an x gun double stroke mechanical stopper type is used.

OFF

Gun Pressure Detection

(Input) X Mechanical

Stopper Type

Signal Control Order

Manipulator Movement

Welding Instruction

(Output)

Welding Conditions

(Output)

Pressure Instruction (Output)

Complete of Welding

(Input)

Manipulator starts moving by welding completion

(Input) signal when "GUN OPEN" is not specified

in spot input allocation information display.

Turns ON/OFF welding instruction, welding condition and pressure instruction simultaniously. However, strictly saying, output welding instruction

immediately after welding condition output.

Anticipater Designation

Stroke Change 2 (Output)

X Mechanical Stopper Type

Gun Full Open Detection (Input)

In case if the "GUN OPEN" is OFF, manipulator starts moving immediately after the OFF of the signal

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1.6 Spot Gun Motion Control

1.6.3 OPERATION MODE = 1 (SHORT OPEN → WELDING → SHORT OPEN)

 Gun Motion Control (With C gun double stroke)

(With X gun double stroke, cylinder type)

 Gun Motion Control (With X gun double stroke, mechanical stopper

type)

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1 Spot Welding Application Using an Air Gun

When "FULL OPEN MONITOR" is OFF in spot gun condition data file operation starts elapse of

"CHANGE TIME (OPEN -> FULL OPEN)" of spot gun condition data file after stroke change (Output)

is output.

Stroke change (Output) characteristics can be changed by parameter.

Short Open

Signal Control Order

Manipulator Movement

Welding Instruction

(Output)

Welding Conditions

(Output)

Pressure Instruction

(Output)

Complete of Welding (Input)

Turns ON/OFF welding instruction, welding condition and pressure instruction simultaniously. However, strictly saying, output welding instruction immediately after welding condition output.

Anticipater Designation

Stroke Change

(Output)

Gun Short Open Detection (Input)

Gun Full Open Detection (Input)

Full Open

When "FULL OPEN MONITOR" is OFF in spot gun condition data file, operation starts in elapse of

"CHANGE TIME(OPEN -> FULL OPEN)" of gun condition data file after stroke change (Output) is

output.

Gun Short Open Detection (Input)

Stroke Change (Output) is output for the time set to "STRK CHANGE OUT TIME(STOPPER)" of spot

gun condition data file.

Full Open

Stopper Stroke Change Output

Time

Gun Pressure Detection

(Input) X Mechanical

Stopper Type

When "GUN PRESSUREDETECTION" is not set, Stroke Change (Output) is output in elapse of "FULL-OPEN STRK OUT DLY(STOPPER)" of spot gun condition data file after pressure instruction is

output.

Signal Control Order

Manipulator Movement

Welding Instruction

(Output)

Welding Conditions

(Output)

Pressure Instruction

(Output)

Complete of Welding (Input)

Turns ON/OFF welding instruction, welding condition and pressure instruction simultaniously. However, strictly saying, output welding instruction immediately after welding condition output.

Anticipater Designation

Stroke Change 1 (Output) X Mechanical Stopper

Type

Stroke Change 2 (Output)

X Mechanical Stopper Type

Gun Full Open Detection (Input)

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1.6 Spot Gun Motion Control

1.6.3.1 OPERATION MODE = 2 (SHORT OPEN → WELDING → FULL OPEN)

 Gun Motion Control (With C gun double stroke)

(With X gun double stroke, cylinder type)

 Gun Motion Control (With X gun double stroke, mechanical stopper

type)

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1 Spot Welding Application Using an Air Gun

Signal Control Order

Manipulator Movement

Welding Instruction

(Output)

Welding Conditions

(Output)

Pressure Instruction

(Output)

Complete of

Welding (Input) Stroke Change

(Output)

Gun Short Open Detection (Input)

Gun Full Open Detection (Input)

Anticipater Designation

When "OPEN MONITOR" is OFF in spot gun condition data file, operation starts moving after welding completion signal (Input) is input.

