Production operation setup allows you to set up a program so that it is run automatically during production.
Table 1. Production Setup Screen
Production Setup ITEM | DESCRIPTION |
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Program Select Mode |
This item specifies which method will be used to select the program to run:
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Production Start Method |
This item specifies which signal is used to start or continue a program:
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Production
Checks - The following items are checked before running
production. When you move the cursor to one of the production check
items and press F3, DETAIL, the following DETAIL screen is displayed.
Prog Select DETAIL Check : At home check 1 Check when run: ENABLED 2 Check when resume: ENABLED 3 Prompt if failure: ENABLED 4 Post error if failure: ENABLED 5 Post warning if forced: ENABLED 6 Force condition: ENABLED
If the specified Production check fails when the program is executed or resumed, the following actions will be taken. If “Check when run” or “Check when resume” are disabled, these actions are ignored. The “Force condition” action takes priority over the other actions. If “Force condition” and “Prompt if failure” are both enabled, only the “Force condition” action is performed.
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Production Check: At Home Check |
When this item is set to ENABLED, production will be run if the robot is at the home position. When you press F3, DETAIL, you can specify in more detail the behavior of the at home checking. SO[6] - User LED#2 - will turn ON when At Home Check is enabled and the robot is in home position. If you do not want to turn this output on, set $SHELL_CFG.$DO_HOME_SOP = FALSE. |
Production Check: Resume Position Toler |
When this item is set to ENABLED, production will be run if the robot is at or near the position in which the program was paused. This check is ENABLED by default. If you move the cursor to this item and press F3, DETAIL, you will not be able to set “Check when resume” to DISABLED. If you want to disable “Check when resume,” go to the SETUP RESUME TOL screen and disable resume tolerance for each motion group. |
Production Check: Simulated I/O |
When this item is set to ENABLED, production will be run if I/O signals are not simulated. |
Production Check: General Override < 100% |
When this item is set to ENABLED, production will be run only if the general override is set to 100%. |
Production Check: Prog Override < 100% |
When this item is set to ENABLED, production will be run only if the program override is set to 100%. |
Production Check: Machine Lock |
When this item is set to ENABLED, production will be run if Robot Lock is set to OFF on the SETUP TEST CYCLE screen. |
Production Check: Single Step |
When this item is set to ENABLED, production will be run if the robot isnot in single step mode. |
Production Check: Process Ready |
This item is application-specific. When this item is set to ENABLED in a spot welding application, the following items will be checked for faults during production initiation.
If a fault is detected, you will see the following prompt box. Application process error Please check process Peripheral equipment CONTINUE RECHECK [STOP]
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Heartbeat timing: default: 1000 ms min: 0 ms max: 10,000 ms |
The heartbeat is an output signal that is pulsed (turns on and off) at the interval you specify in this item. The heartbeat is used by the PLC to verify that the robot is still “alive.” The heartbeat digital output is assigned using the I/O cell output menu. The digital output is pulsed at the heartbeat interval. If the timing is 0 or the output is not assigned, then the heartbeat is disabled. |
Low TEMP DRAM memory: default: 100 kb min: 0 kb max: 9999 kb |
This item allows you to define the lowest amount of TEMP DRAM memory below which an error message with WARN severity will be displayed. This item is checked every time a production program is run. |
Low PERM CMOS memory: default: 50 kb min: 0 kb max: 9999 kb |
This item allows you to define the lowest amount of CMOS memory below which an error message with WARN severity will be displayed. This item is checked every time a production program is run. |
RESET When DEADMAN Pressed |
This item allows you to specify how the system recovers from a DEADMAN release when the teach pendant is turned on:
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You can define program selection to be controlled by the robot service (RSR) mechanism from the Prog Select RSR Setup DETAIL screen.
A Robot Service Request (RSR) is a request for service from an external device. That request comes from a digital input signal on a preassigned RSR input line. You can use up to eight robot service request signals: RSR1, RSR2, RSR3, RSR4, RSR5, RSR6, RSR7, and RSR8.
Any program that you want to execute by using RSRs must be named RSR[nnnn], where [nnnn] represents a four digit number from 0001 to 9999; otherwise, the program will not be executed.
If no other program is currently running, the program assigned to the RSR input line starts. If a program is currently running, the robot stores the signal and runs the program when the other program is finished.
Table 2, " RSR Setup Item Description " lists and describes each RSR setup item.
Table 2. RSR Setup Item Description
RSR SETUP ITEM | DESCRIPTION |
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RSR1 Program Number default: 0 min: 0 max: 999 |
This item allows you to enter a number that when added to the base number defines the program number that will be executed when the RSR1 signal is received. For example, if you entered 0023 for the RSR1 program number and the base number was set to 100, the RSR1 signal would execute program RSR0123. If you enter an invalid program number, the system will ignore this signal. |
RSR2– RSR8 Program Number |
This item allows you to enter a number that when added to the base number defines the program number that will be executed when the RSR2 – RSR8 signal is received. If you enter an invalid program number or a zero, the system will ignore this signal. |
Base Number default: 0 min: 0 max: 9999 |
This item allows you to enter a number that when added to the RSR1– RSR8 program number defines which program will be executed. This base number can be changed from within your program by using the PARAMETER NAME instruction. The parameter that contains the RSR base number is$SHELL_CFG.$job_base . By changing the base number, you can control which group of programs will be executed. |
Job Prefix — SpotTool+ default: RSR |
This item is the three-letter prefix of the program to be selected. The system variable is $SHELL_CFG.$job.root. |
Acknowledge Function default: FALSE |
This item allows you to enable or disable robot acknowledge output signals ACK1-8. FALSE means the signals are disabled. TRUE means the signals are enabled. |
Acknowledge Pulse Width default: 400 ms min: 0 max: 9999 |
This item allows you to set the length (in milliseconds) of the ACK1-8 signal when the acknowledge function is enabled. This time depends on the scan time of your PLC program. |
A Program Number Select (PNS) is a method of selecting the name of a program to be run by some external device. The name of the program to be run comes as a group of input signals from an external device on eight PNS input lines.
