Robot Manipulator Control Theory and Practice - Frank L.lewis

Kawasaki Robot Controller
E Series
Arc Welding
Operation Manual
Kawasaki Heavy Industries, Ltd.
90203－1036DEA
E Series Controller
Kawasaki Robot Arc Welding Operation Manual
PREFACE
This manual describes operating instructions for arc welding specification of the Kawasaki Robot
Controller E series. This manual is supplemental for standard Operation Manual. Read
thoroughly the Safety Manual and other relevant manuals such as the Connection and Installation
Manual for arc weld robot controlled via E series controller. Once the contents of these manuals
are thoroughly read and understood the robot can be used.
This manual provides as much detailed information as possible on the standard operating methods
for arc welding specification of the Kawasaki robot. However, not every possible operation,
condition or situation that should be avoided can be described in full. Therefore, should any
unexplained questions or problems arise during robot operation, please contact Kawasaki Machine
Systems. Refer to the contact information listed on the rear cover of this manual for the nearest
Kawasaki Machine Systems office.
The explanations in this manual include information on optional functions, but depending on the
specification of each unit, not every optional function detailed here may be included with the robot.
Also, note that figures given here may differ partially from actual screens.
1. This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damage, and/or problems relating
to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching, maintenance
or inspection of the robot attend the necessary education/training course(s) prepared by
Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the right to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot is reinstalled
or moved to a different side or sold off to a different use, attach this manual to the robot without
fail. In the event the manual is lost or damaged severely, contact Kawasaki.
Copyright © 2011 Kawasaki Heavy Industries Ltd. All rights reserved.
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E Series Controller
SYMBOLS
The items that require special attention in this manual are designated with the following symbols.
Ensure proper and safe operation of the robot and prevent physical injury or property damage by
complying with the safety matters given in the boxes with these symbols.
！ DANGER
Failure to comply with indicated matters can result in

imminent injury or death.
！ WARNING
Failure to comply with indicated matters may possibly lead to
injury or death.
！ CAUTION
Failure to comply with indicated matters may lead to physical
injury and/or mechanical damage.
[ NOTE ]
Denotes precautions regarding robot specification,

handling, teaching, operation and maintenance.
！ WARNING
1. The accuracy and effectiveness of the diagrams, procedures, and detail

explanations given in this manual cannot be confirmed with absolute
certainty. Accordingly, it is necessary to give one’s fullest attention when
using this manual to perform any work. Should any unexplained questions
or problems arise, please contact Kawasaki Machine Systems.
2. Safety related contents described in this manual apply to each individual work
and not to all robot work. In order to perform every work in safety, read
and fully understand the safety manual, all pertinent laws, regulations and
related materials as well as all the safety explanation described in each
chapter, and prepare safety measures suitable for actual work.
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E Series Controller
INTRODUCTORY NOTES
1. HARDWARE KEYS AND SWITCHES (BUTTON)
E series controller provides hardware keys and switches on the operation panel and the teach pendant
for various kinds of operations. In this manual the names of the hardware keys and switches are
enclosed with a square as follows. The terms “key” or “switch” which should follow the relevant
names are sometimes omitted for simpler expression. When pressing two or more keys at the same
time, the keys are indicated by “+” as shown in the example below.
EXAMPLES
TEACH/REPEAT: indicates the mode switch “TEACH/REPEAT” on the operation panel.