Stroke Change (Output) characteristics can be changed by parameter.

Turns ON/OFF welding instruction, welding condition and pressure instruction simultaniously. However, strictly saying, output welding instruction immediately after welding condition output.

Stopper Type Stroke Change

Output Time

When "GUN PRESSURE DETECTION" is OFF, Stroke Change (Output) is output in elapse of

"OPEN STRK OUT DLY (STOPPER)" time after pressure instruction is output.

Signal Control Order

Manipulator Movement

Welding Instruction (Output)

Welding Conditions

(Output)

Pressure Instruction

(Output)

Complete of

Welding (Input)

Turns ON/OFF welding instruction, welding condition and pressure instruction simultaniously. However, strictly saying, output welding instruction immediately after welding condition output.

Anticipater Designation

Stroke Change 1

(Output)

Stroke Change 2

(Output)

Gun Pressure Detection (Output)

Gun Short Open

Detection (Input)

Gun Full Open Detection (Input)

When "OPEN MONITOR" is OFF, manipulator starts moving after welding completion signal (Input) is input.

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1.6 Spot Gun Motion Control

1.6.3.2 OPERATION MODE = 3 (FULL OPEN → WELDING → SHORT OPEN)

 Gun Motion Control (With C gun double stroke)

(With X gun double stroke, cylinder type)

 Gun Motion Control (With X gun double stroke, mechanical stopper

type)

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1 Spot Welding Application Using an Air Gun

When "FULL-OPEN MONITOR" is OFF, manipulator starts moving after elapse of "CHANGE TIME (OPEN -

> FULL OPEN)" of gun condition data file.

Signal Control Order

Manipulator Movement

Welding Instruction

(Output)

Welding Conditions

(Output)

Pressure Instruction

(Output)

Complete of Welding (Input)

Turns ON/OFF welding instruction, welding condition and pressure instruction simultaniously. However, strictly saying, output welding instruction immediately after welding condition output.

Anticipater Designation

Stroke Change

(Output)

Gun Short Open

Detection (Input)

Gun Full Open

Detection (Input)

When "FULL-OPEN MONITOR" is OFF, manipulator starts moving after elapse of "CHANGE TIME (OPEN -

> FULL-OPEN)" of gun condition file.

Signal Control Order

Manipulator Movement

Welding Instruction

(Output)

Welding Conditions

(Output)

Pressure Instruction

(Output)

Turns ON/OFF welding instruction, welding condition and pressure instruction simultaniously.

However, strictly saying, output welding instruction immediately after welding condition output.

Anticipater Designation

Stroke Change 1

(Output)

Complete of Welding (Input)

Stroke Change 2

(Output)

Gun Short Open Detection (Input)

Gun Full Open Detection (Input)

Gun Pressure Detection (Input)

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1.6 Spot Gun Motion Control

1.6.3.3 OPERATION MODE = 4 (FULL OPEN → WELDING → FULL OPEN)

 Gun Motion Control (With C gun double stroke)

(With X gun double stroke, cylinder type)

 Gun Motion Control (With X gun double stroke, mechanical stopper

type)

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1 Spot Welding Application Using an Air Gun

SUPPLE-

MENT

Stroke Change Response Time

Signal Control Order

Manipulator Movement

Pressure Instruction

(Output)

Stroke Change 1 (Output)

Stroke Change 2

(Output)

Gun Pressure Detection (Input)

Gun Short Open Detection (Input)

Gun Full Open Detection (Input)

Stopper Type Stroke Change Output Time

Stopper Type Stroke Short Open Output Delay Time (when pressure detection OFF)

Manipulator moves immediately without detecting when short open detection is OFF.

When pressure detection is OFF, stroke is changed after elapse of stopper type stroke short open output delay time.

