Motoman UP Series Robot Welding System System Manual

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Part Number:
Release Date:
Document Version:
Document Status:
142717-1
February 22, 2001
2
Final
Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
The information contained within this document is the proprietary property of Motoman, Inc., and may not be
copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,
Inc.
©2003 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications without
notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
TABLE OF CONTENTS
Section
Page
LIST OF FIGURES...........................................................................................................................iv
LIST OF TABLES ............................................................................................................................iv
1
INTRODUCTION
1.1 About this Document .................................................................................................... 1-1
1.2 System Overview .......................................................................................................... 1-2
1.2.1 System Layout ................................................................................................ 1-2
1.2.2 Optional Equipment ........................................................................................ 1-3
1.3 Reference to Other Documentation................................................................................ 1-3
1.4 Customer Service Information ...................................................................................... 1-3
2
SAFETY
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
3
MOTOMAN
Introduction .................................................................................................................. 2-1
Standard Conventions .................................................................................................. 2-2
General Safeguarding Tips............................................................................................ 2-3
Mechanical Safety Devices ........................................................................................... 2-3
Installation Safety ......................................................................................................... 2-4
Programming Safety ..................................................................................................... 2-4
Operation Safety ........................................................................................................... 2-5
Maintenance Safety....................................................................................................... 2-6
EQUIPMENT DESCRIPTION
3.1 SKX-Series Robot Description...................................................................................... 3-1
3.2 XRC Controller ............................................................................................................. 3-1
3.2.1 Playback Panel ............................................................................................... 3-2
3.2.2 Programming Pendant .................................................................................... 3-3
3.2.3 Brake Release ................................................................................................. 3-6
3.3 Operator Stations .......................................................................................................... 3-6
3.3.1 Cycle Start ...................................................................................................... 3-6
3.3.2 Emergency Stop (E-STOP) .............................................................................. 3-6
3.3.3 Hold ................................................................................................................ 3-7
3.3.4 Cycle Latched ................................................................................................. 3-7
3.3.5 Alarm .............................................................................................................. 3-7
3.3.6 Three-position Joystick .................................................................................. 3-7
3.3.7 Positioner Auto/Manual .................................................................................. 3-7
3.3.8 Master Job Start ............................................................................................. 3-7
3.3.9 Operator Station Enable/Disable ..................................................................... 3-8
3.3.10 Reset ............................................................................................................... 3-8
3.3.11 Servo On ......................................................................................................... 3-8
3.4 Positioner Module ........................................................................................................ 3-9
3.5 Stationary Flat Plane Module ........................................................................................ 3-9
i
FabWorld II System Manual
Section
3.6
3.7
4
Page
Welding Equipment .................................................................................................... 3-10
3.6.1 Power Sources .............................................................................................. 3-10
3.6.2 Wire Feeder .................................................................................................. 3-11
3.6.3 Universal Welding Interface (UWI) ................................................................ 3-11
3.6.4 GMAW Torch ................................................................................................ 3-11
3.6.5 Motoman Torch Mount ................................................................................. 3-11
Safety Features ........................................................................................................... 3-11
3.7.1 Arc Screens .................................................................................................. 3-12
3.7.2 Fencing ......................................................................................................... 3-12
3.7.3 Safety Mats ................................................................................................... 3-12
3.7.4 Emergency Stops (E-STOPS) ........................................................................ 3-12
3.7.5 ENABLE Switch ............................................................................................. 3-12
3.7.6 Interference Cubes ........................................................................................ 3-13
3.7.7 Interlocked Cell Door .................................................................................... 3-13
3.7.8 Brake Release ............................................................................................... 3-13
3.7.9 Welding Ground System ............................................................................... 3-13
INSTALLATION
4.1 Materials Required........................................................................................................ 4-1
4.1.1 Customer-supplied Items ............................................................................... 4-1
4.1.2 List of Tools .................................................................................................... 4-1
4.2 Site Preparation ............................................................................................................ 4-2
4.3 Installing the Robot /Positioner Common Base ............................................................ 4-2
4.3.1 Removing the Shipping Brackets .................................................................... 4-4
4.4 Installing the Auxiliary Equipment Common Base ........................................................ 4-4
4.5 Positioner Location Adjustment .................................................................................... 4-6
4.6 Installing the Operator Station ...................................................................................... 4-6
4.7 Installing the Safety Mats.............................................................................................. 4-7
4.7.1 Multiple Mat Layout ........................................................................................ 4-7
4.8 Leveling and Securing the Equipment........................................................................... 4-9
4.9 Connecting the Cables................................................................................................ 4-11
4.9.1 Connecting the Earth Ground ........................................................................ 4-11
4.9.2 Connecting the Robot Cables ....................................................................... 4-12
4.9.3 Connecting the System Interface Box ............................................................ 4-13
4.9.4 Connecting Water Circulator (Optional) ........................................................ 4-14
4.10 Connecting the Power................................................................................................. 4-14
4.11 Conducting a Safety/Operation Check ........................................................................ 4-16
4.12 Installation of Tooling and Fixtures............................................................................. 4-16
FabWorld II System Manual
ii
MOTOMAN
Section
5
Page
OPERATION
5.1 Programming................................................................................................................ 5-1
5.1.1 I/O Assignment ............................................................................................... 5-1
5.1.2 Programming the Positioner ........................................................................... 5-2
5.2 Daily Operation ............................................................................................................. 5-3
5.2.1 Loading the Positioner .................................................................................... 5-3
5.2.2 Start-Up .......................................................................................................... 5-4
5.2.3 Robot Safe (Cube 24) Position ....................................................................... 5-5
5.2.4 Starting the Master Job ................................................................................... 5-5
5.2.5 Shutdown ....................................................................................................... 5-5
5.3 System Recovery .......................................................................................................... 5-6
5.3.1 Alarms and Errors ........................................................................................... 5-6
5.3.2 E-STOP Recovery ........................................................................................... 5-7
5.3.3 Shock Sensor Recovery .................................................................................. 5-8
5.3.4 Using the Brake Release ................................................................................. 5-8
6
MAINTENANCE
6.1 Periodic Maintenance ................................................................................................... 6-1
6.2 Fuse and Circuit Breaker Protection.............................................................................. 6-2
INDEX
MOTOMAN
iii
FabWorld II System Manual
LIST OF FIGURES
Page
Figure
Figure 1-1
Figure 3-1
Figure 3-2
Figure 3-3
Figure 3-4
Figure 3-5
Figure 3-6
Figure 3-7
Figure 4-1
Figure 4-2
Figure 4-3
Figure 4-4
Figure 4-5
Figure 4-6
Figure 4-7
Figure 4-8
Figure 4-9
Figure 4-10
Figure 4-11
Figure 4-12
Figure 4-13
Figure 4-14
Figure 4-15
Figure 5-1
System Layout........................................................................................................... 1-2
XRC Controller.......................................................................................................... 3-1
XRC Playback Panel.................................................................................................. 3-2
Programming Pendant .............................................................................................. 3-3
RS-232C Serial Port.................................................................................................. 3-5
Enable Switch............................................................................................................ 3-5
Operator Station ........................................................................................................ 3-6
Available Power Sources......................................................................................... 3-10
Area Needed for Installation ...................................................................................... 4-2
Unbolting the Robot/Positioner Common Base......................................................... 4-3
Location of Shipping Brackets................................................................................... 4-4
Unbolting Auxiliary Equipment Common (AEC) Base ............................................... 4-5
Location of Auxiliary Equipment Common (AEC) Base ............................................. 4-5
Positioner Relocation ................................................................................................ 4-6
Handling a Safety Mat ............................................................................................... 4-7
Lock Lip Removal...................................................................................................... 4-7
Safety Mat Assembly................................................................................................. 4-8
Placement of the Positioner Safety Mat ..................................................................... 4-9
Robot/Positioner Base Leveling Bolts ..................................................................... 4-10
Robot Cable and Hose Routing ............................................................................... 4-12
Connecting Robot to XRC Controller....................................................................... 4-13
Water Circulator Connections ................................................................................. 4-14
Incoming Power Connections ................................................................................. 4-15
MHT-680 HS/TS – Home/User Defined Load Positions ........................................... 5-4
LIST OF TABLES
Page
Table
Table 3-1
Table 3-2
Table 4-1
Table 5-1
Table 5-2
Table 6-1
Table 6-2
Table 6-3
Positioner Specifications ............................................................................................. 3-9
Stationary Flat Plane Specifications ............................................................................. 3-9
Incoming Power Connections .................................................................................... 4-15
XRC User Inputs .......................................................................................................... 5-2
XRC User Outputs ........................................................................................................ 5-2
Periodic Maintenance .................................................................................................. 6-1
MotoArc 450 CV Fuses and Circuit Breaker ................................................................. 6-2
Universal Welding Interface (UWI) Fuses ..................................................................... 6-2
FabWorld II System Manual
iv
MOTOMAN
SECTION 1
INTRODUCTION
The FabWorld II is part of the FabWorld family of standardized arc welding
solutions. It is a fully integrated welding system, and is supported from wire to
weld by Motoman, Inc.
The FabWorld II features a Motoman arc welding robot and XRC controller with
menu-driven arc welding application software, complete welding package, rotary
plane positioner, operator interface, and a total safety environment.
1.1
About this Document
This manual is intended as an introduction and overview for personnel who have
received operator training from Motoman, and who are familiar with the operation
of this Motoman robot model. For more detailed information, refer to the manuals
listed in Section 1.4. This manual contains the following sections:
SECTION 1 - INTRODUCTION
Provides general information about the FabWorld II and its components, a list of
reference documents, and customer service information.
SECTION 2 - SAFETY
This section provides information regarding the safe use and operation of the
FabWorld II system.
SECTION 3 - DESCRIPTION OF EQUIPMENT
This section provides a detailed description of the major components of the
FabWorld II system. This section also includes a table of component
specifications.
SECTION 4 - INSTALLATION
This section provides instructions for set up and installation of the FabWorld II
system.
SECTION 5 - OPERATION
This section provides instructions for basic operation of the FabWorld II system.
This section also provides procedures for start-up, loading, normal operation, fault
recovery, and shutdown.
SECTION 6 - MAINTENANCE
This section contains a table listing periodic maintenance requirements for the
components of the FabWorld II cell.
MOTOMAN
1-1
FabWorld II System Manual
INTRODUCTION
1.2
System Overview
The FabWorld II provides a complete arc welding solution in a standardized
configuration. The cell is designed around a Motoman arc welding robot and XRC
robot controller and includes a complete welding package. Two rotary plane servo
driven positioners allow the robot to weld in synchronous motion with each
positioner. The cell can also be purchase with a stationary weld table instead of the
headstock/tailstock combination. The cell provides a full complement of safety
features designed to protect both personnel and equipment. Figure 1-1 illustrates
the system layout of the FabWorld II cell.