A+MENU: indicates pressing and holding down A then pressing MENU.
2. SOFTWARE KEYS AND SWITCHES
E series controller provides softw are keys and switches which appear on the screen of the teach
pendant for various kinds of operations depending on specifications and situations. In this manual,
the names of software keys and switches are enclosed by “< >” parentheses. The terms “key” or
“switch” which should follow the relevant names are sometimes omitted for simpler expression.
EXAMPLES
<ENTER>: expresses an “ENTER” key that appears on the teach pendant screen.
<NEXT PAGE>: expresses a “NEXT PAGE” key on the teach pendant screen.
3. SELECTION ITEMS
Very often an item must be selected from a menu or pull-down menu on the teach pendant screen.
In this manual the names of these menu items are enclosed in brackets [XXX].
EXAMPLES
[Auxiliary Function]: Expresses the item “Auxiliary Function” in a menu. To select it, move the
cursor to the relevant item by the arrow keys, and press the ↵ key. For
detailed description, this procedure should be described every time, but “select
[XXX] item” will be used instead for simpler expression.
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E Series Controller
CONTENTS
1.0 Overview of Arc Welding Control·······················································································1-1
1.1 Configuration of Arc Welding Robot System ·····································································1-1
1.2 E Controller Specifications for Arc Welding·······································································1-2
2.0 Hardware Keys on Teach Pendant ·······················································································2-1

2.1 Overview of Teach Pendant ·································································································2-1
2.2 Hardware Keys on Teach Pendant ·······················································································2-2
3.0 Instructions for Operating Screen on Teach Pendant···························································3-1

3.1 Status Area····························································································································3-2
3.2 F keys (Function Keys)·········································································································3-3
3.3 Monitor Screen ·····················································································································3-4
3.3.1 PC Program···························································································································3-4
3.3.2 Arc Status Screen··················································································································3-5
3.3.3 Step Information (Auxiliary Data) Screen ···········································································3-6
4.0 Manual Operation of Robot··································································································4-1

4.1 Manual Operation of Robot··································································································4-1
4.1.1 Aligning Operation ···············································································································4-1
4.1.2 Setting for Keeping Base +Z Direction················································································4-3
4.2 Inching Operation for Weld Wire ························································································4-4
4.3 ON/OFF Operation for Supplying Shield Gas·····································································4-4
5.0 Teaching································································································································5-1
5.1 Overview of Teaching Operation·························································································5-2
5.1.1 Basic Flow of Teaching Operation·······················································································5-2
5.1.2 Type of Teaching Points and Auxiliary Data·······································································5-3
5.1.3 Weld Condition·····················································································································5-4
5.1.3.1 How to Set Weld Condition ·································································································5-4
5.1.3.2 Types of Weld Conditions····································································································5-5
5.2 Teaching for Arc Welding····································································································5-6
5.2.1 Creating a Program Sheet·····································································································5-6
5.2.2 Preparation for Teaching ······································································································5-7
5.2.3 Configuration of Teach Screen·····························································································5-8
5.2.4 Teaching Operation ············································································································5-10
5.3 Setting Other Auxiliary Data······························································································5-17
5.3.1 Setting Option Switches ·····································································································5-18
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E Series Controller
5.3.2 Setting Weld Conditions·····································································································5-18

5.3.3 Setting Special Conditions··································································································5-18
5.4 Real Time Weld Condition Modification Function···························································5-19
6.0 Repeat Operation ··················································································································6-1

6.1 Real Time Weld Condition Modification Function·····························································6-1
7.0 Program Modification···········································································································7-1

7.1 Program Editing Screen········································································································7-1
7.1.1 Step Modification on Program Edit screen ··········································································7-1
7.1.1.1 Pose Data and Auxiliary Data Modification········································································7-1
7.2 Online Editing Function ·······································································································7-4
7.2.1 Screens that Can Use Online Editing Function····································································7-4
7.2.2 Functions Used in Online editing Screen·············································································7-4
8.0 Auxiliary Functions ··············································································································8-1

8.1 Overview of Auxiliary Function ··························································································8-1
8.2 Auxiliary Function List·········································································································8-2
9.0 Touch Sensing Function (Option)························································································9-1