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1.6 Spot Gun Motion Control

1.6.4 Stroke Change Control Method

1.6.4.1 Single Gun, C Double Gun, X Double Cylinder Gun

When OPEN (SHORT) is specified, change the stroke change signal (general output) to short open; when FULL OPEN (LONG) is specified, change the stroke change 1 signal (general output) to full open. However, the stroke change signal ON/OFF characteristics depend on the AP parameter setting.

For the use of C double gun, X double cylinder gun with double solenoid specifications:

Set signal numbers for stroke change 1 and 2 in the spot I/O allocation information window. The inverse signal of stroke change 1 is output as stroke change 2 signal.

1.6.4.2 X Double Mechanical Stopper Type

Stroke change signal (output) is output with double solenoid specifications. The stroke change signal ON/OFF characteristics depend on the AP parameter setting.

 When OPEN (SHORT) is Specified

Process Timing

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1 Spot Welding Application Using an Air Gun

Manipulator moves immediately without detecting when full open detection is OFF.

When pressure detection is OFF, stroke is changed after elapse of stopper type stroke full open output delay time.

Stroke Change Response Time

Stopper Type Stroke Full Open Output Delay Time (when pressure detection OFF)

Stopper Type Stroke Change Output Time

Signal Control Order

Manipulator Movement

Pressure Instruction

(Output)

Stroke Change 1

(Output)

Stroke Change 2

(Output)

Gun Pressure Detection (Input)

Gun Short Open

Detection (Input)

Gun Full Open Detection (Input)

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1.6 Spot Gun Motion Control

 When FULL OPEN (LONG) is Specified

Process Timing

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1.6 Spot Gun Motion Control

1.6.5 I/O Allocation

The I/O necessary for each welder can be set in the general-purpose I/O signal. The following signals are specified on the pseudo input signal window.

1.6.5.1 Input Allocation Window

1. Select {SPOT WELDING} under the main menu.

2. Select {I/O ALLOCATION}.

• Timer Cooling Water Error

• Gun Cooling Water Error

• Transthermo Error

• Air Pressure Decrease

• Weld On/Off

– The input allocation window appears.

3. Specify the signal number.

– Input the numerical value of the desired signal number, and press

[ENTER].

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1.6 Spot Gun Motion Control

1.6.5.2 Output Allocation Window

1. Select {SPOT WELDING} under the main menu.

2. Select {I/O ALLOCATION}.

– The input allocation window appears.

3. Select {DISPLAY} from {DATA}.

4. Select {ALLOCATE OUTPUT}.

– The output allocation window appears.

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NOTE

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1.6 Spot Gun Motion Control

5. Specify the signal number.

– Input the numerical value of the desired signal number, and press

[ENTER].

1.6.5.3 Pseudo Input Signal Window

1. Select {IN/OUT} under the main menu.

2. Select {PSEUDO INPUT SIG}.

• Be sure to confirm that the allocated general-purpose signal is not used in the job. If it is used in the job, the signal is duplicated and the job does not operate normally.

• When the output “WELDING CONDITION PARITY” is set, the parity number is automatically output during welding condition output. The setting of the parity whether it is odd or even is established in the parameter.

• In case if the stroke switching signal is the double-solenoid type (X type 2 step stroke gun mechanical stopper type), allocate two guns; in case if it is the single-solenoid type (other guns), allocate one gun.

– The pseudo input signal window appears.

3. Move the cursor to “ON or “OFF”, and press [INTERLOCK] + SELECT].

– Each time [INTERLOCK] + [SELECT] is pressed, “ (OFF)” and

(ON)” alternate.

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1.6 Spot Gun Motion Control

1.6.6 Allocation Signal Meanings

Table 1-2: Robot Controller Input Signal

Signal Content Source Standard

Setting

WELD COMPLETE This signal specifies that welding has been completed.

When the welding command manual spot operation is executed, it is used as a confirmation signal. When there is no LS open/close confirmation, the welding sequence ends and the next step is executed.

WELD ERR This signal specifies an error in welding results or in

the welder. During welding, an alarm occurs and the robot stops.