HEADSTOCK S2
OPERATOR
STATION
ASSEMBLED
SAFETY
FENCE
TAILSTOCK S2
ROBOT R1
INTERFACE
BOX
CELL DOOR
ARCWELDING
POWER SOURCES
(CUSTOMER PROVIDED)
YASNAC XRC SK16X
POTS YCNEGREME
NO OVRES
YDAER
EDOM
HCAET
YALP
NO
KCOL TIDE
PI R
T
MRALA
TRATS
DLOH
)FFO(
ETOMER
)NO(
FFO
ALARM
ROBOT HOLD
CYCLE LATCHED
OPERATOR STATION
ENABLE / DISABLE
SERVO ON
AB
RESET
BLK
AB
MASTER JOB
START
AB
POSITIONER
AUTO/MAN
M
ERGENC
Y
TORCH
TENDERS
(OPTION)
E
HEADSTOCK S1
E
TE
SE
R/
N
OP
AB
STOP
TAILSTOCK S1
XRC CONTROLLER
Figure 1-1 System Layout
1.2.1
System Layout
The robot manipulator shares a common base with both positioners for ease of
installation and to help maintain proper alignment between the components. The
XRC controller and welding power source also share a common base next to the
welding cell. The robotic cell is fully enclosed by safety fencing with an
interlocking door. Standing in the safety zone prevents robot or positioner motion.
All operator controls, including those on the XRC and welding power supply, are
accessible from outside the safety fencing.
FabWorld II System Manual
1-2
MOTOMAN
INTRODUCTION
1.3
Major Components
The FabWorld II includes the following major components:
• Motoman UP20 or UP6 manipulator and XRC controller
• Rotary plane positioner module
• Two operator stations
• Welding equipment, including the following:
• MotoArc welding power source
• Motoman torch (water-cooled or air-cooled)
• Wire feeder
• Torch mount
• Safety equipment, including the following:
• Safety fencing with arc curtains
• Interlocked safety mats
• Interlocked cell door
• Positioner arc screen
1.3.1
Optional Equipment
The following optional equipment is available for use with the FabWorld II:
• Torch tender
• Com-Arc III seam tracking unit
• Water circulator
• Heavy duty positioner
1.4
Reference to Other Documentation
For additional information refer to the following:
• Motoman UP6 Manipulator Manual (P/N 142104-1)
• Motoman UP20 Manipulator Manual (P/N 144342-1)
• Motoman Operator's Manual for Arc Welding (P/N 142098-1)
• Motoman Concurrent I/O Parameter Manual (P/N 142102-1)
• Com-Arc III Instruction Manual (P/N 132753-1)
• Coordination Instructions for Multi-axes Systems (P/N 139418-1)
• Vendor manuals for system components not manufactured by Motoman
1.5
Customer Service Information
If you are in need of technical assistance, contact the Motoman service staff at
(937) 847-3200. Please have the following information ready before you call:
• Robot Type (UP6 or UP20)
• Application Type (welding)
• System Type (FabWorld II)
• Software Version
• Robot Serial Number (located on the back side of the robot arm)
• Robot Sales Order Number (located on back side of XRC controller)
MOTOMAN
1-3
FabWorld II System Manual
INTRODUCTION
NOTES
FabWorld II System Manual
1-4
MOTOMAN
SECTION 2
SAFETY
2.1
Introduction
.
It is the purchaser's responsibility to ensure that all local, county,
state, and national codes, regulations, rules, or laws relating to
safety and safe operating conditions for each installation are met
and followed.
We suggest that you obtain and review a copy of the ANSI/RIA National Safety
Standard for Industrial Robots and Robot Systems. This information can be
obtained from the Robotic Industries Association by requesting ANSI/RIA
R15.06. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
Ultimately, the best safeguard is trained personnel. The user is responsible for
providing personnel who are adequately trained to operate, program, and maintain
the robot cell. The robot must not be operated by personnel who have not been
trained!
We recommend that all personnel who intend to operate, program, repair, or use
the robot system be trained in an approved Motoman training course and become
familiar with the proper operation of the system.
This safety section addresses the following:
• Standard Conventions (Section 2.2)
• General Safeguarding Tips (Section 2.3)
• Mechanical Safety Devices (Section 2.4)
• Installation Safety (Section 2.5)
• Programming Safety (Section 2.6)
• Operation Safety (Section 2.7)
• Maintenance Safety (Section 2.8)
MOTOMAN
2-1
FabWorld II System Manual
SAFETY
2.2
Standard Conventions
This manual includes information essential to the safety of personnel and
equipment. As you read through this manual, be alert to the four signal words:
• DANGER
• WARNING
• CAUTION
• NOTE
Pay particular attention to the information provided under these headings which
are defined below (in descending order of severity).
DANGER!
Information appearing under the DANGER caption concerns the
protection of personnel from the immediate and imminent hazards
that, if not avoided, will result in immediate, serious personal injury
or loss of life in addition to equipment damage.
WARNING!
Information appearing under the WARNING caption concerns the
protection of personnel and equipment from potential hazards that
can result in personal injury or loss of life in addition to equipment
damage.
CAUTION!
Information appearing under the CAUTION caption concerns the
protection of personnel and equipment, software, and data from
hazards that can result in minor personal injury or equipment
damage.
NOTE:
Information appearing in a NOTE caption provides additional information which is helpful in
understanding the item being explained.
FabWorld II System Manual
2-2
MOTOMAN
SAFETY
2.3
General Safeguarding Tips
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General safeguarding
tips are as follows:
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
should be permitted to operate this robot system.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the robot cell.
• Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs and
Outputs).
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use
lockout/tagout procedures during equipment maintenance. Refer also to
Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health
Standards for General Industry (OSHA).
2.4
Mechanical Safety Devices
The safe operation of the robot, positioner, auxiliary equipment, and system is
ultimately the user's responsibility. The conditions under which the equipment will
be operated safely should be reviewed by the user. The user must be aware of the
various national codes, ANSI/RIA R15.06 safety standards, and other local codes
that may pertain to the installation and use of industrial equipment. Additional
safety measures for personnel and equipment may be required depending on
system installation, operation, and/or location. The following safety measures are
available:
• Safety fences and barriers
• Light curtains
• Door interlocks
• Safety mats
• Floor markings
• Warning lights
Check all safety equipment frequently for proper operation. Repair or replace any
non-functioning safety equipment immediately.
MOTOMAN
2-3
FabWorld II System Manual
SAFETY
2.5
Installation Safety
Safe installation is essential for protection of people and equipment. The following
suggestions are intended to supplement, but not replace, existing federal, local, and
state laws and regulations. Additional safety measures for personnel and
equipment may be required depending on system installation, operation, and/or
location. Installation tips are as follows:
• Be sure that only qualified personnel familiar with national codes, local
codes, and ANSI/RIA R15.06 safety standards are permitted to install the
equipment.
• Identify the work envelope of each robot with floor markings, signs, and
barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against unauthorized entry
into the work envelope.
• Eliminate areas where personnel might get trapped between a moving robot
and other equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching and
maintenance procedures.
2.6
Programming Safety
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. Programming tips are
as follows:
• Any modifications to PART 1 of the controller PLC can cause severe
personal injury or death, as well as damage to the robot! Do not make any
modifications to PART 1. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!
• Some operations require standard passwords and some require special
passwords. Special passwords are for Motoman use only. YOUR
WARRANTY WILL BE VOID if you use these special passwords.
• Back up all programs and jobs onto a floppy disk whenever program changes
are made. To avoid loss of information, programs, or jobs, a backup must
always be made before any service procedures are done and before any
changes are made to options, accessories, or equipment.
• The concurrent I/O (Input and Output) function allows the customer to
modify the internal ladder inputs and outputs for maximum robot
performance. Great care must be taken when making these modifications.
Double-check all modifications under every mode of robot operation to
ensure that you have not created hazards or dangerous situations that may
damage the robot or other parts of the system.
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.
FabWorld II System Manual
2-4
MOTOMAN
SAFETY
•
•
•
•
•
•
2.7
Inspect the robot and work envelope to be sure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
Be sure that all safeguards are in place.
Check the E-STOP button on the teach pendant for proper operation before
programming.
Carry the teach pendant with you when you enter the workcell.
Be sure that only the person holding the teach pendant enters the workcell.
Test any new or modified program at low speed for at least one full cycle.
Operation Safety
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. Operation tips are as
follows:
• Be sure that only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
are permitted to operate this robot system.
• Check all safety equipment for proper operation. Repair or replace any nonfunctioning safety equipment immediately.
• Inspect the robot and work envelope to ensure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Ensure that all safeguards are in place.
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the cell.
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.
MOTOMAN
2-5
FabWorld II System Manual
SAFETY
2.8
Maintenance Safety
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. Maintenance tips are as
follows:
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Check all safety equipment for proper operation. Repair or replace any nonfunctioning safety equipment immediately.
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.
• Back up all your programs and jobs onto a floppy disk whenever program
changes are made. A backup must always be made before any servicing or
changes are made to options, accessories, or equipment to avoid loss of
information, programs, or jobs.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the cell.
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• Be sure all safeguards are in place.
• Use proper replacement parts.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.
• Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs and
Outputs).
FabWorld II System Manual
2-6
MOTOMAN
SECTION 3
EQUIPMENT DESCRIPTION
3.1
UP-series Robot Description
The Motoman UP6 and UP20 robots and XRC robotic controller represent stateof-the-art technology in robotics today. The six-axis UP6 robot has a payload of
6kg (13.2 lbs). It features a 1,373mm (54.05 in.) reach and has a relative
positioning accuracy of ± 0.08mm (0.004 in.). The six-axis UP20 robot has a
payload of 20kg (44.09 lbs). It features a 1658mm (65.2 in.) reach and has a
relative positioning accuracy of ± 0.1mm (0.004 in.).
Each robot can reach below its own base as well as behind itself and can be
mounted on the floor, wall, or ceiling with few modifications. However, the S-axis
has been restricted by hardstops for use in this system. For more information, refer
to the manipulator manual that came with your system.
3.2
XRC Controller
The XRC robotic controller (see Figure 3-1) coordinates the operation of the
FabWorld II system. It controls manipulator movement and welding power supply,
processes input and output signals, and provides the signals to operate the welding
system. It maintains variable data and performs numeric processing to convert to
and from different coordinate systems. In addition, the controller provides the
following: main logic functions, servo control, program and constant data memory,
and power distribution. For more information, refer to the manipulator manual that
came with your system.
BRAKE RELEASE
CONTROL
PLAYBACK BOX
SERVO ON
READY
MODE
PLAY
EMERGENCY STOP
TEACH
EDIT LOCK
ALARM
(OFF)
(ON)
REMOTE
HOLD
START
ON
IP
SET
RE
N/
PE
OFF
TR
O
PROGRAMMING
PENDANT
POWER
DISCONNECT
Figure 3-1 XRC Controller
MOTOMAN
3-1
FabWorld II System Manual
EQUIPMENT DESCRIPTION
3.2.1
Playback Panel
The playback panel (see Figure 3-2) contains the primary system controls and
consists of the features described below. For more information, refer to the
manipulator manual that came with your system.
