Overview
· Process Logger Monitoring allows the user to set limits on process parameters as they are collected by Process Logger, and post faults if the process parameters exceed those limits.
· The fault severity can be set to Warning or Fault(Fault severity will pause the robot). If you have R818 (iRConnect option) loaded, then the fault severity can also be set to Warning with iRConnect, or Fault with iRConnect.
Conditions
· User has some process parameters they want to monitor to make sure they are within some limits.
Step
a The Process Monitor menu provides a method to allow setting tolerances on the process parameters being collected, and enabling the monitoring of those tolerances.
b On this menu you can set the following items.
a)
Application:
b) Fault Output: This output can be mapped to the PLC. This Output will be turned on when any of the items being monitored are out of tolerance, and the severity is set to FAULT.
c) Warning Output: This output can be mapped to the PLC. This Output will be turned on when any of the items being monitored are out of tolerance, and the severity is set to Warning.
d) Alarm Reset Input: This item can be mapped to the PLC. When this input is turned on, the Fault Output and Warning Output to the PLC will be turned off.
e) Enable an item to be monitored, Set Upper and Lower limits, specify a Limit Type, and specify a Fault Severity.
c Cursor down to an item you want to monitor.
a) Specify the Limit Type by cursoring over to the Type column and choose either DIRect or TOLerance.
b) When choosing DIRect, this means that Upper and Lower limits are the direct values to compare the process item’s value to.
c) When choosing TOLerance, , then the ULim and LLim values are a percentage value around an average, this means the process item’s value is compared to a tolerance band around this average.
Note
that the limits are GLOBAL limits.
They apply to all Welds, Seal Seams, Paint Strokes, etc…
Because these limits are Global, most of the time you will set the Limit
Type to Tolerance type, which will then provide limits around a learned average
for each individual Weld, Seal seam, Paint Stroke, etc…
d Cursor to Sev to choose the out of tolerance Severity. Your choices are shown, where items 3 and 4 only show up if the iRConnect (R818) option is loaded.
a) Warning severity will post an error message to the alarm log, but the robot will continue with it’s process.
b) Fault severity will post an error message to the alarm log, but the robot will pause.
e If you choose iRConnect as your severity, then the system will send XX number of history records to the iRConnect system so you can see which history was out of tolerance, and a number of previous histories. The number of histories sent is controlled by $Prcrep.$hsts_to_snd. The default value is 1. Here is a sample of what is sent to the iRConnect system, in this case $Prcrep.$hsts_to_snd was set to 5. The record that was out of tolerance is shown at the bottom, with previous histories above it. The item that was out of tolerance has it’s value highlighted in yellow with red text.
f To activate monitoring on an item, Cursor down to the row of the item you want to monitor, then cursor over to the Act column. Press F4 Y to enable monitoring.
a) If your Lim type is DIR, then the monitoring will become active immediately. If your Lim Type is TOL, then you will be prompted to choose your average tolerance type.
b) By default, Running Average is the default Average type. Running average means to use the already existent long term average for this item.
c) Press F4 choice to choose another tolerance Average Type. The other 2 choices are:
Item #2 means to learn the next X welds, then stop learning.
Item #3 means to learn the next X welds, then continue learning.
g If you choose item #2 or item #3, then a new item will be displayed to allow you to set the value of X. This is the number of samples you want to use to learn the average.
Note: After making choices on this menu, you must press F2 APPLY for the monitoring to become active.
Note: If you chose one of the Learn X choices, then the alarm monitoring will not take place until X samples have been learned for a given weld.
h Now that monitoring is enabled and setup, the related view screens will have new information on them.
a) In the chart menu(pane 3), if an items average has not bee “learned” yet, then the background for the chart will be a pale yellow instead of the standard blue, and the item name at the top of the chart will tell you the current learn count.
b) In the Data menu(pane 2), items that are being monitored will be displayed in red.
i Once an item being monitored has its status changed to learned, the following related views will have additional information displayed on them.
a) In the chart in Pane 3, the data for the given item will be displayed in blue. The Average being used for monitoring will be displayed in green. The Upper limit will have a red data marker, and the lower limit will have a red data marker
j To change the upper and lower limits from the related view chart menu, Press F4 UPP_LIM, or F5 Low_LIM.
k Once you press F4 or F5, the current limits value will be displayed.
l With UPP_LIM or LOW_LIM active, use the up arrow key and down arrow key on the pendant to adjust the chosen limit.
m The limit values that you change in the chart menu are the same limit values you previously set in the Process Monitor SETUP menu.
n If you are using a learned average setup for your Process Monitoring, there may be a situation where your learned average is incorrect (due to process parameter changes, or perhaps a new batch of parts.) If you want to relearn the average there are 2 ways to do this.
