Yaskawa Motoman DCI Server Owner's Manual

YASKAWA
DCISERVER
SYSTEM MANUAL
Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN XXXXXX INSTRUCTIONS
DX100 INSTRUCTIONS
DX100 OPERATOR’S MANUAL
DX100 MAINTENANCE MANUAL
The DX100 operator’s manual above corresponds to specific usage.
Be sure to use the appropriate manual.
Part Number:
Revision:
YASKAWA
159529-1CD
0
MANUAL NO.
159529-1CD 0
159529-1CD
DCIServer
•
This system manual provides an overview of the Yaskawa
DCIServer. It gives general information about the system, a
description of its major components, and the procedures for
installation, system operation, and preventive and repair
maintenance. Be sure to read and understand this manual
thoroughly before installing and operating the DCIServer system.
•
General items related to safety are listed in Section 2 of the DX100
Controller Manual. To ensure correct and safe operation, carefully
read the DX100 Controller Manual before reading this manual.
•
Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure that all covers and shields
are replaced before operating this product.
•
The drawings and photos in this manual are representative
examples, and differences may exist between them and the
delivered product.
•
YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications.
•
If such a modification is made, the manual number will also be
revised.
•
If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
•
YASKAWA is not responsible for incidents arising from
unauthorized modification of its products. Unauthorized modification
voids your product's warranty.
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the Yaskawa DCIServer system.
In this manual, the Notes for Safe Operation are classified as
“WARNING,” “CAUTION,” “MANDATORY,” or “PROHIBITED.”
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
Always be sure to follow explicitly the
items listed under this heading.
Must never be performed
Even items described as “CAUTION” may result in a serious accident in
some situations. At any rate, be sure to follow these important items.
To ensure safe and efficient operation at all times, be sure to
follow all instructions, even if not designated as "CAUTION"
and "WARNING."
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•
Before operating the manipulator, check that servo power is turned
OFF by pressing the EMERGENCY STOP buttons on the operator
station or Programming Pendant (refer to Figure 1). When servo
power is turned OFF, the SERVO ON LED on the Programming
Pendant is turned OFF.
Injury or damage to machinery may result if the Emergency Stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the EMERGENCY STOP buttons do not function.
Figure 1: EMERGENCY STOP Button
•
Release the EMERGENCY STOP button (refer to Figure 2). Once
this button is released, clear the cell of all items which could
interfere with the operation of the manipulator. Then turn servo
power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 2 : Release of EMERGENCY STOP Button
•
Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Ensure that you have a safe place to retreat to in case of
emergency.
Improper or unintended manipulator operation may result in injury.
•
Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning on the power for the DX100 controller.
– Moving the manipulator with the Programming Pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an EMERGENCY STOP
button immediately if there is a problem. The EMERGENCY STOP
buttons are located on the operator station and on the Programming
Pendant.
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Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately and be sure that all other necessary processing has
been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
•
Always return the Programming Pendant to the hook on the cabinet
of the DX100 controller after use.
The Programming Pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
•
Read and understand the Explanation of Warning Labels in the
DX100 Controller Manual before operating the DCIServer system.
Definition of Terms Used Often in This Manual
The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the Programming
Pendant, and supply cables.
In this manual, the equipment is designated as follows:
Equipment
Manual Designation
DX100 controller
DX100
DX100 Programming Pendant
Programming Pendant
Cable between the manipulator and the
controller
Manipulator cable
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Explanation of Warning Labels
The following warning labels are attached to the manipulator (refer to
Figure 3).
Always follow the warnings on the labels.
Also, an identification label with important information is placed on the
body of the manipulator. Prior to operating the manipulator, confirm the
contents.
Figure 3: Warning Labels Location
WARNING Label A
WARNING Label B
Nameplate
Nameplate:
WARNING Label A:
WARNIN
MOTOMAN
TYPE
PAYLOAD
ORDER NO.
kg
MASS
Moving parts
may cause
in ury
kg
DATE
SERIAL NO.
YASKAWA ELECTRIC CORPORATION JAPAN
WARNING Label B:
WARNIN
Do not enter
robot
work area.