Table 3, " PNS Setup Item Description " lists and describes each PNS setup item.
Table 3. PNS Setup Item Description
PNS SETUP ITEM | Description |
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Base Number default: 0 min: 0 max: 9999 |
This item allows you to enter a number that when added to the PNS1-8 binary signal defines which program will be executed. For example, if the PNS1-8 input is 0023, and the base number is 100, then PNS0123 will be executed. This base number can be changed from within your program by using the PARAMETER NAME instruction. The parameter that contains the base number is$SHELL_CFG.$pns_base . By changing the base number, you can control which program will be executed. |
Job Prefix — SpotTool+ application default:PNS |
This item is the three-letter prefix of the program to be selected. The system variable is $PNS_PROGRAM. |
Acknowledge Pulse Width default: 400 ms min: 0 ms max: 9999 ms |
This item allows you to set the length (in milliseconds) of the SNO1-8 and SNACK signals. This time depends on the scan time of your PLC program. |
Style name setup allows you to define the style and programs to run during production, based on RSR/PNS/STYLE bits input from the cell controller.
During production, the robot receives its STYLE selection bits on the UOP inputs followed by a cycle start input from an external device, such as a PLC. The robot checks the program name that corresponds to the STYLE bits. After the robot validates that all safety and I/O signals have been set properly for a production run, the robot runs the program that corresponds to the style number.
Style names are stored in the system variable $STYLE_NAME. Valid flags are stored in the system variable $STYLE_ENABLE. Comments are stored in the system variable $STYLE_COMMENT.
To set up for production operation, you must
Configure the RSR/PNS/STYLE UOP inputs (UIN[9–16]) that will receive style numbers from the cell controller.
Specify the teach pendant programs that will run when a style number is received by the robot controller.
Table 4. Style Name Setup Items
Style name SETUP ITEMs | Description |
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Style |
This item allows you to specify the style number sent by the cell controller to the robot. |
ProgName |
This item is the name of the program that is to be run when the associated style number is selected. |
Valid default: yes |
This item tells when the style is valid and can be used to run a program. If a style is not valid, it cannot be run, and an error will be displayed. |
Comment |
This item is a descriptive label for the part being processed. |
STYLE CONFIG SETUP | |
Acknowledge Function default: false |
This item allows you to enable or disable robot acknowledge output signals ACK1-8. FALSE means the signals are disabled. TRUE means the signals are enabled. |
Acknowledge Pulse Width (msec): default: 0 min: 0 max: 9999 |
This item allows you to set the length (in milliseconds) of the ACK1-8 signal when the acknowledge function is enabled. This time depends on the scan time of your PLC program. |
Max Number in Style Table default: 32 min: 1 max: 255 |
This item controls the number of rows in the style table. The length of the $STYLE_NAME, $STYLE_ENABLE, and $STYLE_COMMENT system variables will be adjusted at Controlled start to this value. |
Table 5. Prog Select STYLE Setup DETAIL Screen Items
ITEMS | DESCRIPTION |
Style |
This item allows you to specify the style number sent by the cell controller to the robot. |
ProgName |
This item is the name of the program that is to be run when the associated style number is selected. |
Valid default: yes |
This item tells when the style is valid and can be used to run a program. If a style is not valid, it cannot be run, and an error will be displayed. |
Comment |
This item is a descriptive label for the part being processed. |
STYLE CONFIG SETUP This item allows you to press the CONFIG function key and display the following items: | |
Acknowledge Function default: false |
This item allows you to enable or disable robot acknowledge output signals ACK1-8. FALSE means the signals are disabled. TRUE means the signals are enabled. |
Acknowledge Pulse Width (msec) default: min: 0 max: 9999 |
This item allows you to set the length (in milliseconds) of the ACK1-8 signal when the acknowledge function is enabled. This time depends on the scan time of your PLC program. |
Max Number in Style Table default: 32 min: 1 max: 255 |
This item controls the number of rows in the style table. The length of the $STYLE_NAME, $STYLE_ENABLE, and $STYLE_COMMENT system variables will be adjusted at Controlled start to this value. |
When you specify OTHER as the program select mode, the program is selected using UOP or OTHER. Also, if the production start method is OTHER, the program is initiated by setting the system variable $SHELL_WRK.$cust_start = 1. You specify the program to run by setting the system variable $SHELL_WRK.$cust_name.
Table 6. Prog Select OTHER DETAIL Screen Items
ITEM | DESCRIPTION |
OTHER Program select mode is enabled |
This method of selection requires that the application must set the variable $shell_wrk.$cust_name to the desired program name. |