WIRE STICK DETECT Specifies when a wire stick is detected. An alarm

occurs and the robot stops.

TMR COOL WTR ERR Specifies a timer cool water error. An alarm occurs

and the robot stops. The servo power stays on.

GUN COOL WTR ERR Specifies a gun cool water error. An alarm occurs and

the robot stops. The servo power stays on.

TRANSTHERMO ERROR Specifies an error from the gun transformer is

transmitted directly to the robot controller. It is normally ON (NC), and when OFF, an alarm occurs. The servo power stays on.

WELD ON/OFF (from PLC)

TIP REPLACE COMPLETE

GUN FULL OPEN DETECT

GUN OPEN DETECT The open/close confirmation LS of a single gun and

GUN PRESS DETECT Specifies the gun pressure status. Welding Gun

AIR PRESS LOW An alarm occurs if the air pressure is low. The servo

Interlock circuit board, etc. PLC welder ON/OFF select switch. Welder status signal which outputs welder ON/OFF signal. While in the ON status, if the welder is switched OFF, spot welding is not performed.

If this signal occurs after tip replacement, turn off the tip replacement demand signal, and the tip hit count is cleared.

When there is a 2 step stroke gun, this signal specifies stroke full open status.

short open confirmation LS of the 2 step stroke gun are connected, and the gun open/close confirmation is performed.

power stays on.

Welder IN13

Welder IN14

Wire Stick Detector, Welder

Cool Water Flow Switch

Gun Transformer

Interlock Circuit Board, etc.

Welding Gun (Full Open Status Detect LS)

Welding Gun (Open/Close Confirmation Detect LS)

(Pressure Status Detect LS)

NOT USED

IN9

IN10

IN11

CN308-B6

IN16

NOT USED

IN15

NOT USED

IN12

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1.6 Spot Gun Motion Control

Table 1-3: Robot Controller Output Signal

Signal Content Source Standard

Setting

WELD COND (Level Signal) 1 (1) 2 (2) 4 (3) 8 (4) 16 (5) 32 (6) 64 (7) 128 (8) WELD COND PARITY

WELD COMMAND The start instruction is output to the welder. It is not

WELD ERR RESET Resets the welder after welder error status.

WELD ON/OFF Screens the robot situation when a signal is input from

TIP CHANGE REQUEST Specifies when the set tip hit count limit has been

GUN PRESS COMMAND

STROKE CHANGE Single Solenoid Double Solenoid

Specifies the welding condition for the welder. Binary/discrete (bit number) can be selected as the output format Corresponding to 255 conditions or less (Parity Bit (Specification) is the most significant bit).

necessary for welders which assume the welding condition signal is a start instruction.

Programming pendant operation output.

the interlock circuit board, etc., and outputs.

reached.

Outputs gun pressure command. Welding Gun NOT USED

When using a 2 step stroke gun, welder open/close status can be changed.

Welder OUT19

used from 4 bit

OUT19 OUT20 OUT21 OUT22

NOT USED

Welder NOT USED

Welder OUT18

Welder OUT17

Interlock Circuit Board, etc.

Welding Gun NOT USED

OUT9

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1.6 Spot Gun Motion Control

1.6.7 Monitor Function for Spot Welding Equipment

Table 1-4: Function List

Function Content Signal

Condition

AIR PRESS LOW Input Signal

TIMER COOL WATER ERROR GUN COOL WATER ERROR

TRANSTHERMO ERROR

When the air pressure is low and this signal turns on, an alarm occurs. The servo power stays on. This function signal must be set in the Concurrent I/O Parameter.

When the water cooling is low and this signal turns on, an alarm occurs. The servo power stays on. This function signal must be set in the Concurrent I/O Parameter.

When a gun transformer error occurs, this input turns off and an alarm occurs. The servo power stays on. This function signal must be set in the Concurrent I/O Parameter.