9.1 Overview of Touch Sensing Function··················································································9-1
9.1.1 Features of Touch Sensing Option Function········································································9-1
9.1.2 Sensing Patterns for Compensation of Workpiece Deviation ·············································9-2
9.2 Wire Check Function··········································································································9-10
9.2.1 Teaching for Wire Check Function····················································································9-10
9.2.2 Wire Check Function at Repeat Operation ········································································9-13
9.3 Workpiece Detection Function···························································································9-14
9.3.1 Teaching for Workpiece Detection Function·····································································9-14
9.3.2 Workpiece Detection Function at Repeat Operation ·························································9-17
9.4 Compensation Function for Workpiece Deviation····························································9-18
9.4.1 Combination of Sensing Patterns ·······················································································9-18
9.4.2 Teaching- Compensation Function for Workpiece Deviation- 1
(Teaching for Each Sensing Pattern) ··················································································9-21
9.4.3 Teaching- Compensation Function for Workpiece Deviation- 2
(Teaching for Combination of Sensing Patterns) ·······························································9-26
9.4.4 Compensation for Workpiece Deviation at Repeat Operation··········································9-32
9.4.5 Continuation and Reset of Workpiece Deviation Compensation······································9-33
9.4.5.1 Continuation and Reset of Compensation··········································································9-33
9.4.5.2 Cases of Continuing/Resetting Compensation···································································9-35
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E Series Controller
9.5 Precautions on Teaching·····································································································9-36

9.6 Error Handling when Operating Touch Sensing Function ················································9-39
9.6.1 Error Message List··············································································································9-39
9.6.2 Errors and Countermeasures ······························································································9-40
10.0 Special Pattern Weaving Function (Option) ······································································10-1

10.1 Overview of Special Pattern Weaving ···············································································10-1
10.1.1 Special Pattern Weaving·····································································································10-1
10.1.2 Pendulum Weaving ············································································································10-3
10.1.3 Weld Current/ Weld Voltage Boosts··················································································10-3
10.1.4 Flow Chart for Using Special Pattern Weaving Function ·················································10-4
10.2 Standard Weaving Patterns Registered for Robot······························································10-5
10.3 Teaching Operation for Special Pattern Weaving····························································10-11
10.4 Creating a New Weaving Pattern·····················································································10-12
10.4.1 Coordinates System and Parameters when Creating Weaving Pattern···························10-12
10.4.2 Creating Weaving Patterns·······························································································10-14
11.0 Servo Torch Function (Option) ··························································································11-1

11.1 Overview of Servo Torch Function····················································································11-1
11.2 Procedure for Setting Servo Torch as External Axis ·························································11-2
11.3 Servo Torch Specification ··································································································11-3
11.3.1 Auxiliary Functions for Servo Torch ·················································································11-3
11.3.2 Differences: Servo Torch Spec. vs. Standard Arc Spec.····················································11-3
11.4 Error Handling when Operating Servo Torch Function ····················································11-4
11.4.1 Error Message List··············································································································11-4
11.4.2 Errors and Countermeasures ······························································································11-4
12.0 Error Message for Arc Weld Specification········································································12-1

12.1 Error Message List··············································································································12-2
12.2 Errors and Countermeasures ······························································································12-3
Appendix 1.0 Program Sheet ···········································································································A-1

Appendix 2.0 Weld Database···········································································································A-3
Appendix 3.0 Pattern Example of Special Pattern Weaving (List)·················································A-7
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E Series Controller 1. Overview of Arc Welding Control
1.0 OVERVIEW OF ARC WELDING CONTROL
The standard E series controller has been incorporated with control functions specific to arc
welding. With these functions, the robot can be programmed to work flexibly and efficiently
with weld machines to produce variety of high quality welds.
1.1 CONFIGURATION OF ARC WELDING ROBOT SYSTEM
Arc welding robot system consists mainly of the following components. See the figure below.
1. Robot for arc welding (RA series robot, etc.)