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Contents
1 Introduction ..................................................................................................................................... 1-1
1.1 About This Document ........................................................................................................ 1-1
1.2 System Requirements........................................................................................................ 1-1
1.3 Reference Documentation ................................................................................................. 1-1
1.4 Customer Support Information........................................................................................... 1-3
2 Installation ....................................................................................................................................... 2-1
2.1 PC Installation.................................................................................................................... 2-1
2.1.1 Hardware Key Installation..................................................................................... 2-3
2.2 Controller Setup ................................................................................................................. 2-3
2.2.1 NX100 Controller Setup........................................................................................ 2-3
2.2.2 DX100 Controller Setup........................................................................................ 2-4
2.3 DCIServer INI File.............................................................................................................. 2-5
3 Variable Editor................................................................................................................................. 3-1
3.1 Index Variable .................................................................................................................... 3-1
3.2 Saving Variables to the PC ................................................................................................ 3-2
3.3 Loading Variables from the PC .......................................................................................... 3-3
3.4 Loading and Saving Job Files............................................................................................ 3-4
3.5 Using the Variable Editor ................................................................................................... 3-5
3.6 Closing a DCIServer Session ............................................................................................ 3-5
3.7 Variable Transfer ............................................................................................................... 3-6
4 Operation ........................................................................................................................................ 4-1
4.1 Main Window ..................................................................................................................... 4-1
4.2 Robot Specific Screen ....................................................................................................... 4-2
4.3 Variable Editor ................................................................................................................... 4-3
4.3.1 Assigning Variable Labels .................................................................................... 4-3
4.3.2 Saving Configuration Files.................................................................................... 4-4
4.3.3 Opening a New Configuration File........................................................................ 4-4
4.3.4 Opening an Existing Configuration File ................................................................ 4-4
4.4 Setting Communications Parameters ................................................................................ 4-5
4.4.1 Communications Setup Options ........................................................................... 4-5
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Contents
5 Programming Tips........................................................................................................................... 5-1
5.1 Optimizing for Cycle Time.................................................................................................. 5-1
5.2 Optimizing for Variable Latency......................................................................................... 5-1
5.3 Optimizing Memory Usage ................................................................................................ 5-1
5.4 Troubleshooting ................................................................................................................. 5-2
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1.1
DCIServer
1
Introduction
About This Document
Introduction
1.1
About This Document
DCIServer is an advanced robot controller communications service. It
serves requests for loading and saving job files and variables to and from
the robot controller. DCIServer also supports simultaneous
communication between the server and multiple controllers. The setup of
the controllers is maintained in an ini file. This manual contains the
following sections:
Section 1 – Introduction
This section provides general information about the DCIServer function, a
list of reference documents, and customer support contact information.
Section 2 – Installation
This section provides a description of the major components of the
DCIServer function.
Section 3 – Variable Editor
This section provides installation procedures for the DCIServer function.
Section 4 – Operation
This section provides an overview of DCIServer function operation,
including start-up, loading, normal operations, fault recovery, and system
shutdown.
Section 5 – Programming Tips
This section provides programming tips for the DCIServer.
1.2
System Requirements
• Supported Robot Controllers - NX100, and DX100
• Operating System - Microsoft Windows 2000, XP, or Server 2003
• Ethernet Function
1.3
Reference Documentation
For additional information on individual components of the DCIServer
system, refer to the following documentation that is included with your
system:
• Motoman DX100 Controller Manual (P/N 155494-1CD)
• Motoman NX100 Controller Manual (P/N 149201-1CD)
• Motoman Maintenance Manual for DX100 (P/N 155492-1CD)
• Motoman Operator's Manual for General (P/N 155507-1CD)
• Motoman DX100 Concurrent I/O Manual (P/N 155491-1CD)
• Motoman NX100 Concurrent I/O Manual (P/N 149230-1CD)
• Motoman INFORM User’s Manual (P/N 155493-1CD)
• Motoman INFORM User’s Manual (P/N 150078-1CD)
• Vendor manuals for system components not manufactured by
Yaskawa
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1.4
DCIServer
1.4
Introduction
Customer Support Information
Customer Support Information
If you need assistance with any aspect of your DCIServer system, please
contact Motoman Customer Support at the following 24-hour telephone
number:
(937) 847-3200
For routine technical inquiries, you can also contact Motoman Customer
Support at the following e-mail address:
[email protected]
When using e-mail to contact Motoman Customer Support, please provide
a detailed description of your issue, along with complete contact
information. Please allow approximately 24 to 36 hours for a response to
your inquiry.
Please use e-mail for routine inquiries only. If you have an
urgent or emergency need for service, replacement parts,
or information, you must contact Motoman Customer
Support at the telephone number shown above.
Please have the following information ready before you call:
• System
DCIServer
• Primary Application
Arc Welding, Handling, etc.
• Controller
NX100, DX100
• Software Version
Access this information on the
Programming Pendant’s LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} {VERSION}
• Robot Serial Number
Located on the robot data plate
• Robot Sales Order Number
Located on the controller data
plate
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2.1
DCIServer
2
Installation
PC Installation
Installation
2.1
PC Installation
MotoSoft software is provided on a single DVD-ROM with a browser/
installer utility. (Motoman DVD-ROM Browser, P/N 141720-1). You must
install DCIServer from the Motoman DVD Browser onto your hard drive;
you cannot run the program from the DVD. Please refer to the CD
Browser for detailed installation instructions.