Normal: OFF (NO) Signal Function

Normal: ON (NC) Signal Function

Method of Use

This signal can be used during the low air pressure signal in the spot input allocation display if the set general-purpose input external input is on. To reset the alarm, turn the signal off, and it will return to the alarm reset operation.

This signal can be used during the low water cooling signal in the spot input allocation display if the set general-purpose input external input is on. To reset the alarm, turn the signal off, and it will return to the alarm reset operation.

Even though usually a timer error is transmitted to the timer from the gun, and the main signal is transmitted from the gun transformer, an alarm may occur. Also if the pressure, full open status, short open status signal, etc. is transmitted from the robot controller, the signal line from the timer to the gun becomes a transthermo error only. If this signal is checked on the robot side, the signal line transmitted to the timer disappears, and the cable handling is made easier.

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1.6 Spot Gun Motion Control

1.6.8 Spot Welding Exclusive Signal Allocation List

 :Connector

:Connector and terminal block

Table 1-5: Spot Welding Exclusive Signal Allocation List (20010 to 20037)

Input Signal Number

20010  EXTERNAL START EXTERNAL START

20011  --

20012  MASTER JOB CALL MASTER JOB CALL

20013  ALARM/ ERROR RESET ALARM/ ERROR RESET

20014  --

20015  SELECT PLAY MODE SELECT PLAY MODE

20016  SELECT TEACH MODE SELECT TEACH MODE

20017  --

20020  INTERFERENCE 1

20021  INTERFERENCE 2

20022  - WELD ON/OFF

20023  - WELD INTERRUPT

20024  INTERFERENCE 3

20025  INTERFERENCE 4

20026  --

20027  --

20030  IN1 IN1

20031  IN2 IN2

20032  IN3 IN3

20033  IN4 IN4

20034  IN5 IN5

20035  IN6 IN6

20036  IN7 IN7

20037  IN8 IN8

Input Method

Signal Name

No Allocation Set Allocation Set

INTERFERENCE 1

ENTRANCE PROHIBITED

INTERFERENCE 2 ENTRANCE PROHIBITED

INTERFERENCE 3 ENTRANCE PROHIBITED

INTERFERENCE 4 ENTRANCE PROHIBITED

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1.6 Spot Gun Motion Control

:Connector

 :Connector and terminal block

Table 1-6: Spot Welding Exclusive Signal Allocation List (30010 to 30037)

Output Signal Number

30010  DURING RUNNING DURING RUNNING

30011  SERVO ON SERVO ON

30012  MASTER JOB HEAD MASTER JOB HEAD

30013  DURING ALARM/ERROR

30014  BATTERY ALARM BATTERY ALARM

30015  REMOTE MODE

30016  PLAY MODE SELECTED PLAY MODE SELECTED

30017  TEACH MODE SELECTED TEACH MODE SELECTED

30020  IN CUBE 1 IN CUBE 1

30021  IN CUBE 2 IN CUBE 2

30022  TASK ORIGIN TASK ORIGIN

30023  INTERMEDIATE START OK

30024  IN CUBE 3 IN CUBE 3

30025  IN CUBE 4 IN CUBE 4

30026  --

30027  --

30030  OUT1 OUT1

30031  OUT2 OUT2

30032  OUT3 OUT3

30033  OUT4 OUT4

30034  OUT5 OUT5

30035  OUT6 OUT6

30036  OUT7 OUT7

30037  OUT8 OUT8

Input Method

Signal Name

No Allocation Set Allocation Set

DURING ALARM/ERROR

OCCURRENCE

SELECTED

(SEQUENCE CONTINUING)

OCCURRENCE

REMOTE MODE SELECTED

INTERMEDIATE START OK (SEQUENCE CONTINUING)

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1.6 Spot Gun Motion Control

:Connector

 :Connector and terminal block

Table 1-7: Spot Welding Exclusive Signal Allocation List (20040 to 20067)