MODE
BUTTONS
SERVO ON
READY
ALARM/ERROR
INDICATOR
MODE
PLAY
EMERGENCY STOP
E-STOP
TEACH
SERVO ON
READY
EDIT LOCK
ALARM
(OFF)
(ON)
REMOTE
HOLD
START
START
BUTTON
EDIT LOCK
REMOTE
MODE
HOLD
BUTTON
Figure 3-2 XRC Playback Panel
Servo On Ready
The SERVO ON READY pushbutton turns servo power ON. The switch lights
when servo power is on. In TEACH mode, the SERVO ON READY pushbutton
operates only when the TEACH LOCK button on the programming pendant is ON
and the ENABLE switch on the programming pendant is held in.
Mode
The Mode push buttons (PLAY, TEACH and REMOTE) set the robot's mode of
operation.
NOTE:
Changing modes from PLAY to TEACH, during playback, will cause the program to cease
execution (similar to HOLD); to resume operation, press PLAY and then START.
Alarm/Error
The ALARM/ERROR indicator light turns ON whenever an alarm or error
condition occurs.
Emergency Stop (E-STOP)
Pressing E-STOP ceases all system operation. The E-STOP button on the
playback panel is connected in series with the system Emergency Stop circuit.
Start
Pressing the START button while in PLAY mode with servo power on, causes
playback execution of the current job to begin.
Hold
The HOLD button is a normally closed, momentarily actuated switch. Pressing
HOLD halts operation of the manipulator until another Start signal is sent.
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3-2
MOTOMAN
EQUIPMENT DESCRIPTION
3.2.2
Programming Pendant
The programming pendant (see Figure 3-3) is the primary user interface for the
system. The pendant has a 4x5-inch, 12-line, 40-character LCD display and
keypad. The system uses the INFORM II robot language and a menu-driven
interface to simplify operator interaction with the robot. By using the pendant, the
operator can teach robot motion, and perform programming, editing, maintenance,
and diagnostic functions. The programming pendant consists of the items
described below. For more information, refer to the manipulator manual that came
with your system.
NOTE:
The programming pendant LCD display goes dark after a few minutes of inactivity. Press any
key to restore screen.
MENU AREA
STATUS AREA
GENERAL PURPOSE
DISPLAY AREA
EMERGENCY
STOP BUTTON
CURSOR
AXIS KEYS
ENTER KEY
ENABLE
SWITCH
NUMERIC KEYPAD
Figure 3-3 Programming Pendant
General Purpose Display Area
The General Purpose Display Area displays the currently selected menu choice.
Menu Area
The Menu Area contains menu selections for the currently selected screen.
Emergency Stop (E-STOP)
The E-STOP button on the programming pendant is connected in series with the
system Emergency Stop circuit. Pressing the E-STOP button interrupts this circuit
and stops all system operation.
Keypad
The user keypad on the programming pendant serves as an input device. The keys
are grouped into different functional sections to simplify operator use.
MOTOMAN
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FabWorld II System Manual
EQUIPMENT DESCRIPTION
Status Area
The Status Area shows system status via the following symbols:
•
Active Robot, External Axis, or Base Axis
R1, R2, R3; S1, S2, etc.; or B1, B2, etc.
•
Coordinate System
u
Joint,
•
World,
Tool, or
User Frame
Manual Speed Setting
M
L
Inching,
•
Cylindrical,
H
Low,
Medium, or
High
Cycle Mode
S Step, C 1-Cycle, or A Auto
•
System Status
E-Stop,
•
S
Stop,
R
Running/Start,
H
Hold, or
A
Alarm
Additional Pages (when applicable)
TOP MENU Key
The TOP MENU key returns the pendant display to the initial start-up menu. The
cursor key can then be used to choose from the following menu icons:
• JOB
This icon accesses job selections including: Master Job, Select Job, Job
Capacity, and Create New Job while in TEACH mode.
•
•
ARC WELDING, GENERAL, HANDLING, and SPOT WELDING
This icon allows you to select the applications available to the controller.
VARIABLE
This icon accesses the display and editing menu for the arithmetic variables
and display of position variables.
•
IN/OUT
This icon accesses DETAIL and SIMPLE displays of all XRC I/O signals. In
EDITING or MAINT. mode, Universal Outputs can be forced ON or OFF.
•
ROBOT
This icon accesses robot information including: CURR.POS, POWER ON/
OFF, POS, COMMAND POS, SECOND HOME POS, OPE ORIGIN POS,
and TOOL and USER COORDINATE.
•
SYSTEM INFO
This icon provides Version information for both hardware and software,
Alarm History, and Monitoring Time.
Area Key
The Area key moves the cursor to the different areas of the display screen.
Cursor Key
The Cursor key is an 8-way, directional key that moves the up, down, left or right
to highlight a desired item that can then be chosen using the SELECT key.
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MOTOMAN
EQUIPMENT DESCRIPTION
SELECT Key
The SELECT key is used to choose the item currently highlighted by the cursor.
TEACH LOCK Key
The TEACH LOCK key locks operation of the robot with the programming
pendant. Operation is not possible from the playback panel or operator station.
Servo power can not be applied in TEACH mode unless TEACH LOCK is ON.
RS-232C Serial Port
This 9-pin serial port (see Figure 3-4) is used for data communication between the
XRC and a floppy disk controller (FC1 or FC2), FDE (Floppy Disk Emulator)
software, or other form of communication.
RS-232C
SERIAL PORT
Figure 3-4 RS-232C Serial Port
ENABLE Switch
The ENABLE switch (see Figure 3-5) is a three-position switch located on the left
rear of the programming pendant. It is a safety feature that controls servo power
while in TEACH mode. When pressed in, this switch enables servo power to be
turned on. However, should the operator release the switch, or grasp it too tightly,
servo power is immediately disabled, preventing further robot movement.
BACK OF
PROGRAMMING
PENDANT
ENABLE SWITCH
Figure 3-5 Enable Switch
MOTOMAN
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FabWorld II System Manual
EQUIPMENT DESCRIPTION
3.2.3
Brake Release
WARNING!
Releasing brakes could cause personal injury or machine damage.
Always support the axis to be released BEFORE you release it.
The Brake Release Control is a safety feature that allows you to release the
automatic brakes on the robot in case of an emergency or robot failure. The Brake
Release Control is mounted on the front of the XRC cabinet (see Figure 3-1).
Provide adequate support for axis to be released. Support should be able to
withstand the payload and the approximate weight of robot.
3.3
Operator Stations
Both operator stations (see Figure 3-6) include a NEMA enclosure on a standalone pedestal. The following paragraphs describe the operator station controls.
CYCLE START
CYCLE START
ALARM
ROBOT HOLD
CYCLE LATCHED
RESET
MASTER JOB
START
POSITIONER
AUTO/MAN
OPERATOR STATION
ENABLE/DISABLE
SERVO ON
HOME
REVERSE
FORWARD
CYCLE START
WARNING!
Figure 3-6 Operator Station
3.3.1
Cycle Start
WARNING!
The operation of the CYCLE START palm buttons is dependent on the
structure of the Master job. Altering the Master job could result in
injury to personnel or damage to the equipment.
The green CYCLE START palm buttons, located on the sides of the operator
station, initiate a positioner sweep cycle if the robot is in the Safe or Home position
(Cube 24). If the CYCLE START buttons are pressed while the robot is outside
Cube 24, the CYCLE START command is latched into the XRC. Once the robot
returns to Cube 24 and Output #1 is on, the CYCLE START command is executed
and the positioner sweeps. An anti-tiedown timer, normally set to 10 seconds,
prevents the operator from holding the palm buttons down and continuously
cycling the positioner.
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MOTOMAN
EQUIPMENT DESCRIPTION
3.3.2
Emergency Stop (E-STOP)
Pressing an E-STOP button or interrupting a door interlock interrupts this circuit
and stops all system operation. The operator station E-STOP, the robot E-STOP,
and the sliding door interlocks are connected in series in the Emergency Stop
circuit. Brakes are applied to the robot and all servo power is removed from the
system. The system E-STOP lights come on and all positioner motion is stopped.
3.3.3
Hold
The HOLD button is a normally closed, momentarily actuated switch. Pressing the
HOLD button stops the operation of the manipulator until another Start signal is
sent. The indicator light stays ON only while the HOLD button is pressed.
Operation resumes at the point in the program where the HOLD state was initiated.
Refer to the manipulator manual for more information.
3.3.4
Cycle Latched
CYCLE LATCHED indicates that the positioner will sweep and begin to weld
immediately after the current weld cycle is complete.The CYCLE LATCHED
lamp operates illuminates when positioner CYCLE START command has been
latched. It is not necessary to wait for the robots to finish welding and return to the
Safe position (Cube 24) before pressing the CYCLE START palm buttons to
sweep the positioner. Pressing the Cycle Start palm buttons while either robot is
still in motion locks the CYCLE START command into the XRC. The CYCLE
LATCHED light comes on, indicating CYCLE START latching. The positioner
sweeps once the robots finish the current job and return to the Safe position (Cube
24). Stepping on the safety mats will unlatch the CYCLE START command from
the XRC.
3.3.5
Alarm
The ALARM lamp is connected to the robot SERVO ON and ALARM
OCCURRENCE outputs. The ALARM lamp turns on when the robot encounters
an alarm condition or when servo power is cut.
3.3.6
Three-position Joystick
A spring loaded joystick controls rotary positioner rotation to access the user
defined load position(s). Moving the joystick right (forward) and letting go causes
the tooling plate to rotate clockwise at 30 degree intervals. Moving the joystick left
(reverse) and letting go causes the tooling plate to move counterclockwise 30
degree intervals. Home position on the joystick resets the headstock to zero
degrees.
3.3.7
Positioner Auto/Manual
The POSITIONER AUTO/MANUAL selector switch is used to select
AUTOMATIC or MANUAL mode for the positioner. The selector switch is
connected to robot Input #2. When the selector switch is in the AUTOMATIC
position, the robot processes the part after the positioner sweeps. In MANUAL
mode, the robot does not process the part after the positioner sweeps, but remains
in the Safe position.
NOTE:
MOTOMAN
The Positioner Auto/Manual command is dependent on the structure of the Master job.
3-7
FabWorld II System Manual
EQUIPMENT DESCRIPTION
3.3.8
Master Job Start
The robot will start the current active job when MASTER JOB START is pressed.
The MASTER JOB START button is connected to the robot external start input.
The operator station must be enabled and servo power ON for the MASTER JOB
START button to work.
3.3.9
Operator Station Enable/Disable
The OPERATOR STATION ENABLE/DISABLE selector switch transfers
primary control of the ArcWorld cell from the XRC to operator station. The
REMOTE MODE button on XRC playback panel lights when the operator station
is enabled. Most programming pendant functions are disabled while in REMOTE.
3.3.10
NOTE:
3.3.11
Reset
A minor alarm or error condition is cleared when the RESET button is pressed.
The RESET button is connected to the robot alarm reset input. A minor alarm or
error condition is cleared when this button is pressed. In addition, the RESET
button and the RIGHT CYCLE START buttons are interlocked and, when pressed
simultaneously, reset the positioner when servo power is ON in Play mode. In
Teach mode, the positioner is automatically reset when servo power is turned ON.