By default, DCIServer is installed in c:\Program Files\Yaskawa America
Inc\DCIServer\.
It is necessary to remove all previous installations of
DCIServer. To uninstall DCIServer, proceed as follows:
1. Double-click Add/Remove Programs in the Windows
Control Panel.
2. Select "DCIServer" from the list and click Add/Remove.
3. Click Yes to confirm deletion of the DCIServer program
files.
To install DCIServer, proceed as follows:
1.
Insert CD Browser into your CD-ROM drive.
2. The setup program starts automatically.
Setup executes automatically when the DVD is inserted into
the DVD-ROM drive unless auto execute has been disabled
on your computer. If the setup program fails to auto
execute, refer to the directions on the DVD label for more
information. You may be required to reboot your PC before
continuing with the installation.
3. Click the Communication Software button.
4. Select DCIServer and follow the install wizard instructions as it guides
you through the installation process.
5. During installation, MotoCmd Hub is also installed. Select “Both” Client
and Server installation.
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2.1
Installation
PC Installation
6. Select the network interface card used to communicate with the robot.
7. The option 'Produce communication log' enables a log file with
detailed information about the communication server to be produced.
The option 'Debug mode' is used by software developers and should
be disabled by default.
8. Click OK to proceed.
9. When installation is complete, click [Finish]. Shortcuts to the
DCIServer software are installed on the Desktop as well as in the
Programs folder of the Start Menu.
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2.2
DCIServer
2.1.1
Installation
Controller Setup
Hardware Key Installation
The hardware key supplied with DCIServer must be installed on your
computer or DCIServer will not function properly. The hardware key
attaches to the computer’s USB port. This port is commonly used to
connect printers and other peripheral devices to your computer. To attach
the hardware key, proceed as follows:
1. Disconnect any device currently connected to your computer’s parallel
port.
2. Carefully insert the hardware key into the USB port. If the key does not
fit, do not force it. The key should fit snugly but does not require
significant force to insert.
2.2
Controller Setup
Before you can begin using DCIServer, you must establish an ethernet
connection between the robot controller and remote PC, and set
transmission parameters for your system. To complete setup, complete
the appropriate steps for your controller.
2.2.1
NX100 Controller Setup
DCIServer requires a standard Ethernet cable (category 5 or more) to
connect the PC to the NX100 controller. A shielded Ethernet cable is
recommended to reduce noise in an industrial environment. If you are not
using a switch/router, you may require a crossover Ethernet cable.
Connect the Ethernet cable (shielded cable; category 5 or more) to the
RJ-45 transmission connector located on the bottom of the NCP01 board
inside the CPU rack.
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2.2
DCIServer
Installation
Controller Setup
Control circuit board
JANCD-NCP01
CPU
TYPE JANCD-NCP01
TYPE
JANCD-NCP01
DATE
REV
SUPPLY
POWER
CPS-NX1
No.
DATE
FujiElectricCo.,Ltd.
JAPAN
LED
0 1
SOURCE
01020304050607080910
11121314151617181920
21222324252627282930
+5VSB
A B C D E F GH J K
L MN P Q R S T U V
PON
CNSP1
+5V
+24V
CNTU
VIDEO
OTHER
FAN
CNRI
OHT
CNM
CN05
(+24V1)
CNRO
CN04
(+24V2)
IDE
CNFAN
CN03
(TU)
ATX
CNBAT
USB1(L)
USB1(R)
CN02
(REMOTE)
CN01
(AC IN)
INPUT
200-240V AC
50/60Hz
3A
PS2
Front Face (View without Cover)
(LAN0)
Data transmission function connector
(LAN1)
Programming pendant connector
Bottom Face
2.2.2
DX100 Controller Setup
DCIServer requires a standard Ethernet cable (category 5 or more) to
connect the PC to the DX100 controller. A shielded Ethernet cable is
recommended to reduce noise in an industrial environment. If you are not
using a switch/router, you may require a crossover Ethernet cable.
Connect the Ethernet cable (category 5 or more) to the CN104 RJ-45 LAN
connector which is located on the front face of the YCP01 board inside the
CPU rack.
There are two RJ-45 connectors at the front face of the
YCP01 board. CN104 is the bottom one used for the
Ethernet function. Do not use the CN105 connection as it is
used exclusively for the programming pendant.
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2.3
DCIServer
Installation
DCIServer INI File
Fig. 2-1: Fig. Ethernet Connection
DX100
CONTROLLER
NX100/
TYPE
ERCR-
POWER!SUPPLY
480V
50/60Hz
3PHASE
INTERRUPT!CURRENT
kVA
kA
SERIAL!No.