1. If you want to relearn for all welds, then you can do this on the Process Monitor SETUP menu by disabling the Monitor and then re-enabling it. This will reset the learned average for ALL welds on the controller.
2. If you want to relearn for just ONE weld, then use the editor related view function.
a.
In the editor
select your desired TP program, and choose the weld you wish to relearn.
b.
Initiate the
Process Data related view menu by choosing i-FCTNàPROCESS
DATA.
c.
In Pane 2, cursor
to the item you wish to relearn.
This item will have red text showing it is a monitored item.
d.
Press F3 RELEARN
to clear the learned average for only this current weld, and current item you
are viewing. (This can also be done in Pane 3 by using the F3 RELEARN) key.
o Process Logger Monitoring also provides local override control via a TP macro.
a) For example, you may want to only monitor one weld that is giving you a problem. So instead of turning on monitoring globally for all welds, you can just enable it for the one weld you want.
b) Process Monitoring local override is controlled via the karel macro prlogmon()
c) Optionally you can use the prlogmonover.tp macro which calls prlogmon() karel macro. Prlogmonover.tp is listed below, it just wraps the karel macro with comments about the parameters.
PRLOGMONOVER.TP
1: !Process Logger Monitor ;
2: !Local Override ;
3: ! ;
4: !Calling prlogmon provides a ;
5: !one-shot override to a specific ;
6: !weld for a specific process ;
7: !monitor setting. ;
8: ! ;
9: !There are 6 possible parameters ;
10: !The first 4 are required. ;
11: !The last 2 are optional. ;
12: ! ;
13: !PARM1=PROC_ID to apply ;
14: ! override to. ;
15: !PARM2=ENABLE/DISABLE ;
16: !PARM3=Item Index from SETUP Menu ;
17: !PARM4=Sev. 1=W,2=F,3=iRW,4=iRF ;
18: !PARM5=Option Upp Lim (Direct) ;
19: !PARM6=Option Low Lim (Direct) ;
20: ! ;
21: !Fill in values for the 4-6 ;
22: !parameters below. ;
23: ! ;
24: CALL PRLOGMON(AR[1],AR[2],AR[3],AR[4],AR[5],AR[6]) ;
d) There can only be one active override at a time, so if you call prlogmon() before a previous prlogmon() has been applied to the specified weld, it will override the previous prlogmon settings.
e) There are 6 possible parameters for this macro. The first 4 are required, the last 2 are optional.
f) prlogmon(Process_ID, Enable/Disable, item_index, severity, upp_lim, low_lim)
(1) Process_ID; The Process ID of the instruction you want the override applied to.
(2) ENABLE/DISABLE; 1=Enable, 0 = Disable
(3) Item_index; This is which Process Parameter you want the override applied to. Item_index is the # number from the process monitor setup menu.
(4) Severity; This is the alarm severity if the Process Item is out of tolerance. 1=warning, 2=fault, 3=warning with iRConnect, 4=fault with iRConnect.
(5) Upp_lim; optional parameter if you want to change the upper limit.
(6) low_lim; optional parameter if you want to change the lower limit.
(a) Note, when using this local override macro, the limit values are the direct limit values to compare the process items value to.
g) Here are a few examples of how you can use the local override macro prlogmon().
(1) SPOT Example 1: Fault if “Time to Force” is more than 200ms for WID=10
13: CALL PRLOGMON(10, 1, 2, 2, 200,0)
14: L P[3] 2000 mm/sec CNT100
15: L P[4] 2000 mm/sec CNT50
: SPOT(WID=10,SD=1,P=1,t=3.0,S=1,ED=1)
(2) SPOT example 2: Disable “Weld Time” monitoring for WID=20
13: CALL PRLOGMON(20, 0, 1, 2)
14: L P[3] 2000 mm/sec CNT100
15: L P[4] 2000 mm/sec CNT50
: SPOT(WID=10,SD=1,P=1,t=3.0,S=1,ED=1)