The positioner only needs to be reset after initial power-up and after an emergency
stop while in Play mode.
Resetting the positioner may cause positioner motion. Be careful when resetting the positioner
while robot is close to tooling. If an Emergency Stop occurs during programming, be sure to
reset the positioner before resuming programming.
Servo On
The SERVO-ON pushbutton enables servo power. In TEACH mode, the SERVO
ON pushbutton operates only when the ENABLE switch on the programming
pendant is held in.
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MOTOMAN
EQUIPMENT DESCRIPTION
3.4
Positioner Module
MHT-680 HS/TS Positioner
This positioner consists of a headstock and tailstock (HS/TS) mounted on the
positioner common base providing 3m (118 in.) between mounting plates. For
positioner specifications, refer to Table 3-1. Refer to Section 6, Maintenance
procedures.
NOTE:
In high humidity areas, use surface protection to prevent corrosion of the tooling plates.
Table 3-1 Positioner Specifications
Conditions
Specifications
Capacity
HS only
340kg (750 lbs) load, center of gravity, 6in. overhang, 6in. off-center.
323mm (12.7 in.) over hang C.G. (1100N·m Bearing Moment)
136mm (5.35 in.) off center C.G. (1100N·m Holding Moment)
HS/TS
Combined HS/TS capacity 680kg(1500 lbs.) 3in. off-center of
gravity.
68mm (2.67 in.) off center C.G
Rotation
Speed
Max. Load Inertia
3.5
0 to12.4 RPM variable speed.
74.5kg·m2.
Chassis
Standard height: 787mm (31.98 in.)
Swing radius 769mm (30.28 in.) above floor.
Sweep Time
with Capacity
3 seconds for 180 degree sweep with maximum total load of 598kg
(1,320 lbs)
Temperature Operating
Range
4–43°C (40–110˚F)
Humidity (maximum)
Non-condensing 10–90% relative humidity
Shock (maximum)
Less than 0.5 G
Electrical
Requirements
208V AC/120 Hz/Two-phase supplied by the XRC controller
Welding Current Rating
600 amperes at 100% duty cycle.
Stationary Flat Plane Module
The stationary flat plane module is a steel table with a ground flat steel top.
Table 3-2 Stationary Flat Plane Specifications
Conditions
MOTOMAN
Specifications
Work Surface
Dimensions
3599.94mm L x 609.6mm W x 899.92mm H x 12.7mm thick
(141.73 in.L x 24 in.W x 35.43 in.H x 3/4 in. thick)
Part/Fixture
Rating
907.2kg (2000 lbs)
3-9
FabWorld II System Manual
EQUIPMENT DESCRIPTION
3.6
Welding Equipment
In its standard configuration, the ArcWorld system includes a power source, wire
feeder, torch, and torch mount. Optional equipment including water circulators,
Com-Arc units, and torch tenders may included to enhance performance.
3.6.1
Power Sources
Motoman offers several different power sources for use with the FabWorld II
system depending on your system’s application. The following are some of the
more common power sources used (see Figures 3-7 and 3-8). However, the power
source your system uses may be different. For more specific information, refer to
the vendor manual that came with your system.
ON
CURRENT
INPUT
CABLE
HEAT
WATER
ALARM
INDICATOR
OFF
CRATER
CRATER CURRENT CRATER VOLTAGE
ON
CO2
SOLO
OFF
MAG
FON
PENETRATION
AMMETER
VOLTMETER
A
V
GAS
FUSE
Ø16
Ø14
Ø12
WIRE TYPE
FLOW
AUTO
WIRE DIA
POWER
ALARM
GAS FLOW
_
ON
0
OFF
CONTROL
POWER
ON
CRATER
CURRE
NT
OFF
CRATER
VOLTAG
E
ON
CRATE
R
ALARM
INDICA
TOR
OFF
CO
2
PENE
TRATI MAG
ON
AMM
ETE
SOLO
GAS
R
FON
WIRE
VOL
TME
A
KOBELCO UC350
POWER SOURCE
CURR
INPUTENT
CABLE
HEAT
WATE
R
Ø16
Ø14
FUSE
TYPE Ø12
FLOW
WIRE
TER
AUTO
DIA
GAS
FLOW
V
POW
ER
ALA
RM
_
ON
0
CONTR
POWEOL
R
CIRCUIT BREAKERS
OFF
WIRE FEEDER #1
WIRE FEEDER
10 AMP
10 AMP
REMOTE
CONTROL
115 V 9A
5
115 V 9A
6
4
INPUT
POWER
7
3
A
V
2
ON
1
OFF
0
LOCAL
REMOTE
(A)
(V)
Vb
SEARCH MODE
(DC 300V OUTPUT)
POWER
Tp
Vp
Vp
MOTOARC 450
POWER SOURCE
CHECK
Vb
Tp
CONTROL
ROBOT REMOTE 4
3
2
1
LOCAL
5
6
7
8
9
0
10
VOLTAGE
4
5
6
3
2
7
1
9
0
10
CURRENT
-2
+2
L. PULSE
-4
+4
S. PULSE
PULSE OFF
8
ARC CHARACTERISTIC
STEEL
ALUMINUM
STAINLESS
NORMAL
AUTO
ADJUSTMENT -2
-4
GAS CHECK
INDIVIDUAL
Tp
Vb
Vp
+2
-2
+4 -4
PULSE VOLT.
-2
+2
+4 -4
+2
+4
BASE VOLT.
PULSE WIDTH
MOTOWELD P350
POWER SOURCE
Figure 3-7 Available Power Sources
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MOTOMAN
EQUIPMENT DESCRIPTION
3.6.2
Wire Feeder
The PWF4 wire feeder mounts on the robot arm. This 4-roll wire feeder provides
reliable wire feeding at rates up to 750 inches per minute (IPM). An integral gas
valve provides fast gas response time. The wire feeder has an inch forward button
to help simplify set-up and reduce change-over time. Interchangeable feed rolls are
used to accommodate different types and sizes of wire. A Shock Sensor Override
switch located on the front of the feeder is used to recover from torch impact.
3.6.3
Universal Welding Interface (UWI)
The UWI provides microprocessor control to the wire feeder and MotoArc series
power source. It scales the signals from the XRC controller to the appropriate
levels required for control of the welding components. It also provides isolation of
the power source analog signals.
NOTE:
3.6.4
Some power sources available with the FabWorld II system do not use the UWI. For more
information specific to your system, refer to the vendor manuals shipped with your system.
GMAW Torch
The ArcWorld system uses either an air-cooled or a water-cooled robotic/automatic
GMAW torch. These are heavy-duty torches designed for quick replacement while
requiring minimum robot reprogramming. The GMAW torch is installed at the end
of the robot wrist. For applications that use the water-cooled torch, the ArcWorld
system includes a water circulator kit.
3.6.5
Motoman Torch Mount
The Motoman Torch Mount protects the robot, workpiece, fixture, and positioner.
It provides multi-directional impact detection, including Z-axis collisions. Torch
impact causes a system E-STOP and immediately stops all system operation.
Servo power is removed from the system and brakes are applied to the robot. All
positioner and door motion is also stopped.
3.7
Safety Features
The FabWorld II system incorporates a host of safety equipment. When all
standard safety precautions are taken, the safety equipment helps to ensure safe
operation of the robotic cell.
ANSI/RIA R15.06 Robot Safety Standard
This standard stipulates that the user is responsible for safeguarding.
ANSI/RIA R15.06: Users are responsible for determining whether the provided
safeguards are adequate for plant conditions. Users must also ensure that
safeguards are maintained in working order.
MOTOMAN
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FabWorld II System Manual
EQUIPMENT DESCRIPTION
3.7.1
Arc Screens
WARNING!
Although the arc curtain blocks dangerous arc radiation, never look
directly at the arc without protective eyewear!
Two separate arc screens are used on the ArcWorld system. The first is a metal arc
screen on the positioner. This screen blocks arc radiation and sparks from the
welding operation. The material used to cover the safety fencing of the entire
robotic cell acts as the second arc screen. This material reduces the amount of
ultra-violet radiation that escapes from the robotic cell.
3.7.2
Fencing
The safety fencing provided with the ArcWorld system encloses the entire robotic
cell. It forms a physical barrier preventing entry into the robot operating envelope
during automatic operation.
3.7.3
Safety Mats
The FabWorld II safety mats help prevent serious injury to anyone entering the
positioner area during the sweeping process. In PLAY mode, if the positioner is
sweeping and a safety mat is activated, servo power is removed from the system
and all positioner motion stops. Servo power is reapplied by pressing SERVO ON.
However, the positioner will only continue its motion after it is reset using the
RESET and right CYCLE START buttons on the operator station.
If the positioner is not in motion but the CYCLE START input has been latched
(indicated by the STATION READY light), the CYCLE START input is unlatched
and the STATION READY light turns off when the safety may is activated. Servo
power remains ON.
3.7.4
Emergency Stops (E-STOPS)
In addition to the safety features described above, the FabWorld II has strategically
placed E-STOPS. These are operator actuated devices that, when activated,
immediately stop all system operation. Brakes are applied to the robot and all
servo power is removed from the system. The system E-STOP lights come on and
all positioner motion is stopped. The following is a list of their locations:
• The playback box on the controller
• The programming pendant
• The operator station
3.7.5
ENABLE Switch
The ENABLE switch is a safety feature which controls servo power while in
TEACH mode. When pressed in, this switch allows the operator to turn servo
power ON and initializes the system. However, should the operator release the
switch or grasp it too tightly, servo power is immediately disabled, preventing
further robot movement. For detailed information about the operation of the
ENABLE switch, refer to the XRC section in the manipulator manual that came
with your system.
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MOTOMAN
EQUIPMENT DESCRIPTION
3.7.6
Interlocked Cell Door
A safety interlock on the cell entrance door prevents entry into the cell during
PLAY mode. Opening the cell door with the robot in PLAY causes an E-STOP.
Brakes are applied to the robot and all servo power is removed from the system.
The system E-STOP lights come on and all positioner motion is stopped.
3.7.7
Interference Cubes
Cubic interference zones prevent interference between multiple manipulators or a
manipulator and peripheral devices. The XRC monitors the robot tool center point
(TCP) during operation. If the TCP enters one of the these software-defined
interference zones, an output is turned on in the XRC. These outputs can be used to
interlock the activity of other manipulators or peripheral devices. The XRC has
eight possible cubes available. These cubes are internally tied to the following
Specified Outputs:
R1 = SOUT #081 - 104
The FabWorld II uses interference cubes to interlock robot position with positioner
motion. The robot Home or Safe position (Cube 24) is defined behind the
positioner, clear of the sweep zone. Each axis is placed in a position that provides
the least amount of strain on the servo motors, with the U- and L- axes at 90 degree
angles and the B axis in a relaxed, vertical position. This prevents drifting when
servo power is off. Before the positioner can sweep, the robot must be in this safe
position.
3.7.8
Brake Release
WARNING!
Releasing brakes could cause personal injury or machine damage.
Always support the axis to be released BEFORE you release it.