DATE
MADE!IN!JAPAN
NJ2533-1
NJ1530
WARNING:
DISCONNECT AND LOCKOUT
MAIN POWER BEFORE
SERVICING
PENDANT
CN107
PENDANT
CONNECTION
(CN-105)
CN106
CN105
CN104
CN103
JANCD-YCP01- E
ETHERNET
CONNECTION
(CN-104)
USER SUPPLIED
COMPUTER
(Ethernet Cable)
Cutouts are available on the sides of the controller cabinet for cable
routing.
Refer to Section 3.3 “Ethernet Communication Settings” of the Ethernet
Function manual (P/N 157130-1CD) for setup instructions.
2.3
DCIServer INI File
Before using DCIServer, there must be a valid INI file installed in the PC
installation folder that matches your real work cell configuration. This INI
file controls various parameters about the communications between the
robot and the PC. The default location is 'C:\Program
Files\Motoman\DCIServer'.
The default INI file looks like this...
# DCIServer settings
# ==================
# General Settings #
# Customer -Name used to identify this instance of DCI Server.
# NbrRobots -Number of robots in use. Valid values range from 1-16.
#
# Robot Specific Settings #
# IP -IP Address in this format: xxx.xxx.xxx.xxx e.g 192.168.255.1
# Name -Name representing each defined robot. This name will be
referenced on the robot button.
# Path -An absolute path to the robot specific service folder.
# BIndex -The B variable to use as the DCI 'Index' variable for SAVEV and
LOADV. Acceptable values are 0-99.
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DCIServer INI File
# SevenAxis -Used to notify DCI Server that the robot has seven axis.
Valid values are 0 = six axis, 1 = seven axis.
#
[Settings]
Customer=SES
NbrRobots=1
[Robot_1]
IP=192.168.255.1
Name=SES
Path=C:\Temp\SES
BIndex=99
SevenAxis=0
[Robot_2]
IP=
Name=
Path=
BIndex=
SevenAxis=
[Robot_3]
IP=
Name=
Path=
BIndex=
SevenAxis=
.....
There are two sections of importance. The parameters under the
[Settings] heading are global and effect all robots connected to the
DCIServer.
[Settings]
'Customer=' This value is displayed in the title bar of the main DCIServer
form.
'NbrRobots=' This parameter controls how many robots are used in the
system.
The robot settings are specified individually under a heading for each
robot. For example, the settings for robot 1 are listed under the [Robot 1]
heading.
[Robot 1]
'IP=' defines the IP Address of the robot controller
'Name=' defines the name that is used for the button and variable XML
file.
'Path=' defines the folder path to the location where the jobs and variable
XML file reside.
'BIndex=' defines the B variable that is used as the 'index' variable on the
robot.
'SevenAxis=' This informs DCIServer if a robot has seven axis. 0 indicates
a six axis robot and 1 indicates a seven axis robot.
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2.3
Installation
DCIServer INI File
This information is repeated for each active robot up to the system
maximum of 16.
If you make changes to the ini settings the computer must be re-started for
those changes to take affect.
In the main screen a 'Start' button is provided to manually start the
communication server. By default, a communication service is installed by
the setup program. This service launches automatically upon Windows
start up. Manual starting of the service is not necessary but is provided in
the event it is required for debugging purposes. When the communication
service is running this button text will display 'Stop' and act as a way to
stop the communication process. The communications service will
continue to run and function even after you close the DCIServer user
interface.
Each robot defined in the system INI has a button representing the
communication status of that robot as well as launch a detailed screen
about that individual robot. This button also changes color to indicate the
communications status. The button is gray during normal communication.
A warning turns the button yellow and an error turns the button red. There
is an automatic ping-service in DCIServer which checks the ability to
communicate with each robot at a random interval. If you make changes
to the ini settings the computer must be re-started for those changes to
take affect. However, the ping service does not guarantee that you have a
valid connection to the robot. An exception should be created for the
DCIServer application in the Windows fire wall if you are using it on the
selected interface card. Please consult the Windows help file for
information on how to create an exception. If a robot is unreachable, this
be considered an error and the button turns red.
If you click on a button, a controller-specific window appears:
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2.3
Installation
DCIServer INI File
This window shows the last 50 logs made for this particular robot. There is
a button for manual restart of the communication service for the robot.
This can be useful after a breakdown in communication. Another
important thing when restarting the communication is to make sure that
the robot is set to Teach mode and then back to Play mode before
restarting the robot job.