2. E Series Controller for arc welding
3. Arc welding torch
4. Other devices for arc welding (weld power supply, wire feeder, gas supplying unit, cable, etc.)
5. Other optional devices (torch cleaner, etc.)
This manual mainly focuses on No.2 above, regarding items relating to E Series Controller for arc
welding. For details about other materials, see the standard operation manual, specification
sheets, etc.
Wire feeder
E Series Controller
for arc welding
Robot main body

for arc welding
Weld power supply
Arc welding torch
1-1
E Series Controller 1. Overview of Arc Welding Control
1.2 E CONTROLLER SPECIFICATIONS FOR ARC WELDING
Specifications for arc welding control are as follows. For details about other standard
specifications, refer to the Operation Manual for E series controller.
1. Necessary boards: Arc welding interface board (1TW/1GN boards)

Optional daughter boards (when using optional functions)
2. Arc welding control functions: Command of arc welding voltage/current to the weld power
supply, motor control for wire feed (including inching/retract),
gas supply ON/OFF, weld stuck detection
3. Optional control function: Touch sensing, special pattern weaving, etc.
1-2
E Series Controller 2. Hardware Keys on Teach Pendant
2.0 HARDWARE KEYS ON TEACH PENDANT
This chapter describes hardware keys on teach pendant specially for arc welding specification.
For details about other standard keys, refer to Operation Manual for E series controller- 2.4
Switches on Teach Pendant and Functions of Hardware Keys.
2.1 OVERVIEW OF TEACH PENDANT
Figure 2.1 shows the arrangement of the hardware keys on arc welding teach pendant.
Figure 2.1
2-1
E Series Controller 2. Hardware Keys on Teach Pendant
2.2 HARDWARE KEYS ON TEACH PENDANT
This chapter describes the function of each of the hardware keys for arc welding closed by
in Figure 2.1
Keys Function
Feeds weld wire when pressed. See 4.2 Inching Operation for Weld
Wire for more details. Pressing F key <Wire Inching> changes the speed
at which wire is fed.
Manually turns ON shield gas supply when pressing A + GAS ON. The
gas is turned ON only while the key is pressed.
Retracts weld wire when pressed. The wire is retracted only while the
key is pressed. See 4.2 Inching Operation for Weld Wire for more
details. Pressing F key <Wire Inching> changes the speed at which wire
is pulled back. Pressing A + CND.CHG. displays Real Time Condition
Modify screen in C area.
A + WELD ON/OFF selects weld ON and OFF during repeat/check
operations.
A + INSTR. selects the instructions column under “Mtd” on block

teaching screen. See 5.2.3 Configuration of Teach Screen for picture.
A + CND.NUM. selects the weld condition number column on block

teaching screen. See 5.2.3 Configuration of Teach Screen for picture.
A + WELD CND. selects the weld conditions (Spd Amp Vlt Tmr Amp
Vlt) set for the weld condition number on block teaching screen. See
5.2.3 Configuration of Teach Screen for picture.
A + SPEC.CND. selects the special condition column on block teaching
screen. See 5.2.3 Configuration of Teach Screen for picture.
A + OPTION selects the option switch column on block teaching screen.

See 5.2.3 Configuration of Teach Screen for picture.
A + JT6 +/- executes 45° align operation while in base mode.
A + JT7 +/- executes 90° align operation while in base mode.
2-2
E Series Controller 3. Instructions for Operating Screen on Teach Pendant
3.0 INSTRUCTIONS FOR OPERATING SCREEN ON TEACH PENDANT
This chapter describes the screens on the teach pendant used for operating the arc welding
functions. For details about other standard operating screens, the functions available on each
screen and their operation procedures refer to Operation Manual for E series controller-2.4
Switches on Teach Pendant and Functions of Hardware Keys.
3-1
3.1 STATUS AREA
When weld is set ON by pressing A + WELD ON/OFF, the following icon is displayed in the
status (F) area as shown below.
When Weld ON:
Weld OFF :< Arc OFF>