The Brake Release Control is a safety feature that releases the automatic brakes on
the robot in case of an emergency or robot failure. The Brake Release Control is
mounted on the front of the XRC cabinet (see Figure 3-1). Refer to Section 5.3.4
for the proper operation of the brake release.
3.7.9
Welding Ground System
The welding ground system consists of a spring-loaded, copper brush block that
contacts the backside of the faceplate. The ground cable to the welding power
source is connected to this brush block.
NOTE:The ground cable connection to the brush block must be secure. If the connection is
loose, arcing can occur and cause the insulator to melt.
MOTOMAN
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FabWorld II System Manual
EQUIPMENT DESCRIPTION
NOTES
FabWorld II System Manual
3-14
MOTOMAN
SECTION 4
INSTALLATION
The FabWorld II system can be installed easily in just a short time by three
workers. The more people involved (within reason), the more quickly installation
can be completed. Follow established safety procedures at all times throughout
the installation process. Failure to use safe work practices can result in damage to
the equipment and injury to the workers.
CAUTION!
Installation of the FabWorld II System is not a task for the novice.
The FabWorld II System is not fragile, but it is a highly sophisticated
robotic system. Handle components with care. Rough handling can
damage system electronic components.
4.1
Materials Required
All system hardware necessary for installing the FabWorld II system is included
with the system. This section identifies customer-supplied items and tools required
to perform installation.
4.1.1
Customer-supplied Items
•
•
•
•
•
•
•
4.1.2
List of Tools
•
•
•
•
•
•
•
•
MOTOMAN
Gas bottles for the welding torches
Incoming power supply
Two earth ground cables with two earth ground stakes
Weld wire
Incoming air supply: 0.04 cm at 620.5 kPa (1.5 scfm at 90 psi)
Stepladder
Forklift and/or overhead crane
Safety glasses
Face shields
Gloves
Level
Ratchet with 3/4-in. socket
Adjustable wrench set
Hammer drill with appropriate
concrete bits
Phillips and flat screwdrivers
4-1
•
•
•
•
•
•
•
Hammer
Socket set
Forklift and/or overhead crane
Air-impact gun with 3/4-in.
socket
Open-end wrench set
Two socket-head (Allen)
Wrench sets (standard and
metric)
FabWorld II System Manual
INSTALLATION
4.2
Site Preparation
To prepare your site, proceed as follows:
1. Clear the floor space needed for the unit (see Figure 4-1).
NOTE:
The FabWorld II system will require a minimum area of 2.5m (8.2 ft) by 3.9m (12.9 ft); however,
we recommend an additional 2.43 to 3.05m (8 to 10 ft) on all sides.
2. Gather all customer-supplied items and required tools (see Section 4.1.2).
OPERATOR
STATION
SAFETY MAT
POWER
SOURCE
4610mm
(15.12 ft)
XRC
3.0 m (9.84 ft)
SAFETY MAT
OPERATOR
STATION
5630mm (18.47 ft)
Figure 4-1 Area Needed for Installation
4.3
Installing the Robot /Positioner Common Base
The robot/positioner common base and the operator station are shipped on a
wooden shipping skid. To install the robot/positioner common base, proceed as
follows:
CAUTION!
Handle FabWorld II components carefully to avoid damage.
1. Unbolt the robot/positioner common base from wooden shipping skid using a
3/4 in. socket (see Figure 4-2).
FabWorld II System Manual
4-2
MOTOMAN
INSTALLATION
WARNING!
The robot/positioner common base weighs 1905kg (4200 lbs). Be
sure that your crane or forklift is capable of handling this much
weight or damage to the equipment or injury to personnel can result.
2. Using a forklift, remove common base from wooden shipping skid.
SHIPPING BOLT
LEVELING BOLT
Figure 4-2 Unbolting the Robot/Positioner Common Base
3. Place robot/positioner common base in position (see Figure 4-1).
NOTE:
Make sure there is adequate room on all sides of the positioner for the operator station, safety
mats, and auxiliary equipment common base.
4. Carefully remove protective plastic wrapping from robot and torch.
5. Inspect robot, torch, and positioner for shipping damage.
NOTE:
If damage is found, notify shipper immediately.
6. Remove operator station from skid and set safely aside.
MOTOMAN
4-3
FabWorld II System Manual
INSTALLATION
4.3.1
Removing the Shipping Brackets
CAUTION!
Failure to remove shipping brackets from robot before operating the
FabWorld II may result in damage to the robot drive mechanisms.
Three yellow brackets (see Figure 4-3) prevent the robot from moving during
shipping. Two angle brackets secure the lower arm assembly to the S-axis housing.
The smaller bracket on the rear of the robot prevents the S-axis housing from
pivoting. After the robot is in place, remove all shipping brackets.
YELLOW
SHIPPING
BRACKET
YELLOW
SHIPPING
BRACKET
Figure 4-3 Location of Shipping Brackets
4.4
Installing the Auxiliary Equipment Common Base
The auxiliary equipment common (AEC) base contains the XRC controller and the
welding power source. It may also include the optional water circulator and/or
ComArc III unit. The AEC base is shipped on a separate wooden shipping skid.
The accessories box is secured to the top of the welding power source. To install
the AEC base, proceed as follows:
1. Unbolt AEC base by removing four shipping bolts (see Figure 4-4).
WARNING!
The AEC base weighs 680kg (1500 lbs). Be sure that your crane or
forklift is capable of handling this much weight or damage to the
equipment or injury to personnel can result.
2. Using a forklift, lift base and remove it from wooden shipping skid.
FabWorld II System Manual
4-4
MOTOMAN
INSTALLATION
SHIPPING BOLT
LEVELING B0LT
YASNAC XRC SK16X
SERVO ON
READY
MODE
PLAY
EMERGENCY STOP
TEACH
EDIT LOCK
ALARM
(OFF)
(ON)
REMOTE
HOLD
START
ON
SET
RE
N/
PE
OFF
TRIP
O
[
3.
4.
5.
6.
NOTE:
Figure 4-4 Unbolting Auxiliary Equipment Common (AEC) Base
Place AEC base approximately 0.6m (2 ft) beside FabWorld II cell (see
Figure 4-5).
Carefully remove plastic wrapping and cardboard from AEC base.
Remove accessories box from welding power source and set safely aside.
Inspect AEC base for any shipping damage.
If damage is found, notify shipper immediately.
1.3 m
(4.27 ft)
XRC
POWER
SOURCE
OPERATOR
STATION
[
Figure 4-5 Location of Auxiliary Equipment Common (AEC) Base
MOTOMAN
4-5
FabWorld II System Manual
INSTALLATION
4.5
Positioner Location Adjustment
Both the headstock and tailstock are moved inward on the common base for
shipping purposes. The welding cell can be safely operated with these components
shifted in, however, moving the headstock/tailstock out will allow larger parts to be
fixed to the positioner. To move each piece, simply remove the four bolts at the
base and carefully slide (see Figure 4-6) the headstock/tailstock forward to the next
set of predrilled holes. Then insert the bolts to fasten down the headstock/tailstock
components.
SLIDE HEADSTOCK
OUTWARD
SLIDE TAILSTOCK
OUTWARD
SLIDE HEADSTOCK
OUTWARD
SLIDE TAILSTOCK
OUTWARD
Figure 4-6 Positioner Relocation
4.6
Installing the Operator Station
To install the operator station, proceed as follows:
1. Unload operator station.
2. Carefully remove protective plastic wrapping from operator station.
3. Inspect operator station for shipping damage.
NOTE:
If damage is found, notify shipper immediately.
4. Place operator station outside fence to front of positioner (see Figure 4-5).
5. Insert a 1/4 in. concrete drill bit through center of lag holes in operator
station and drill holes for lag bolts.
6. Vacuum concrete dust from holes.
7. Lag operator station to floor.
FabWorld II System Manual
4-6
MOTOMAN
INSTALLATION
4.7
Installing the Safety Mats
Safety mats require special handling to prevent damage to the internal electrode
assembly. Grasp mat by its long edges and lift, causing a slight bow down the
length of the mat (see Figure 4-7). This prevents the mat from kinking lengthwise.
Place the mat cord and junction box on top of mat during handling to reduce
tripping hazards.
MAT CORD AND JUNCTION BOX
PLACED ON TOP TO AVOID
TRIPPING OR DAMAGE
HOLD MAT BY THE SIDES
AND ALLOW TO BOW, AS
SHOWN, TO AVOID DAMAGE
Figure 4-7 Handling a Safety Mat
CAUTION!
Mats are susceptible to edge damage and damage from bending. Be
careful not to impact the edges or corners of the mats. Do not
attempt to lift large mats without help.
4.7.1
Multiple Mat Layout
A T-shaped aluminum extrusion, called the active joiner, is used to abut two safety
mats together to increase sensitivity. On the extrusion there are adhesive strips that
bond to each mat so that debris will not accumulate under the mats. At least three
of the outside edges of the mat layout will need perimeter anchoring trim to hold
the mats in place.
Prepare Safety Mats
To prepare the mats for installation with the active joiner proceed as follows:
1. Vacuum or sweep floor surface where mat will be mounted to ensure surface
is flat, smooth, and free of debris.
2. Use a sharp utility knife and a straight edge to remove the lock lip from both
mats at the point they will join one another. Only remove the lip from the
mat on the side that is joining another mat (see Figure 4-8).
REMOVE
LOCK LIP
HERE
Figure 4-8 Lock Lip Removal
MOTOMAN
4-7
FabWorld II System Manual
INSTALLATION
NOTE:
Set Up
After the lock lips have been removed on adjoining mat ends, do a trial run.
Location of safety mat must be in front of positioner with back perimeter trim even
with fence ends (see Figure 4-1).
1. Put the safety mats, active joiner strips, and perimeter anchoring trim
together in the desired configuration.
2. Once proper fit is ensured, expose one adhesive strip and secure the active
joiner to one of the mats.
3. Expose the other adhesive strip and put the second mat in place.
4. Repeat this process until all mats using the active joiner are joined together.
• The active joiner should be positioned up to the mat’s dimensional edge, just inside the
lock lip.
MAT
ADHESIVE STRIP
2 IN. RAMP TRIM
ACTIVE JOINER
Figure 4-9 Safety Mat Assembly
Finish installation
Once the trial run is complete and the mat is adhered to active joiner, the rest of the
assembly can be anchored.
1. Using hardware provided, bolt safety mat junction box to front of positioner.
2. Place safety mat perimeter trim in position.
NOTE:
For the perimeter trim, use a 1/4-in. drill bit.
3. Holding perimeter trim securely in place, drill 2.54 cm (1 in.) deep through
pre-drilled holes into floor.
4. Remove perimeter trim.
5. Remove any debris that may be underneath mat.
6. Reposition perimeter trim.
7. Insert appropriate anchors into holes for perimeter trim.
8. Insert #10 x 1-1/4-in. screws into perimeter trim, and tighten screws until
they hold mat securely.