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3.1
DCIServer
3
Variable Editor
Index Variable
Variable Editor
This section introduces you to the variable editor. It contains:
• A brief overview of the mechanics of data transfer between controller
and DCIServer
• Information on creation and/or modification of required robot
program structure
• Detailed instructions for use of variable editor.
3.1
Index Variable
The variable names used to identify different variables have two
components. A prefix letter identifies the type of variable; B for byte, I for
integer, and R for real. The second component of the variable name is a
variable index with a value ranging from 00 to 99.
The controller commands LOADV and SAVEV do not send the variable
index to the PC. The PC receives only the type of variable (B, I, and R)
and its value. As a result, the PC has no way of knowing which of a
particular type of variable is being loaded or saved. Before the PC can
properly store or retrieve a variable, the controller must upload the
variable index to the PC.
In the case of P-variables, all P-variables being used in an application
must be uploaded before they can be downloaded. You must use an
Index Variable to identify the variable index. Any byte variable can be
used as the Index Variable. The default B index variable defined in the ini
file is B99. This can be changed to any B variable of your choosing.
In the sample programs listed in this section, B(00) is used as the Index
Variable. Every time the controller loads or saves a variable, it must first
issue a SET B00 command that specifies the appropriate variable index,
followed by a SAVEV B00. This gives the PC the variable index of the
variable to be saved or loaded. When the controller next gives a SAVEV or
LOADV command for a particular type of variable, the PC recognizes the
specific variable identified by the Index Variable, B(00).
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3.2
DCIServer
Variable Editor
Saving Variables to the PC
•
When stepping through or developing a program, make
sure that for each variable you want the program to load
or save you first set and save the Index Variable.
Otherwise, DCIServer and the controller will run out of
synchronization and cause various errors.
•
You do not need to specify an Index Variable to load or
save jobs. This requirement applies only to variables.
•
For additional information on variables and variable
types, refer to your Programming or Operator's Manual.
Creating/Modifying the Robot Program Structure DCIServer lets you
modify program variables while a robot is in cycle. However, it is the
controller that directs the operation of the robot. The controller must issue
requests to the PC to download variables to the controller.
NOP
CALL JOB: SAVEV ‘Call job to download variables from PC’
*mainloop ‘Identifies start of subroutine’
SET B00 1 ‘Index=1’
SAVEV B00 ‘B(01) is the variable being saved or uploaded to the PC’
CALL JOB: DC1 IF B01=1 ‘These three lines call job based on value of
variable B(01)’
CALL JOB: DC2 IF B01=2
CALL JOB: DC3 IF B01=3
JUMP *mainloop ‘Jumps back to beginning of subroutine, can include
conditional statement’
END
3.2
Saving Variables to the PC
Variables can be saved from the controller to the PC as often as required.
The following example shows how to save the desired variables from the
controller to the PC. Comments regarding specific program lines appear
to the right of the program line. These comments do not appear in the
actual program listing.
NOP
SET B00 1 ’Index=1’
SAVEV B00 ‘B(00) is an index counter whose value is the index of the
variable being saved - tells the PC which variable is to be loaded’
SAVEV B01 ‘B(01) is the variable being saved or uploaded to the PC’
SET B00 2 ‘Index=2’
SAVEV B00 ‘Upload index value’
SET B02 0 ‘Set B(02)=0’
SAVEV B02 ‘Upload B(02) to PC’
SET B00 3 ‘Index=3’
SAVEV B00 ‘Upload index value’
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3.3
DCIServer
Variable Editor
Loading Variables from the PC
SET B03 0 ‘Set B(03)=0’
SAVEV B03 ‘Upload B(03) to PC’
SET B00 1 ‘Index=1’
SAVEV B00 ‘Upload index value’
SAVEV P001 Upload P(001) to PC
SET B00 0 Index=0
SAVEV B00 Upload index value
SAVEV P000 Upload P(001) to PC
SET B00 1 Index=1
SAVEV B00 Upload index value
SET I01 1000 Set I(01)=1000
SAVEV I01 Upload I(01)
SET B00 2
SET D02 2000000
SAVEV B00
SAVEV D02
SET B00 3
SAVEV B00
SET R03 300
SAVEV R03
SAVEJ JOB: DC3 JBI
LOADJ JOB: DC3 JBI
RETURN
END
3.3
Loading Variables from the PC
Variables can be downloaded from the PC to the controller as often as
required. The following example shows how to download the desired
variables from the PC to the controller.
