SETUP PRODUCTION SCREEN


SETUP PRODUCTION SCREEN

Production operation allows you to define and enable job entry and execution options and control options to be used in production.

Table 1. Production Setup Items

Production SETUP ITEM Description

Job Entry Options

Production queues used

(for display only)

This item is for display only. If set to YES, a queue of jobs and colors is maintained on the robot controller. Subsequent job initialization sequences will execute the next job and color until the queue is empty. If set to NO, jobs and colors are not maintained on the robot controller and each job initialization sequence will determine the job and color.

Job init type

This item specifies the form of the job input signal. When Job init type is set to JOB-BIN, then Production queues used and Color queue used are automatically set to YES, and the job input is a binary value that is read during initialization. When Job init type is set to INITSEQ, then Production queues used and Color queue used are automatically set to NO, and the job, repair, tutone, and color numbers are read in a sequential binary form during initialization.

Color queue used

(for display only)

This item is a display item and refers to the color change system only. If YES is displayed, color queues are enabled. In this case, when the robot performs a color change, the queue that stores the system colors will be used in production. If NO is displayed, color queues are disabled.

Job Queue Options

Repeat last

This item specifies whether the last job entered into the job queue is repeated in production.

Clear on production

This item specifies whether to clear the entire job and color queues on production entry. If set to YES, the entire job and color queues will be cleared when production mode is entered. If set to NO, the job and color queues will not be cleared.

Synchronize Queue

This item is used to synchronize the START (detect) signal with the job. The conveyor position is remembered when the job ID (init) signal is received. When the start signal DETECT signal is received, the job will run if the distance traveled from the ID signal to the START signal falls within the user-defined tolerance. The conditions for which the job will not run are the following:

  • The job has not traveled far enough. The warning message (Sync Queue Job before window) will be displayed, the job will be kept, and the START signal will be ignored.

  • The job has traveled too far. The warning message(Sync Queue Job passed window) will be displayed, the job is removed from the queue, and the next job is looked at to see if the START signal belongs to it.

Note

This option cannot be enabled if Repeat last is set to YES.

ID to start dist

(mm)

This item is the distance from the ID signal to the START signal in millimeters.

Tolerance +/- in

(mm)

This item is a tolerance (or window) for the distance entered. The tolerance is used for both the positive and negative directions of the part position.

Job Execution Options

Start signal ignore

This item indicates whether you must have a start signal to start a job in production. If set to YES, the start signal will be ignored. For line tracking systems, this must be set to YES. Therefore, the robot will not wait for a start signal, but will process each part based on the part detect input.

Cycle timing mode

This item sets up how the cycle should be timed. If set to ST-END, the cycle will be timed from the start of the program to the end of the program. If set to ST-LG, the cycle will be timed from the start of the program to the end of the last gun off. Cycle timing mode can only be set to ST-END.

Clear times when edit

This item, when set to YES, means that the gun on and cycle timings are reset when the editor is used.

Start Job at Home

The robot must always start the job from the programmed Home position.

PLC control/status Options

Cancel/continue

This item allows the cell controller to cancel or continue a job when an error occurs.

Miscellaneous Options

Resave timing difference

(RTD)

This item identifies how different the cycle and gun on times must be before they are saved. The cycle and gun on times are saved in the header of each process. During production, these times are recalculated each time the process executes. If the time in the process header is less than RTD, these values will not be saved in the header. If the time in the process header is greater than or equal to RTD, these values will be saved in the header.

Deadman auto reset

This item is set to NO at the time of the first cold start. You can set this item to YES after the first Cold start. The setting is saved in the CMOS and the value is saved between cold starts. When set to YES, if an E-Stop or HOLD error occurs, resuming the E-Stop or HOLD will reset the cell controller automatically if the teach pendant is enabled and the DEADMAN switch is held (this is the equivalent of pressing the Reset button on the teach pendant). The cell controller will be reset; i.e., the Booth Reset digital output DOUT[48] is turned ON automatically and the error message is cleared.

TP error recovery

This item is available as an option, and if loaded, the flag for TP ERror Recovery in the Production SETUP Screen is set to YES after you setup the application. You can also reset the flag from the Production SETUP menu if the option is loaded. If the option is not loaded, the message "TP Error Recovery option is not loaded" will be displayed and TP error recovery will be reset to FALSE (NO) automatically.

  • When TP error recovery is set to TRUE (YES), and the Use Force menu item is also set to YES in the Production SETUP menu, an Error Recovery menu will be displayed on the TP screen when a recoverable error message is cleared.

  • When TP error recovery is set to TRUE (YES), and if the Use Force Menu item is set to FALSE (NO) in the Production SETUP menu, the Error Recovery menu will not be displayed automatically when a recoverable error message is cleared; however, you still have the opportunity to Recover Error from the TP screen by pressing Menu, selecting Alarm, and selecting Recovery. You will be given the choice to cancel or continue the production process.

Force menu

If this item is set to YES in the Production SETUP Menu, the Status screen will be forced when in production mode and the Select Menu will be forced when in teach mode. If the TP Error Recovery item is also set to YES, the Cancel/Continue Menu will be forced when a recovery error message is cleared. If Force menu is set to NO in the Production SETUP Menu, the corresponding Menus screen will not be displayed.

Enable TP in Prod

If this item is set to YES, the teach pendant can be enabled while in production mode. This option requires the ability to reset while the controller is in production mode. Below is the prcedure for using the Enable TP In Production option;

  1. Enter T1 mode. It is crittical that the PaintTool Production Input remains asserted. If PaintTool production input is cleared all Jobs will be Canceled and all body detects will be cleared.

  2. Enable Teach Pendent.

  3. Reset the system using Teach Pendent Reset key.

  4. Press SHIFT + COORD to change the motion group.

  5. Jog the robot(s) as necessary.

    Caution

    Care should be taken when moving the robot without the job being cancelled. The robot will return to its stopped position prior to resuming program on a continue. Errors encountered while jogging may affect the recovery state.

  6. Disable Teach Pendent.

  7. Reset and Select Cancel Continue.

Warning

Do not perform a FNCTN Abort All. This will require a power cycle to recover.

Between Parts Timer

(min)

Units: min

Range: 0 - 60

This item is a dynamic counter that decrements every second to zero from the initial entered value after the part is sprayed. It stops when a cleanout is performed or when another part is sprayed. An alarm output triggers when the countdown expires (reaches zero). The alarm output turns OFF when the controller power is turned off and then on again, or when a new job executes. This item is for the AccuChop option ONLY.

Set Process Champion

ModeValues: Manual or Auto

This item allows you to change the process champion mode to either Manual or Auto. In manual mode, you can choose when to collect data in your process by using the Process Champion event macros (refer to the Process Champion chapter). In auto mode, PaintTool automatically collects data for each job cycle. This item is for the Process Champion option ONLY.