FabWorld II System Manual
4-8
MOTOMAN
INSTALLATION
YASNAC XRC SK16X
POTS YCNEGREME
NO OVRES
YDAER
EDOM
HCAET
YALP
NO
KCOL TIDE
T
PIR
MRALA
TRATS
DLOH
)FFO(
ETOMER
)NO(
FFO
PERIMETER TRIM
E
TE
SE
R/
N
OP
SAFETY MATS
ALARM
ROBOT HOLD
CYCLE LATCHED
OPERATOR STATION
ENABLE / DISABLE
SERVO ON
AB
MASTER JOB
START
AB
POSITIONER
AUTO/MAN
AB
M
ERGENC
Y
E
RESET
BLK
AB
STOP
Figure 4-10 Placement of the Positioner Safety Mat
4.8
Leveling and Securing the Equipment
After everything is in position, level the equipment and secure it to the floor. The
lag bolts are shipped in the accessories box. To level and secure the equipment,
proceed as follows:
1. Level robot/positioner base by adjusting leveling bolts (see Figure 4-11).
2. Insert a 1/2-in. concrete drill bit through center of leveling bolts and drill
holes for lag bolts.
3. Vacuum concrete dust from holes.
4. Lag robot/positioner common base to floor.
5. Level AEC base by adjusting leveling bolts (see Figure 4-11).
6. Insert a 1/2-inch concrete drill bit through center of leveling bolts and drill
holes for lag bolts.
7. Vacuum concrete dust from holes.
8. Lag auxiliary equipment common base to floor.
MOTOMAN
4-9
FabWorld II System Manual
INSTALLATION
LEVELING BOLT
YASNAC XRC SK16X
POTS YCNEGREME
NO OVRES
YDAER
EDOM
HCAET
YALP
NO
KCOL TIDE
T
PIR
MRALA
TRATS
DLOH
)FFO(
ETOMER
)NO(
FFO
TE
SE
R/
ALARM
ROBOT HOLD
CYCLE LATCHED
NE
OP
OPERATOR STATION
ENABLE / DISABLE
SERVO ON
AB
MASTER JOB
START
AB
POSITIONER
AUTO/MAN
AB
M
ERGENC
Y
E
RESET
BLK
AB
STOP
LEVELING BOLT
Figure 4-11 Robot/Positioner Base Leveling Bolts
FabWorld II System Manual
4-10
MOTOMAN
INSTALLATION
4.9
Connecting the Cables
After components are level and securely in place, the cables should be unwrapped
from around the equipment and laid out according to the cable diagram included in
the system drawing package. Each cable connection is clearly identified for ease of
installation.
CAUTION!
Route wires and cables away from hazardous work areas to avoid
wire breakage and unnecessary interruption of cell operation.
4.9.1
Connecting the Earth Ground
The robot and the XRC must each be connected to an earth ground. An earth
ground is a ground in which the equipment is connected to a ground stake driven
into the earth. The ground stake must be driven a minimum of eight feet into the
earth, and the earth must be treated with chemicals in order to reduce resistance to
the ground stake. Deeper ground stakes may be required depending on area soil
conditions. A maximum of 100 ohms ground resistance is recommended. To
ground the robot and the XRC, proceed as follows:
WARNING!
• If proper earth grounds cannot be provided, do not use the
equipment! Serious injury or death can occur.
• Do not place the MIG system within 50 feet of other sources of
noise (i.e., GTAW arc starters, plasma cutters, induction
furnaces, high-power-resistance spot welders, dielectric
heaters, etc.). Equipment that generates impulse or highfrequency noise can cause unexpected equipment operation and
failure, which can result in serious injury or death.
NOTE:
If the robot and the XRC are within 15 feet of each other, a common earth ground may be used.
Otherwise, separate earth grounds must be used.
1. Connect one end of robot earth ground cable to lug marked EARTH
GROUND on bottom back of robot.
2. Connect other end of robot earth ground cable to earth ground stake.
3. Connect one end of second earth ground cable to common ground bus bar
inside XRC.
4. Connect other end of second earth ground cable to earth ground stake.
MOTOMAN
4-11
FabWorld II System Manual
INSTALLATION
4.9.2
Connecting the Robot Cables
Two cables, 1BC and 2BC, connect the robot to the XRC controller. The 1BC
cable supplies power to the robot servo motors. The 2BC cable provides
communication between the controller and the robot.
CAUTION!
Route wires and cables inside robot/positioner common base to
avoid wire breakage and unnecessary interruption of cell operation
(see Figure 4-12).
YASNAC XRC SK16X
POTS YCNEGREME
NO OVRES
YDAER
EDOM
HCAET
YALP
NO
KCOL TIDE
PIR
T
MRALA
TRATS
DLOH
)FFO(
ETOMER
)NO(
FFO
E
TE
SE
R/
N
OP
Figure 4-12 Robot Cable and Hose Routing
If the robot has a water-cooled torch, two cables and three hoses must be
connected to various components. If the robot has an air-cooled torch, two cables
and one hose must be connected to various components. These cables and hoses
are enclosed in a leather casing. In addition to these cables, the robot I/O and
power cables must be connected to the robot. To connect the robot and system
cables and hoses, proceed as follows:
1. Unpack programming pendant and plug connector into receptacle on right
side of XRC controller.
2. Unpack two large black manipulator cables, connected to XRC controller,
and route to back of robot (see Figure 4-12).
3. Carefully engaging connectors, connect two cables (labeled 1BC and 2BC)
to 1BC and 2BC connections on back of robot (see Figure 4-13).
FabWorld II System Manual
4-12
MOTOMAN
INSTALLATION
FROM XRC
CONTROLLER
Figure 4-13 Connecting Robot to XRC Controller
4.9.3
Connecting the System Interface Box
The system interface box is mounted on the back of the system fencing. To connect
the system interface box, proceed as follows:
1. Locate and unpack Door Switch cable and connect to side of interface box.
2. Unpack safety mat cable and connect between safety mat junction box and
interface box.
3. Unpack operator station cable and connect to interface box.
4. Unpack two positioner cables from interface box and connect to left side of
XRC cabinet.
MOTOMAN
4-13
FabWorld II System Manual
INSTALLATION
4.9.4
Connecting Water Circulator (Optional)
If your system uses the water-cooled welding torch, it is necessary to connect the
Motoman water circulator. To connect the water circulator, proceed as follows:
1. Connect two water hoses for weld torch to connections on water circulator
marked WATER-IN and WATER-OUT (see Figure 4-14).
WATER OUT
WATER IN
TO POWER SOURCE
Figure 4-14 Water Circulator Connections
2. Plug power cable into electrical outlet on back of power source.
4.10
Connecting the Power
After all of the system components have been properly installed, connect the
power to the FabWorld II. To connect incoming power to the FabWorld II, proceed
as follows:
DANGER!
Power should be connected only by a qualified electrician. Electrical
and grounding connections must comply with applicable portions of
the national electrical code and/or local electrical codes or damage
could occur.
1. Install 3-phase power wiring to the circuit breaker located inside the right
wall of the XRC cabinet (see Figure 4-15). Table 4-1 shows the size and type
of wire needed.
2. Tighten screws to the torque indicated in Table 4-1.
FabWorld II System Manual
4-14
MOTOMAN
INSTALLATION
CONNECT INCOMING,
3-PHASE POWER HERE
M5 THREADED STUD
(Ground Termination)
ON
YASN
AC
TRIP
OFF
SERVO
ON
READY
XRC
SK16X
MODE
PLAY
TEACH
EN
SET
/RE
EMERGEN
CY STOP
OP
EDIT
(OFF)
LOCK
(ON)
REMOTE
ALARM
HOLD
START
POWER DISCONNECT
THE
MANIPU
SHOULD
LATOR
HAVE
ORDER.
NO.
AND
THE
THE
CONTRO
SAME
ORDER
LLER
SSM179
NUMBER
-1-7
N.J1S30
YASNAC
XRC
TYPE
POWER ENCM-RX60
SUPPLY
200/220V
03
50/60HZ
SERIAL
3PHASE
DATE NO.
SSM179-2-1
10-1998
YASKAWA
3.0KVA
0-1
P/N
ELECTRIC 16
CORPORA
MADE
IN JAPAN
TION
NJX03-1
Figure 4-15 Incoming Power Connections
3. Install an M5 lug on the incoming ground wire.
4. Terminate the ground wire to the frame ground M5 threaded stud with M5
hardware provided.
NOTE:
MOTOMAN
The FabWorld II is configured for three-phase 460/480V AC, unless other voltage was
requested. If other voltage is required for your plant, you must make the necessary
modifications to the transformer. For more information, refer to the manipulator manual that
came with your system.
Table 4-1 Incoming Power Connections
Lug Data
60/75˚ C wire
Catalog No.
TCAL14
Wire Size
#14-7 Copper
#12-8 Aluminum
Torque
#14-7, 4.0 N•m (35 lb.-in.)
4-15
FabWorld II System Manual
INSTALLATION
4.11
Conducting a Safety/Operation Check
Before installing the tooling and fixtures for your application, take a few minutes
to perform a safety/operation check. To conduct a safety/operation check, proceed
as follows:
1. Check that all three yellow shipping brackets have been removed from the
robot (see Section 4.3.1).
2. Be sure the safety mats are placed correctly (see Section 4-6).
3. Check that the cell door is closed and latched.
4. Check that all cable connections are tight.
5. Check air line connections to the optional torch tender and wire cutter.
6. Be sure that the welding power source is set correctly (refer to the welding
power source vendor's manual).
7. Verify that incoming line power matches the input power specified on the
sticker on the front of the XRC.
Your FabWorld II is now ready for power-up. The FabWorld system should be
operated only by personnel who have received operator training from Motoman
and who are familiar with the operation of this Motoman system. Turn the main
power ON, and continue the safety/operation check.
8. Check operation of all system E-STOPS (pendant, operator station,
breakaways, playback panel).
9. Check operation of system Hold buttons.
4.12
Installation of Tooling and Fixtures
Your FabWorld II system is now ready for the installation of tooling and fixtures
for your application. Installation of tooling and fixtures should be performed by
personnel who are familiar with the operation of this system. Tooling and fixtures
are supplied by the customer. After tooling is installed, test the positioner for
proper operation.
FabWorld II System Manual
4-16
MOTOMAN
SECTION 5
OPERATION
The FabWorld II is a fully integrated robotic GMAW welding cell. The robot
welds parts on the active station. Once the robot is finished with this process, it
returns to the Safe position. The operator is then able to enter the safety zone and
safely process the parts.
5.1
Programming
The operation of this system is programming dependent. The following operating
instructions are based on one possible configuration of this system. Your system
configuration and job structure may differ slightly from that presented here,
however basic operation will be the same.
Any changes made to your system configuration and/or job structure will alter the
operation of this cell. Motoman recommends you do not modify the original jobs
and system configuration that came with your system. If modifications need to be
made, they should be made to copies of these jobs and not to the originals. If you
need to modify existing jobs, make copies of originals first. This way you will
always be able restore your systems to the original configuration. Modifications
should only be performed by personnel who have received operator training from
Motoman, and who are familiar with the operation of this Motoman system. If you
have questions concerning the configuration of your system please contact the 24
hour Service Hotline, at (937) 847-3200 (see Section 1.5).