NOP
SET B00 1 Set index variable to 1
SAVEV B00 Upload index variable to
PC
LOADV B01 Download B(01) from
PC to the controller
SET B00 1 Set index variable to 1
SAVEV B00 Upload index variable to
PC
LOADV P001 Download P(01) from
PC to the controller
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3.4
DCIServer
Variable Editor
Loading and Saving Job Files
SET B00 2 Set index variable to 2
SAVEV B00 Upload index variable to
PC
LOADV B02 Download B(02) from
PC to the controller
SET B00 3
SAVEV B00
LOADV B03
SET B00 0
SAVEV B00
LOADV P000
JUMP *11 IF B03 <>3
LOADJ JOB: DC3.JBI
*11
RET
END
3.4
Loading and Saving Job Files
The controller can use DCIServer to access the remote PC for off-line
storage and retrieval of job files. This capacity helps to conserve online
storage. It also allows the user to edit jobs in an ASCII text editor (such as
NotePad) while DCIServer runs in background. With an ASCII editor and
DCIServer the user can access and edit job files without taking the robot
out of cycle.
You can save jobs as either independent or related files. The .JBI and
.JBR file extensions identify each of these file types respectively. A job
saved as an independent file contains only the instructions for the named
job. In a job saved as a related file, the program instructions are searched
for internal job calls. Any jobs, frames, and tools called in the program
instructions are appended to the end of the file. The resulting file then
contains the program instructions for all related jobs.
For example, saving the MAIN job we used above as an independent file
would store only the MAIN instructions. However, when we save the same
job as a related file, the instructions for SAVEV, DC1, DC2, and DC3 are
appended to the end of the MAIN instructions and stored in a single file.
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3.5
DCIServer
3.5
Variable Editor
Using the Variable Editor
Using the Variable Editor
The DCIServer Variable Editor lets the user save and modify program
variables while the robot is in cycle. Variables can be modified and then
downloaded back to the controller. To begin using the Variable Editor,
proceed as follows:
1. From the Communication portion of the main window, click the Start
button. A communications link between the controller and the PC is
established.
DCIServer communication must be ON before putting the
robot in cycle. DCIServer must remain ON until after the
robot is taken out of cycle.
2. At the robot controller, select the master job and place the robot in
cycle as follows:
3.6
a)
Press TEACH mode.
b)
Select the master job.
c)
Place the controller in AUTO mode.
d)
Press CYCLE START.
Closing a DCIServer Session
DCIServer must remain ON until after the robot is taken out of cycle. To
end a DCIServer session, proceed as follows:
1. From the robot controller, press HOLD or change mode to TEACH or
REMOTE. This takes the robot out of cycle.
2. Click the Stop button on the Commucication protion of the main
window.
If you assigned variable labels during the current session
and have not already saved them, you must save these
labels in a configuration file before you close the session.
Otherwise, the current label assignments will only apply to
the default configuration file.
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3.7
DCIServer
3.7
Variable Editor
Variable Transfer
Variable Transfer
DCIServer gives you the ability to transfer variables to/from the robot.
1. Click the View Variables button on the main window. The Variable
Editor window appears.
2. Select the variable type tab you wish to modify.
3. Click in the Name field of the variable number you wish to change and
type the new name.
4. Click in the Present Value field and type in the new value.
You may need to use the horizontal scroll bar to view all the
Axes, and Var Type values for the P and EX variables.
5. The controller uploads and downloads the new variables as directed
by the Master job.
The first time DCIServer is started, a blank XML file with the robot name is
created in the robot working directory. This XML file acts as the source
and destination for all the variable transfers with the robot.
The XML file can be edited with a text editor or manipulated by an external
program depending on what you are trying to accomplish.
Clicking on the 'Live Update' button continously upddates the variable
view but results in a slow down of the data transfer.
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3.7
Variable Editor
Variable Transfer
XML data displayed in a text editor
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4.1
DCIServer
4
Operation
Main Window
Operation
This chapter provides detailed operation information for DCIServer,
including detailed step-by-step instructions. To launch DCIServer, select
DCIServer from the Windows Start menu.
DCIServer is located in the Motoman program group unless you specified
another group during installation.
4.1
Main Window
When you first start DCIServer, the main window appears.

Start Button
The [Start] button manually starts the communication server. By default, a
communication service is installed by the setup program. This service
launches automatically upon Windows start up. Manual starting of the
service is not necessary but is provided for debugging purposes. When
the communication service is running, this button’s text will display 'Stop'
and act as a way to stop the communication process. The
communications service will continue to run and function even after you
close the DCIServer user interface.

Robot (Test) Button
Each robot defined in the system INI file has a button used to launch a
detailed screen for that individual robot. The Robot buttons also change
color to indicate the communication status; gray for normal
communication, yellow for warning, and red indicates an error. The
DCIServer includes an automatic ping-service that checks each robot
communication at a random interval. If a robot is unreachable, this be
considered an error and the button turns red.