Weld ON:<Arc ON>
When Weld OFF:
Weld ON: Icon lights up
3-2
3.2 F KEYS (FUNCTION KEYS)
The chart below shows the functions of the arc weld specification F keys (shown as 1 to 3 in
figure below), displayed on teach mode screen. For other F keys, see the Operation Manual for
E series controller 2.6 Operation Keys on Teach Pendant Screen.
2 3
Operation When pressed with A key

No. Functions
key Operation Functions
1 Displays the arc status Displays the arc status
monitor (see 3.3.2 for details monitor (see 3.3.2 for details
on arc status monitor). on arc status monitor).
When weld is ON, the icon When weld is ON, the icon
lights up. lights up.
2 Displays the real time Displays the real time

condition editing screen. For condition editing screen. For
details on real time condition details on real time condition
editing screen, see 5.4 and 6.1. editing screen, see 5.4 and 6.1.
3 Sets the speed to feed or Sets the speed to feed or
retract the wire via retract the wire via
Wire Inching and Wire Wire Inching and Wire
Retract. The speed changes Retract. The speed changes
in 3 levels from 1 to 3 every in 3 levels from 1 to 3 every
time the key is pressed. time the key is pressed.
3-3
3.3 MONITOR SCREEN
In arc welding specification, the items below are added to the standard specification menu.
1. PC program (Monitor function no. 27)
2. Arc status (Monitor function no. 82)
3. Step information (Monitor function no. 83)
Figure 3.1
For details on other monitor functions on the menu, see the Operation Manual for E series
controller 2.9 Monitor Screen.
3.3.1 PC PROGRAM
Selecting [PC Program] in Figure 3.1 displays the screen in C area similar to Figure 3.1
Figure 3.2
This screen displays the data of up to five PC programs.
3-4
3.3.2 ARC STATUS SCREEN
Selecting [Arc Status] in the screen shown in Figure 3.1 displays current robot status, arc weld
conditions, etc. as shown in Figure 3.3.
Figure 3.3
The following items are shown highlighted when the I/O signal is ON.
Input Signal: Current Detect, Pole Stuck, Torch Interfere, Wire Touch, Wire Stuck
Output Signal: Arc ON, Wire Inching*, Wire Retract*, Gas ON, Touch Sensor ON, Weld ON
In Figure 3.3, Torch Interfere and Weld ON are ON.
NOTE* For Wire Inching or Wire Retract, only one output signal can be ON. They cannot be
ON simultaneously.
In Curr. Comm. and Volt. Comm., the current command values are displayed.
Current Command: 0.00 - 15.00 V
Voltage Command: 0.00 - 15.00 V
3-5
3.3.3 STEP INFORMATION (AUXILIARY DATA) SCREEN
Selecting [Step (Aux)] in Figure 3.1 displays the screen in C area as shown in Figure 3.4.
Figure 3.4
This screen displays all the auxiliary data for the selected step in the selected program. During
repeat operation, etc., when a step moves forward, the contents of the currently running step are
displayed.
3-6
E Series Controller 4. Manual Operation of Robot
4.0 MANUAL OPERATION OF ROBOT
When wire feeder or shield gas supplying unit are connected to E series controller, the teach
pendant can be used to manually inch/retract weld wire or turn ON/OFF gas supply in addition to
the normal robot operations by teach pendant. For details about connecting devices, see
Installation and Connection Manual for arc welding E series controller.
4.1 MANUAL OPERATION OF ROBOT
Same as standard specification robots, the arc welding robot can be driven manually in the
desired mode: joint, base coordinate based, or tool coordinate based. For more details, see
Operation Manual for E series controller- 4.0 Manual Operation of Robot.
This section describes the align operation, a function useful for arc weld teaching. Instructions
are also given for setting the robot installation posture in Aux. Function 0505 Robot Installation
Posture. In addition, the fixing of the +Z base axis in vertical direction regardless of the posture
set in Aux. 0505 is explained in detail.
4.1.1 ALIGNING OPERATION
Aligning function rotates the tool to make the Z axis of the tool coordinates parallel to the nearest
base coordinate axis during teaching. This is convenient for aligning the tool direction with the
Z axis of the base coordinates (especially when teaching downward welds) before teaching a weld
line.
RX and RY rotate → parallel to Z axis.
Base coordinate
system
1. Press INTER and select base mode.