5.1.1
I/O Assignment
The FabWorld II uses the following user and dedicated inputs and outputs (see
Table 5-1 and Table 5-2).
XRC Dedicated Inputs
• Servo On
• External Job Start
• Alarm Reset
• REMOTE mode ON
• Hold
• External Emergency Stop
XRC Dedicated Outputs
•
•
•
•
Servo Power ON
TEACH mode
Cube 24
Alarm Occurrence
For more information on user and dedicated I/O, refer to the XRC Concurrent I/O
Parameters Manual (P/N 142102-1).
MOTOMAN
5-1
FabWorld II System Manual
OPERATION
Table 5-1 XRC User Inputs
Input
Assignment
IN#001
CYCLE START S1
IN#002
AUTO/MANUAL
IN#003
CYCLE START S2
IN#004
ZONE 1 ACTIVE
IN#005
ZONE 3 ACTIVE
IN#006
HS1 IN SAFE
IN#007
HS2 IN SAFE
IN#008
IN#009
S1 FORWARD
IN#010
S1 HOME
IN#011
S1 REVERSE
IN#012
S2 FORWARD
IN#013
S2 HOME
IN#014
S2 REVERSE
IN#015 thru 016
NOT USED
Table 5-2 XRC User Outputs
Output
5.1.2
Assignment
OUT#001
STATION1 LATCHED
OUT#002
STATION2 LATCHED
OUT#003 thru 016
NOT USED
Programming the Positioner
The rotation axis of the positioner(s) is controlled by the XRC external axis
function. The motion points for the external axes are taught and recorded in the
program in the same manner as any of the robot axes. The speed and position are
controlled by the XRC. Pressing the GROUP AXIS button on the teach pendant
changes the motion keys from robot axis keys to positioner axis keys.
FabWorld II System Manual
5-2
MOTOMAN
OPERATION
5.2
Daily Operation
The procedures below represent the typical operating sequence from power up to
shutdown. Yours basic operating procedures may vary depending on your situation.
• Perform Start-up Procedures.
• Move robot to Safe position.
• Select master job.
• Perform Operation Cycle.
• Perform Shutdown Procedures.
5.2.1
Start-Up
To start up the FabWorld II cell from a Power-Off condition, proceed as follows:
1. Turn on welding power source disconnect.
2. Set MAIN POWER switch on XRC to ON.
3. Set INPUT POWER switch on welding power source to ON.
4. Open regulator valve on welding gas supply.
5. Make sure enclosure door is closed and securely latched.
6. Disable operator station.
7. Press TEACH mode button on XRC playback panel.
8. Place robot in Safe position (Cube 24).
5.2.2
Robot Safe (Cube 24) Position
To move the robot to the Safe position (Cube 24), proceed as follows:
1. Press TEACH mode button on XRC playback panel.
2. Press TOP MENU on programming pendant.
3. Select JOB icon using cursor keys and press SELECT.
4. Cursor to SELECT JOB and press SELECT key.
5. Using cursor keys, move cursor to Cube 24 job and press SELECT. Cube 24
job appears on display screen.
6. Turn servo power ON by pressing SERVO ON, pressing TEACH LOCK and
holding in ENABLE switch.
7. Use INTERLOCK and FWD buttons on programming pendant to jog robot
to Safe (Cube 24) position.
5.2.3
Starting the Master Job
With the system powered up and in TEACH mode, call up the Master job, then
proceed as follows:
1. Press TOP MENU key on programming pendant.
2. Select JOB icon using cursor keys and press SELECT.
3. Cursor to SELECT JOB and press SELECT key. Job list appears on display
screen.
4. Using cursor keys, move cursor to Master job and press SELECT. Master job
appears on display screen.
5. Make sure both enclosure doors are closed and securely latched.
MOTOMAN
5-3
FabWorld II System Manual
OPERATION
6. Press PLAY mode button on XRC playback panel. Job playback operation is
enabled.
7. Press SERVO ON button on playback panel.
8. Reset positioner by simultaneously pressing RESET and right CYCLE
START buttons on operator station.
9. Place ENABLE/DISABLE switch on operator station in ENABLE position.
XRC is placed in REMOTE mode and system control is transferred to
operator station.
10. Press MASTER JOB START button on operator station. The Master job
cycles, waiting for a Cycle Start input from operator station.
The FabWorld II cell is now ready for operation.
5.2.4
Perform Operation Cycle
Rotary Positioners
1. Load parts onto both sides of fixture at station 1.
2. Press both CYCLE START palm buttons on operator station 1. CYCLE
LATCHED light comes on and robot begins welding parts at zone 1.
3. During zone 1 welding process, load zone 3 fixture with parts on both sides
and press both CYCLE START palm buttons.
4. When robot finishes welding, it returns to Safe position in zone 2 then begins
welding in zone 3. This allows the operator to enter zone1 and process parts.
NOTE:
Before sweeping at first power up, make sure the correct job has been loaded.
Stationary Flat Plane Module
1. Load parts onto fixture at zone 1.
2. Press both CYCLE START palm buttons on operator station 1. CYCLE
LATCHED light comes on and robot begins welding parts at zone 1.
3. During zone 1 welding process, load zone 3 fixture with parts and press both
CYCLE START palm buttons.
4. When robot finishes welding, it returns to Safe position in zone 2 then begins
welding in zone 3. This allows the operator to enter zone1 and process parts.
NOTE:
Before sweeping at first power up, make sure the correct job has been loaded.
Loading the Positioner
The headstock tooling plate can be rotated from the home position (zero degrees)
using the three-position joystick at the operator station. Moving the joystick
FORWARD rotates the headstock tooling plate clockwise 30 degree while moving
it to REVERSE rotates the tooling plate counterclockwise.
As the tooling plate rotates, a factory installed screw located at home position,
activate a limit switch. When activated, the limit switch overrides the safety mat
functions. That allows operator access to the positioner without disrupting cycle
time in the other zone.
Safety mat functions are active during rotation of the headstock because the next
tooling plate screw have not yet reached the limit switch.
Eleven user defined load positions (see Figure 5-1) are available on the tooling
plate at 30 degree intervals. One additional set of screws, to be used for a user
defined load position, are provided.
NOTE:
A screw with washer must be used at the user defined load position holes.
FabWorld II System Manual
5-4
MOTOMAN
OPERATION
Home Position
Once the positioner is loaded properly, step off the safety mat and select
HOME POSITION on the joystick. The headstock will rotate back to zero
degrees position with the screw(s) activating the limit switch to allow CYCLE
START.
Depress both CYCLE START push buttons now to permit the robot to sweep
the positioner and begin to weld when ready.
SCREW
ADAPTER
PLATE
30º
USER DEFINED
LOAD POSITION
0º
LIMIT SWITCH
TOOLING
PLATE
FACTORY PRESET
HOME POSITION
Figure 5-1 MHT-680 HS/TS – Home/User Defined Load Positions
5.2.5
Shutdown
Use the following procedure to shut down the FabWorld II cell after operation is
complete:
1. Make sure the robot is in the Safe position (Cube 24).
2. Turn off system servo power by pressing E-STOP button on operator station,
programming pendant, or playback panel.
3. Press TEACH mode button on playback panel.
4. Set controller Main Power switch to OFF position.
5. Set Main Power switch on welding power source to OFF position.
6. Close regulator valve on welding gas supply.
The FabWorld II cell is now shut down.
MOTOMAN
5-5
FabWorld II System Manual
OPERATION
5.3
System Recovery
Under certain conditions you will be required to clear an alarm or error. Clearing
an alarm or error requires different operator actions depending on the type. The
paragraphs below describe the different types of alarms and errors you may
encounter and how to remedy them when you do.
5.3.1
Alarms and Errors
Alarms and errors will cause the program to stop. There are three levels of alarms
and errors: Error Messages, Minor Alarms, and Major Alarms. For more detailed
information about alarm recovery, refer to manipulator manual that came with
your system.
Error Messages
These are simple errors such as pressing the START button when the robot is not in
PLAY mode, or enabling the programming pendant without the servo power being
live. Errors like these are cleared by pressing the CANCEL button on the
programming pendant.
Minor Alarms
Minor alarms are usually programming errors. Minor alarms might occur if a circle
has been programmed with fewer than three circular points, etc. These alarms are
cleared by pressing the RESET (F5) soft key on the programming pendant.
Major Alarms
Major alarms are hardware failures. Major alarms might occur because of a servo
tracking error or an abnormal speed and are usually associated with crashes. To
clear these alarms, you must turn off the controller and then turn it on again.
FabWorld II System Manual
5-6
MOTOMAN
OPERATION
5.3.2
E-STOP Recovery
An E-STOP can occur under any of the following conditions:
• Pressing the E-STOP button on the operator station, programming pendant,
or playback panel.
• Opening sliding door on robot enclosure when robot is in PLAY mode.
• Stepping on safety mat when positioner is sweeping.
• Actuating shock sensor on torch mount.
To restart the FabWorld II system after an E-STOP condition occurs, follow the
procedure below.
1. To clear E-STOP condition, perform any of the following actions that apply:
• Release the E-STOP button on the operator station, programming
pendant, or XRC playback panel.
• Close sliding door.
• Step off safety mat.
• Clear Shock Sensor condition (see Section 5.3.3).
CAUTION!
If an emergency stop condition occurs while the positioner is
sweeping, the positioner will continue the sweep when system is
reinitialized.
2. Press SERVO ON button on operator station, or playback panel.
3. Press RESET button and right CYCLE START button on operator station to
initialize system.
4. Ensure operator station is enabled.
5. Press MASTER JOB START button on operator station.
The FabWorld II cell is now ready to continue operation.
MOTOMAN
5-7
FabWorld II System Manual
OPERATION
5.3.3
Shock Sensor Recovery
The FabWorld II welding package includes a Motoman gun mount. This mount is
designed to protect the torch from damage in case of a crash. A slight deflection of
the torch activates a SHOCK SENSOR message, which triggers an E-STOP
condition. To clear the E-STOP condition, you must override the shock sensor and
move the robot clear of the impact. To override the shock sensor, proceed as
follows:
CAUTION!
It is possible to crash the robot with the Shock Sensor Override
Switch left in the “Override” position. Always remember to
reactivate the Shock Sensor before continuing system operation.
1.
2.
3.
4.
5.
NOTE:
Press TOP MENU on programming pendant.
Select ROBOT icon using cursor keys and press SELECT.
Cursor to OVERRUN-S.SENSOR and press SELECT key.
Select RELEASE to release shock sensor.
Turn servo power ON by holding ENABLE switch on the programming
pendant and pressing SERVO ON.
TEACH LOCK must be ON to turn servo power on in TEACH mode.
6. Move manipulator clear of impact position.
The FabWorld II cell is now ready to continue operation.
5.3.4
Using the Brake Release
The brake release control panel is located on front of the XRC. Each axis brake is
controlled by an individual axis buttons. Simultaneously pressing the ENABLE
button and one of these axis buttons releases the indicated axis. To release the
brakes, proceed as follows:
1. Press E-STOP button on programming pendant, playback panel, or operator
station, to be sure servo power is OFF.