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4.2
DCIServer
4.2
Operation
Robot Specific Screen
Robot Specific Screen
Clicking on a Robot (Test) button from the Main window brings up the
control screen for that particular robot.

Restart
The [Restart] button is used to manually restart the communication
service for the robot. This can be useful after a breakdown in
communication.
It is important to cycle the robot between Teach and Play
mode before restarting the robot job.

View Log
The [View Log] button opens the log window. This window shows the last
50 logs made for this particular robot.

View Variables
The [View Variables] button opens the variable editor window. From this
window you can assign variable labels to any or all variables.
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4.3
DCIServer
4.3
Operation
Variable Editor
Variable Editor
DCIServer allows you to assign variable labels to any variable. Using
variable labels does not affect the robot program, DCIServer only uses the
labels internally. This makes variables more easily recognizable.
For example, if the value of variable B1 determines which job the robot
performs, we might rename this variable "Robot Seq." DCIServer now
substitutes any reference to variable B1 with the label "Robot Seq."
DCIServer also lets you save variable label assignments in the
configuration .dci files. You can then retrieve the appropriate file for use as
required. By doing this, you can maintain a configuration file for each robot
program.
4.3.1
Assigning Variable Labels
To assign variable labels, proceed as follows:
1. Click the [View Variables] button on the main window. The variable
editor window appears.
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4.3
DCIServer
Operation
Variable Editor
2. Select the variable type tab you would like to assign labels.
3. Click in the Name field of the variable number you would like to label
and simply type in the label you would like to use.
Changes are automatically saved to the default configuration file.
However, if you want to keep the assigned labels for use in future
sessions, you should save and rename them to a configuration file.
Otherwise, label assignments may accidently be overwritten during future
sessions.
4.3.2
Saving Configuration Files
To save variable label assignments to a configuration file, proceed as
follows:
1. In the main window, select File > Save as, or use the keyboard
shortcut Ctrl+S.
2. Specify the new file name and location and click Save.
4.3.3
Opening a New Configuration File
To create a new configuration file, proceed as follows:
1. In the main window, select File > New, or use the keyboard shortcut
Ctrl+N.
2. Specify the file name and location and click Save.
4.3.4
Opening an Existing Configuration File
To open an existing configuration file, proceed as follows:
1.
In the main window, select File > Open, or use the keyboard shortcut
Ctrl+O.
2. Navigate to the desired dci file and click Open.
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4.4
DCIServer
4.4
Operation
Setting Communications Parameters
Setting Communications Parameters
In order for the controller and PC to work together, the communications
parameters set up on each device must match. Typically, you need to
configure DCIServer communications parameters only if:
• Controller parameters are changed.
• DCIServer is connected to a different controller.
DCIServer uses the same default communications
parameters as the controller. If these parameters have been
changed on the controller or if you want to use a
communications port on the PC other than COM 1, follow
the instructions below
Table 4-1: Default Communications Settings
Baud Rate
9600
Data Length
8
Stop Bits
1
Parity
even
COM Port
1
DCIServer uses the communications settings chosen within
DCI. The program ignores any communications settings
selected through the Windows Control Panel.
To configure the communication parameters, proceed as follows:
1.
In the main window, select Settings > Communication. The
Communications Setup window appears.
2. Select the desired values from the pull down menus for each setting.
To restore the port setup to the factory default settings,
click the Restore Defaults button.
3. Click OK.
4.4.1
Communications Setup Options
Two options are available for DCIServer.
• Open Comm On Startup - This option opens communications automatically on startup.
• Run Minimized - The program loads and immediately reduces to its
iconized form.
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4.4
Operation
Setting Communications Parameters
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5.1
DCIServer
5
Programming Tips
Optimizing for Cycle Time
Programming Tips
In this section we offer some techniques and hints to optimize the
operation of DCIServer for your particular applications.
5.1
Optimizing for Cycle Time
The techniques listed below can be incorporated into your processes,
either singly or in combination, to reduce total cycle time.
- Set up a byte variable that when true indicates that the values of other
variables have not changed. Write an instruction sequence in the job
program that tests the value of the change variable. In this sequence,
jump to a variable download sequence when the change variable tests
false. By waiting until changes occur to download variables, you reduce
the average number of downloads per cycle to a minimum.
SET B00 6 ‘Set B(00)=6’
SAVEV B00 ‘Upload index value’
LOADV B06 ‘B(06) is the change variable’
JUMP IF B06
<>0
insert the variable download instructions here, these will
only execute when the change variable B(06) equals 0
*skipseq
RET
END
5.2
Optimizing for Variable Latency
For some operations the robot needs to update variable values frequently.
The techniques listed below help satisfy the requirement to reduce
variable latency.
