Robotic Arc Welding Interfacing

Josh Williamson
Fronius USA LLC
6797 Fronius Drive
Portage, IN 46368

Presentation Topics
/ What is a Robotic Interface???
/ Interface History
/ Communication Protocols

/ Smart Interfaces
/ Overview of a robotic shipbuilding project.

What is a Robotic Interface???

The connection and

interaction between the
robot, the welding hardware,
and the user.

What is a Robotic Interface

The connection and
interaction between
the robot, the welding
hardware, and the
user.
Robot and
Positioning
Equipment

Robot
Technician

Robot
Controller
and Teach
Pendant

Welding
Power
Source &
Interface

Interface Basic Signals

Presentation Topics
/ What is a robotic interface???
/ Interface History
/ Communication Protocols

/ Smart Interfaces
/ Overview of a robotic shipbuilding project.

Interface History

1982 Motoman System

7

General Interface trends

Interfaces progression over the last 25 years:
Relays and discrete i/o
Discrete i/o with 2 or 3 analog channels
Increased functionality and process control
Improved user interfaces (4 digits Windows type indefinite)
Increased communication interfaces
(16 in/out 1024 signals, field buses, Ethernet)

Increased computational power (8 kb 13 Mb)

Easier to setup and diagnose

Interface History

Early 80s Motoman RX Controller

9

Current Motoman DX Controller

Interface History

ABB S1 Controller 1974-1982

10

ABB IRC5 Controller

Presentation Topics
/ What is a robotic interface???
/ Interface History
/ Communication Protocols

/ Smart Interfaces
/ Overview of a robotic shipbuilding project.

11

Interface Communication Protocols

Profi-Bus
Developed 1989 in Germany

EtherNet IP

Software necessary to create network

IP Industrial Protocol

GSD file (general station description)

Developed by Rockwell 1990

Based on Common Industrial Protocol (CIP)

DeviceNet

Ethernet (Modbus) UDP

Maintained by a community (PI)

Uses ethernet cables

Energy savings

Developed in 1979

GSD file (general station description)

No Royalty-Fee

Wireless

Discrete I/O

Developed by Rockwell

Troubleshooting physical signals

Based on CIP

Time consuming setup

Noise Sensitive

Additional i/o boards sometimes needed

EDS file (electronic data sheet)

12

Profi-Net

Simple Interface

13

Ethernet Interface BitMap

14

Troubleshooting (error codes)

EFD xxx
Error with the wire feed system, refer to wire feeder error codes for more details
Err 049, 051, and 052
Error detected in mains power input (phase missing or voltage too low/high). Check mains.
Err PE
Voltage detected on earth ground. Check for isolation between welding ground points and earth ground
points.
No H2O
Error with the coolant system, check cooler for operation and system for good flow.
STOP
Communication or E-Stop condition with robot. Check for Robot Ready and Error Reset signals from robot.

Weld Process
The flow rate of the shielding gas is a critical aspect of
the welding process. Too high OR too low will have a
serious impact on weld results.

Fronius Options
Typically, the weld system opens and closes the gas
valve. If flow monitoring is desired within the system, the
following options are available.

Rule of thumb for the flow rate: 10 12 times the

diameter in l/min of flow
- 1.2mm x 10 = 12 l/min
- 1 l/min = 2.1 CFH

Gas Pressure Sensor

- 12 l/min x 2.1 = 25 CFH

Helium and Hydrogen require about 50% more flow
than other gases due to their lighter weights.

Correct flow rate

Manually set gas valve that reports a gas error to the weld
system when flow is too low. Only errors out for low flow
and doesnt report specific flow information.

Excessive flow rate

Digital Gas Sensor

The specific gas flow is set, regulated, and monitored
using this device. Not only is a low or high flow rate
detected, but the system also reports back specific gas
flow data.

Presentation Topics
/ What is a robotic interface???
/ Interface History
/ Communication Protocols

/ Smart Interfaces
/ Overview of a robotic shipbuilding project.

17

Smart Interfaces

18

Smart Interfaces

19

Smart Interfaces

20

Smart Interfaces

21

Smart Interfaces

22

Smart Interfaces

23

Smart Interfaces

24

Smart Interfaces

25

Smart Interfaces

26

Smart Interfaces

27

Smart Interfaces

28

Smart Interfaces

29

Smart Interfaces

30

Presentation Topics
/ What is a robotic interface???
/ Interface History
/ Communication Protocols

/ Smart Interfaces
/ Overview of a robotic shipbuilding project.

31

Tech Support USA

Service & Application Support
Weld Testing & Development

32

Fronius USA /Product Overview / 6/11/2013

All information is without guarantee in spite of careful editing - liability excluded.

Intellectual property and copyright: all rights reserved. Copyright law and other laws protecting intellectual property apply to the not otherwise marked content of this presentation respectively documents (texts, pictures, graphics,
animations etc.). It is not permitted to use, copy or alter the content of this presentation for private or commercial purposes without express authorisation from Fronius.