2. Provide adequate support for axis to be released. Support should withstand
payload of robot and approximate weight of robot. Listed below is the weight
of each robot available:
UP6 – 135kg (297 lb)
UP20 – 260kg (573 lb)
WARNING!
Releasing brakes could cause personal injury or machine damage.
Always support the axis to be released BEFORE you release it.
3. Release specific axis brake by pressing and holding corresponding axis
button and ENABLE button at same time.
NOTE:
You must hold both the axis and ENABLE buttons down for the axis to remain released.
Releasing either button will automatically lock the brakes again.
FabWorld II System Manual
5-8
MOTOMAN
SECTION 6
MAINTENANCE
6.1
Periodic Maintenance
Table 6-1 provides periodic maintenance items and intervals for the FabWorld II
system. Keep in mind that the maintenance intervals serve as guidelines only. You
should adjust the frequency of maintenance to suit your specific work conditions.
For periodic maintenance procedures and schedules for the individual components
of your FabWorld II, refer to the manipulator and additional manuals that came
with your system.
CAUTION!
Use only the antifreeze provided by Motoman. Automotive
antifreezes contain stop-leak additives that will clog the small torch
water-cooling ports, and damage the gaskets in the water circulator
pump.
Table 6-1 Periodic Maintenance
Frequency
Daily
Component
Procedure
Water circulator
(For water-cooled torch
applications only.)
Check the fluid in the water circulator.
Add fluid as required. Use only distilled
water and approved antifreeze (Motoman
P/N 131224-1).
Wire Cutter (option)
Clean the unit with detergent machine
cleaner.
Apply grease to the wire cutting mechanism through the grease zirk provided.
6 Months
PWF Pancake Wire Feeder
Clean feed roll grooves with industrial
machine cleaner. Replace feed rolls as
required.
Annually
Water Circulator Kit (option)
Flush the system completely. Refill as
needed.
5,000 hours
Shaft seal
Replace shaft seal. Contact Motoman
Service Department at (937) 847-3200.
20,000 hours
or 5 years
Lubrication
Flush and relubricate using Molywhite
grease.
20,000 hours
or 5 years
Overhaul
If worn or damaged, replace after
disconnecting the motor from the
controller. Contact Motoman Service
Department at (937) 847-3200.
Weekly
H=Hours of Operation
MOTOMAN
6-1
FabWorld II System Manual
MAINTENANCE
6.2
Fuse and Circuit Breaker Protection
Table 6-2 through Table 6-3 give the locations of fuses and circuit breakers that are
significant to the operation of the total system. In most cases, spare fuses are
placed in the accessory bag with the controller.
WARNING!
Replace fuses with those of the same type and rating. Replacement
with fuses of higher amperage rating or lower voltage will damage
the robot controller and/or auxiliary equipment, necessitating costly
replacement.
Abbreviations:
CB — designates circuit breaker
F, FU, or 101FU — designates fuse
Table 6-2 MotoArc 450 CV Fuses and Circuit Breaker
Designator
Rating
Part #
Location
Purpose
CB1
10A 115V
203627-7
Upper rear panel
Protects 115V circuit.
CB2
10A 24V
203627-7
Upper rear panel
Protects 24V circuit.
F1
0.5A
W-11166-11
On contactor box
Protects contactor circuit.
Table 6-3 Universal Welding Interface (UWI) Fuses
Designator
Rating
F1
8A 250V
FU1
4A 250V
FU2
Part #
Location
Purpose
On KXA motor
speed control
Limits damage from
shorts or component
breakdowns in DC power
supply module.
Wickman
19374K-4A
On interface board
Protects 115V circuit.
0.25A
125V
Wickman
19303K250A
On interface board
Protects shock sensor circuit.
FU3
0.5A
125V
Wickman
19303K500A
On interface board
Protects 24V circuit.
Fuse
1A 250V
TD-1
Front of ComArc
box
Protects 200V circuit.
FabWorld II System Manual
6-2
MOTOMAN
INDEX
Numerics
E
1-Cycle, Cycle Mode Symbol, 3-4
Earth Ground, Connecting, 4-11
Emergency Stop (E-STOP), 3-2, 3-3, 3-6
Emergency Stop (E-STOP), Operator Station, 3-6
Emergency Stops (E-STOP), 3-12
ENABLE Function Key, 3-4, 3-5
ENABLE Switch, 3-5, 3-12
Enable/Disable, Operator Station, 3-8
Equipment Description, 3-1
Error Messages, 5-6
E-STOP Recovery, 5-7
E-Stop, Status Symbol, 3-4
A
About this Document, 1-1
Active Joiner, 4-7, 4-8
Alarm, 3-7
Alarm, Operator Station, 3-7
Alarm, Status Symbol, 3-4
Alarm/Error, 3-2
Alarms and Errors, 5-6
ANSI/RIA, 2-1
ANSI/RIA R15.06 Robot Safety Standard, 3-11
Antifreeze, 6-1
Arc Screens, 3-12
Area Key, 3-4
Auto, Cycle Mode Symbol, 3-4
F
Fencing, 3-12
Fuse and Circuit Breaker Protection, 6-2
Fuses, 6-2
B
G
Brake Release, 3-13
Brake Release, Controller, 3-6
Brake Release, Using, 5-8
General Safeguarding Tips, 2-3
GMAW Torch, 3-11
C
High, Manual Speed Setting Symbol, 3-4
Hold, 3-2, 3-7
Hold, Status Symbol, 3-4
Home Position, 5-3
Capacity, Positioner Specifications, 3-9
Chassis, Positioner Specifications, 3-9
Circuit Breaker, 6-2
Clearing an alarm or error, 5-6
Connecting the Cables, 4-11
Cursor Key, 3-4
Customer Service Information, 1-3
Customer-Supplied Items, 4-1
Cycle Latched, 3-7
Cycle Mode, 3-4
Cycle Start, 3-6
Cycle Start, Operator Station, 3-6
Cylindrical, Cooridinate Symbol, 3-4
D
Dedicated, Inputs, 5-1
Dedicated. Outputs, 5-1
Display, 3-3
Display Area, 3-3
MOTOMAN
H
I
I/O Assignment, 5-1
Inching, Manual Speed Setting Symbol, 3-4
Inputs, 5-2
Inputs, Dedicated, 5-1
Inputs, User, 5-2
Installation, 4-1
Installation Safety, 2-4
Installing the Auxiliary Equipment Common Base, 4-4
Interference Cubes, 3-13
Interlocked Cell Door, 3-13
Introduction, 1-1
Introduction, Safety, 2-1
J
Joint, Cooridinate Symbol, 3-4
FabWorld II System Manual
INDEX
L
P (continued)
LCD display, 3-3
Leveling and Securing the Equipment, 4-9
List of Tools, 4-1
Loading the Positioner, 5-3
Low, Manual Speed Setting Symbol, 3-4
Positioner Module, 3-9
MHT-680 HS/TS Positioner, 3-9
Programming, 5-2
Specifications, 3-9
Stationary Flat Plane Module, 3-9
Power Sources, 3-10
Power, Connecting, 4-14
Programming Pendant, 3-3
Programming Safety, 2-4
Programming-Operation, 5-1
M
Maintenance, 6-1
Maintenance Safety, 2-6
Major Alarms, 5-6
Manual Speed Setting, 3-4
Master Job Start, Operator Station, 3-7
Master Job, Starting, 5-5
Materials Required, 4-1
Mechanical Safety Devices, 2-3
Medium, Manual Speed Setting Symbol, 3-4
Menu Area, 3-3
Minor Alarms, 5-6
Mode, 3-2
Mode Select, 3-2
MotoArc 450 CV Fuses and Circuit Breaker, 6-2
O
Operation, 5-1
Rotary Positioners, 5-3
Stationary Flat Plane Module, 5-3
Operation Safety, 2-5
Operation, Daily, 5-3
Operator Station Description, 3-6
Operator Station, Installation, 4-6
Optional Equipment, 1-3
Outputs, 5-2
Outputs, Dedicated, 5-1
Outputs, User, 5-2
Outputs-dedicated, 5-1
P
Payload, 3-1
Periodic Maintenance, 6-1
Playback Panel, 3-2
Positioner Auto/Manual, 3-7
Positioner Auto/Manual, Operator Station, 3-7
Positioner Location Adjustment, 4-6
FabWorld II System Manual
R
Reach Capabilties, 3-1
Reference to Other Documentation, 1-3
Relative Positioning Accuracy, 3-1
Reset, 3-8
Reset, Operator Station, 3-8
Restarting the FabWorld II System, 5-7
Robot and Positioner Common Base, Installing, 4-2
Robot Cables, Connecting, 4-12
Robot Description, 3-1
Robot Language, 3-3
Robot Safe (Cube 24) Position, 5-5
Robot Sales Order Number, 1-3
Robot Serial Number, 1-3
Robotic Industries Association, 2-1
Rotation, 3-9
RS-232C Serial Port, 3-5
Running/Start, Status Symbol, 3-4
S
Safety, 2-1
Safety Features, 3-11
Safety Mat
Description, 3-12
Finish Installation, 4-8
Installation, 4-7
Mat Layout, 4-7
Preparation, 4-7
Set Up, 4-8
Safety/Operation Check, 4-16
Select Key, 3-5
Servo On Ready, 3-2
Servo On, Operator Station, 3-8
MOTOMAN
INDEX
S (continued)
W
Servo Power, 3-2
Shipping Brackets, Removal, 4-4
Shock Sensor Override Switch, 5-8
Shock Sensor Recovery, 5-8
Shutdown, 5-5
Site Preparation, 4-2
Software Version, 1-3
Spare Parts List, 6-1
Standard Conventions, Safety, 2-2
Start, 3-2
Start-Up, 5-4
Station Ready, 3-7
Status Area, 3-4
Step, Cycle Mode Symbol, 3-4
Stop, Status Symbol, 3-4
Sweep Time, 3-9
System Interface Box, Connecting, 4-13
System Layout, 1-2
System Overview, 1-2
System Recovery, 5-6
Water Circulator Pump, 6-1
Water Circulator, Connecting, 4-14
Welding Equipment, 3-10
Welding Ground System, 3-13
Wire Feeder, 3-11
World, Cooridinate Symbol, 3-4
X
XRC Controller, 3-1
T
TEACH LOCK Key, 3-5
Three-position Joystick, Operator Station, 3-7
Tool, Cooridinate Symbol, 3-4
Tooling and Fixtures, Installation, 4-16
Top Menu Key, 3-4
ARC WELDING, GENERAL, HANDLING, and SPOT
WELDING, 3-4
IN/OUT, 3-4
JOB, 3-4
ROBOT, 3-4
SYSTEM INFO, 3-4
VARIABLE, 3-4
Torch Mount, 3-11
U
Universal Welding Interface (UWI), 3-11
Universal Welding Interface (UWI) Fuses, 6-2
User Frame, Cooridinate Symbol, 3-4
MOTOMAN
FabWorld II System Manual
INDEX
FabWorld II System Manual
MOTOMAN
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