Output Signal Number

20040  IN17 IN17

20041  IN18 IN18

20042  IN19 IN19

20043  IN20 IN20

20044  IN21 IN21

20045  IN22 IN22

20046  IN23 IN23

20047  IN24 IN24

20050  IN9

20051  IN10

20052  IN11 TRANSTHERMO ERR

20053  IN12 AIR PRESS LOW

20054  IN13 WELD COMPLETE

20055  IN14 WELD ERR

20056  IN15 GUN OPEN DETECT

20057  IN16 TIP REPLACE COMPLETE

20060  IN25 IN25

20061  IN26 IN26

20062  IN27 IN27

20063  IN28 IN28

20064  IN29 IN29

20065  IN30 IN30

20066  IN31 IN31

20067  IN32 IN32

Input Method

Signal Name

No Allocation Set Allocation Set

TIMER COOL WATER ERROR

GUN COOL WATER ERROR

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1.6 Spot Gun Motion Control

 :Connector

 :Connector and terminal block

Table 1-8: Spot Welding Exclusive Signal Allocation List (30040 to 30067)

Output Signal Number

30040  OUT17 OUT17

30041  OUT18 OUT18

30042  OUT19 OUT19

30043  OUT20 OUT20

30044  OUT21 OUT21

30045  OUT22 OUT22

30046  OUT23 OUT23

30047  OUT24 OUT24

30050  OUT9 WELD ON/OFF

30051  OUT10 WELD ERR RESET

30052  OUT11 WELD COND 1

30053  OUT12 WELD COND 2

30054  OUT13 WELD COND 3

30055  OUT14 WELD COND 4

30056  OUT15 GUN PRESS COMMAND

30057  OUT16 TIP CHANGE REQUEST

30060  OUT25 OUT25

30061  OUT26 OUT26

30062  OUT27 OUT27

30063  OUT28 OUT28

30064  OUT29 OUT29

30065  OUT30 OUT30

30066  OUT31 OUT31

30067  OUT32 OUT32

Input Method

Signal Name

No Allocation Set Allocation Set

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1.7 Instruction List

Data variables are denoted in parentheses “<>”. If multiple items are shown in one section, select one of the items.

Table 1-9: Spot Welding Instructions

GUNCL Function Presses a gun.

Format GUN # (<gun No.>) 1-8

T=<gun pressing time (sec.)> 0.01-655.35

ATT=<anticipator condition (sec.)> 0-655.35

Example MOVL V=1000 NWAIT

GUNCL GUN # (1) T=2.0 ATT=0.5 MOVL V=1000

SPOT Function Start up the welding sequence from gun pressure.

Format GUN # (<gun 1 No.>) 1-8

MODE=<gun 1 operation mode specification> 0-4

WTM=<gun 1 welding condition> 1-255

GUN # (<gun 2 No.>) 1-8

MODE=<gun 2 operation mode specification> 0-4

WTM=<gun 2 welding condition> 1-255

ATT=<anticipator condition (sec.)> 0-655.35

Example MOVL V=1000 NWAIT

SPOT GUN # (1) MODE=2 WTM=2 ATT=0.5 MOVL V=1000

STROKE Function Alternates short open and full open of a double stroke gun at any

time than welding.

Format GUN # (<gun No.>) 1-8

LONG SHORT

Example MOVL V=1000

STROKE GUN #(1) LONG MOVL V=1000

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YRC1000

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OPERATOR’S MANUAL

FOR SPOT WELDING USING AIR GUN

HEAD OFFICE 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan Phone +81-93-645-7703 Fax +81-93-645-7802

YASKAWA America Inc. (Motoman Robotics Division) 100 Automation Way, Miamisburg, OH 45342, U.S.A. Phone +1-937-847-6200 Fax +1-937-847-6277

YASKAWA Europe GmbHRobotics Divsion ) Yaskawastrasse 1, 85391 Allershausen, Germany Phone +49-8166-90-100 Fax +49-8166-90-103