[ NOTE ]
Aligning operation is not possible in joint or tool modes.
4-1
2. While pressing down the TRIGGER, press A + JT6 +/- for aligning at 45°, and A + JT7 +/-
for aligning at 90°. For 90° alignment, robot arm stops and align is complete when Z axis of
the tool becomes parallel to the base coordinates Z axis.
Z
X
45° Z
X
45° Base coordinates Base coordinates
Y system Y system
45° alignment 90° alignment
[ NOTE ]
Aligning operation can also be used for aligning the tool coordinates with
the base coordinates X or Y axes. Before aligning, move the tool near the
desired base coordinates axis and then execute the procedure described
above.
4-2
4.1.2 SETTING FOR KEEPING BASE +Z DIRECTION
The +Z direction of the base coordinate motion can be set perpendicular upwards during teaching,
once the actual installation posture is made to match the posture set in the controller.
The direction of robot’s base coordinates is set as shown in the figure below. However, the
value of the base coordinates must have O, A, and T set to 0(zero) in Aux. Function 0506 Base
Coordinates.
Floor Ceiling
Wall Wall 2
4-3
Setting procedure
1. Display Aux. Function 0505

Robot Installation Posture. To
display auxiliary function screens,
refer to Operation Manual for E
series controller- 8.2 How to Use
Auxiliary Functions.
2. Move cursor to the desired item

by pressing ↵ and if the setting is
correct, press ↵ again.
(Installation angle can be
specified only in some models so
normally, this should not be
changed.)
4.2 INCHING OPERATION FOR WELD WIRE
Press WIRE INCHING or WIRE RETRACT to feed or withdraw weld wire. Inching operation
is possible when both weld power supply and controller power are ON regardless of ON/OFF
status of TRIGGER, TEACH LOCK, RUN/ HOLD, etc. However, inching operation for servo
torch spec. (Option) is possible only when TRIGGER, TEACH LOCK and MOTOR ON are ON
and RUN/ HOLD is set to RUN in teach mode.
4.3 ON/OFF OPERATION FOR SUPPLYING SHIELD GAS
Press A + GAS ON to turn ON/OFF shield gas supply. Gas ON/OFF operation is possible
when both weld power supply and controller power are ON regardless of ON/OFF status of
TRIGGER, TEACH LOCK, RUN/ HOLD, etc.
4-4
E Series Controller 5. Teaching
5.0 TEACHING
This chapter describes procedures for teaching and editing programs via the teach pendant using a
simple arc welding program as an example. For details on programming via AS language, refer
to Arc Welding AS Language Reference Manual for E series controller.
5-1
5.1 OVERVIEW OF TEACHING OPERATION
5.1.1 BASIC FLOW OF TEACHING OPERATION
Teach horizontal fillet welding between P1 and P2 as shown below.
Teaching point Teaching contents

Step1 Starts operation from P0.
P0
Step2 Starts welding from P1.
P1
Step3 Completes welding at P2. P3
Step4 Evacuates robot to P3.
P2
First enable manual operation of the robot, then start teaching by the following procedure with
teach pendant.
Move the tip of the torch to the point, P0/P1/P2/P3 in

the figure above manually.
Select a type of teaching

for points P0/P1/P2/P3.
Air Cut (AC) Weld Start (WS) Weld Continue Weld End (WE) Arc Spot (AS)
point (P0/P3) point (P1) (WC) point point (P2) point
(Set weld condition.) (Set AS condition.)
No Set standard
auxiliary data to the
point?
Change auxiliary data. Yes
Press ↵ to
confirm.
Yes
Final point?
No
To next point. End
5-2
5.1.2 TYPE OF TEACHING POINTS AND AUXILIARY DATA
The table below shows the types of teaching points and auxiliary data which are set/modified for
arc weld teaching. Set the teaching points with auxiliary data, instructions (Mtd).
Types of teaching points Auxiliary data that can be set/modified