• Include instructions in your job programs to get variables as often as
required. If necessary, you could update each variable as it is used in
the program. Doing so ensures that the robot always uses the most
current value for any given variable.
• Write several different instruction sequences to update specific variables or groups of variables. By attaching each instruction sequence
to a different conditional statement, you can update variables only
under specific circumstances.
• Call a different sequence to update selected variables as the robot
starts each new task. This method updates groups of variables as
needed in a specific instruction sequence, rather than downloading
all at once.
5.3
Optimizing Memory Usage
In some cases, minimizing controller memory overhead may be a
concern. The following techniques help to conserve memory.
• Write program instructions tying controller load sequences to conditional statements.
• Save jobs as individual rather than related files. While the use of
related files can simplify some operations, the resulting files can be
very large. This approach is most effective when the master job contains references to several jobs, but is not likely to use all of them
during a specific session.
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5.4
DCIServer
5.4
Programming Tips
Troubleshooting
Troubleshooting
DCI Stops Functioning Normally
Did you turn off the computer and controller?
If not, turn off both and restart.
Is at least one portion of the program functioning? (Loading or saving
certain jobs?)
If Yes, what kind of jobs are working or causing problems?
Are jobs from the same controller/robot?
If jobs are from a different system, the jobs may be incompatible.
Are any of the jobs dependent upon a job not there or currently running?
This may affect the saving of a job from controller to the PC.
Do any of the jobs have position variables?
If a job using any type of position variable is loaded into the controller, the
position variable must be defined in the controller. This is true for FDE and
VDE as well.
Were any of the jobs created with MotoSim?
If jobs were created for a different robot, CMOS file or all.prm file may
affect compatibility.
Are any of these jobs extremely long or for dual robots?
They may be out of memory. DCIServer may also need more time to
gather the information. Change parameter RS034 to a value between 30 100.
Create small sample jobs using different functions.
Run the jobs separately to isolate any problem caused by a specific
function. For example, create jobs that employ:
- Motion only
- Position variables (if you are using them)
- Welding commands only
- Incorrect syntax, etc.
Did you make any changes to the controller or computer?
Try reverting to the original settings to see if that affected DCIServer
(other users may have changed settings).
Check cables. Make certain all cables are connected. Check for
intermittent connections by disconnecting and reconnecting cables.
Replace cables if necessary. Long cables can degrade signal quality. Also
check for added equipment such as welding power sources, positioners,
etc. Electrical noise from nearby devices can cause malfunction.
Check to see if a cable is damaged by swapping the cable in question with
a good cable. If you do not have an extra cable, visually check cable for
damage.
Close any other applications you have running.
Certain software can interfere with DCIServer.
Did you encounter an Alarm 5920-1 (Insufficient memory) message?
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5.4
DCIServer
Programming Tips
Troubleshooting
You may have too many jobs open or several jobs may be too long.
Eliminate some jobs, break jobs down into smaller jobs, or download jobs
to reduce memory requirements.
Did you encounter an Alarm 5930-22 (Time out)?
The PC is not responding. This typically occur on systems running
Windows 3.11.
- Cables are not connected or they do not have a good connection.
- Operator error
- DCIServer turned off
Try setting RS034 to a value between 30 and 100.
The default setting is "30" (30 seconds). Increase the setting to give the
controller more time to respond to the PC.

DCIServer Does Not Work After Installation
Are system parameters set properly?
Refer to Chapter 3 Installation and verify parameter settings for your
configuration.
Are the cables connected?
Have you created a fire wall exception in Windows?
Have you edited the ini file properly?
Verify data cable connections between robot controller and PC.
Is the Hardware Key correctly installed on the computer’s USB port?
Applications
Download jobs
Jobs with syntax errors will not be loaded.
Download variables
Position variables must be defined before jobs using those position
variables can be loaded. This is also true for jobs loaded with FDE or
VDE. This has been used to shift to corners of boxes of various sizes.
Memory
When running out of memory, DCI can save the jobs to the computer,
delete those jobs from the controller, and load when needed. Another
option is to purchase expanded memory.
Modified jobs
The SAVEJ and SAVEV functions will save the current version of the job
or variable to the computer. This may be useful if a vision system is used
to shift a robots position. It may be used to backup all jobs on the
computer on a weekly or routine schedule. To backup the entire system
setting, it is highly recommended to use FDE.
Saving variable
May be useful if a database on the computer is used to track schedules.
Activation
Computer Programming
DCIServer can communicate with a maximum of 16 individual robots.
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SYSTEM MANUAL
YASKAWA ELECTRIC CORPORATION
YASKAWA
Specifications are subject to change without notice
for ongoing product modifications and improvements.
MANUAL NO.
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