YASKAWA Nordic AB Verkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden

Phone +46-480-417-800 Fax +46-486-414-10

YASKAWA Electric (China) Co., Ltd. 22F, One Corporate Avenue, No.222, Hubin Road, Huangpu District, Shanghai 200021, China Phone +86-21-5385-2200 Fax 㸩86-21-5385-3299

YASKAWA SHOUGANG ROBOT Co. Ltd. No7 Yongchang North Road, Beijing E&T Development AreaChina 100176 Phone +86-10-6788-2858 Fax +86-10-6788-2878

YASKAWA India Private Ltd. (Robotics Division) #426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India

YASKAWA Electric Korea Corporation

35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea 07326

Phone +82-2-784-7844 Fax +82-2-784-8495

YASKAWA Electric Taiwan Corporation 12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan

YASKAWA Electric (Singapore) PTE Ltd. 151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741 Phone +65-6282-3003 Fax +65-6289-3003

YASKAWA Electric (Thailand) Co., Ltd. 59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road, Huaykwang, Bangkok 10310, THAILAND Phone +66-2-017-0099 Fax +66-2-017-0199

PT. YASKAWA Electric Indonesia Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma, Jakarta 13610, Indonesia

Fax +91-124-475-8542Phone +91-124-475-8500

Fax +886-2-8913-1513Phone +886-2-8913-1333

Fax +62-21-2982-6741Phone +62-21-2982-6470

Specifications are subject to change without notice for ongoing product modifications and improvements.

MANUAL NO. RE-CSO-A055

Printed in Japan November 2017 17-11

YASKAWA YRC1000 OPERATOR’S MANUAL FOR SPOT WELDING USING AIR GUN

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 System Overview of Spot Welding System Using an Air Gun

1.2 Function Keys

1.3 Teaching

1.3.1 Manual Spot Welding Function

1.3.1.1 Manual Dry Spotting

1.3.1.2 Stroke Switching

1.3.1.3 Welding On/Off

1.3.1.4 Resetting Alarms

1.3.2 Registering Work Instructions

1.3.2.1 GUNCL Instruction

1.3.2.2 SPOT Instruction

1.3.2.3 STROKE Instruction

1.3.2.4 STRWAIT Instruction

1.4 Setting Welding Conditions (for Air Gun)

1.4.1 Settings for Manual Spot Welding

1.4.2 Spot Welder Condition Data Setting

1.4.3 Spot Gun Condition Data File

1.5 Spot Welding Diagnosis

1.5.1 Spot Welding Diagnosis Window

1.5.1.1 Setting Tolerance Value

1.5.1.2 Tip Hit Count Clear

1.6 Spot Gun Motion Control

1.6.1 Gun Motion Control

1.6.1.1 X Type Gun

1.6.1.2 C Type Gun

1.6.2 Process Timing

1.6.2.1 OPERATION MODE = 0 (SINGLE GUN, OPEN → WELDING → OPEN)

1.6.3 OPERATION MODE = 1 (SHORT OPEN → WELDING → SHORT OPEN)

1.6.3.1 OPERATION MODE = 2 (SHORT OPEN → WELDING → FULL OPEN)

1.6.3.2 OPERATION MODE = 3 (FULL OPEN → WELDING → SHORT OPEN)

1.6.3.3 OPERATION MODE = 4 (FULL OPEN → WELDING → FULL OPEN)

1.6.4 Stroke Change Control Method

1.6.4.1 Single Gun, C Double Gun, X Double Cylinder Gun

1.6.4.2 X Double Mechanical Stopper Type

1.6.5 I/O Allocation

1.6.5.1 Input Allocation Window

1.6.5.2 Output Allocation Window

1.6.5.3 Pseudo Input Signal Window

1.6.6 Allocation Signal Meanings

1.6.7 Monitor Function for Spot Welding Equipment

1.6.8 Spot Welding Exclusive Signal Allocation List

1.7 Instruction List