Air cut point (no welding) Interpolation mode (joint, linear), Speed, Accuracy, Timer,
OX, WX, J/E
Weld start point (to begin Interpolation mode (joint, linear), Speed, Timer, OX, WX
welding)
Weld continue point (halfway Interpolation mode (linear, circular1, circular2)
through welding) Weld data
(Weld speed, Weld current, Weld voltage, Polarity Ratio*)
Weaving data
(Width, Frequency, Pattern*)
OX
Weld end point (to finish Interpolation mode (linear, circular2)
welding) Weld data
(Weld speed, Weld current, Weld voltage, Polarity Ratio*)
Weaving data
(Width, Frequency, Pattern*)
Crater weld data
(Time, Weld current, Weld voltage)
OX
Arc spot point (to weld by arc Interpolation mode (joint, linear), Speed, Accuracy, Timer
spot) Arc spot weld data
(Time, Weld current, Weld voltage, Polarity Ratio*)
OX, WX
NOTE* Polarity ratio and weaving pattern are options.
5-3
5.1.3 WELD CONDITION
By itself pose data for P0 to P3 is insufficient for operating the robot arc welding functions.
Additional data must also be taught to the robot, for example the speed for moving from P0 to P1,
how closely the torch tip comes to the taught point when arriving at P1 (accuracy), etc. This is
called auxiliary data. Furthermore, data specifying the weld quality such as weld speed, weld
current, weld voltage, etc. is also needed, which is called weld condition.
5.1.3.1 HOW TO SET WELD CONDITION
Two methods for setting the weld conditions are available during teaching.
1. Weld condition: Indirect setting

Store only the weld condition number in the program steps. During program execution, the
weld conditions set to that number are used. (100 condition numbers 0 to 99 are available.)
Useful when applying the same weld conditions at several steps, because:
(1) it is simple to specify the condition number instead of specifying a lot of condition
parameters.
(2) weld condition change is reflected all at once in all steps taught by the same condition
number.
Ö Convenient when setting same weld conditions to several steps.
2. Weld condition: Direct setting

Store weld conditions directly to each step in a program. Use this method when changing the
weld conditions in a step already taught by indirect setting of weld condition (per 1. above).
Unlike indirect setting above, changing the weld conditions for blocks of steps is not possible.
Weld conditions do not change unless step is modified/deleted, or the welding conditions are
changed via Aux. Function 1406 Arc Weld Condition Modify or 1407 Arc Spot Weld
Condition Modify.
Ö Convenient for setting the weld conditions to specific steps.
For setting procedure, refer to 8.0 Auxiliary Functions.
5-4
5.1.3.2 TYPES OF WELD CONDITIONS
The following weld conditions are available as shown in the table below.
Parameter of weld condition Description

Weld speed Sets motion speed in welding.
Basic Condition
(Unit: cm/min)
Weld current Sets weld current.
(Unit: Ampere (A))
Weld voltage Sets weld voltage.
(Unit: Volt (V))
Weaving width Sets amplitude in weaving.
(Unit: mm)
Weaving Condition
Set 0 when not executing weaving.

Weaving frequency Sets frequency in weaving.
(Unit: Hertz (Hz))
Set 0 when not executing weaving.
Weaving pattern No. Sets pattern in weaving.
(Option) When option is not mounted, only simple harmonic
motion is available and this parameter is not displayed.
Crater stopping time Sets stopping time in crater treatment.
(Unit: Second (sec))
Set 0 when not executing crater treatment.
Crater condition
Crater current Sets crater current in crater treatment.

(Unit: Ampere (A))
Crater voltage Sets crater voltage in crater treatment.
(Unit: Volt (V))
Arc spot time Sets arc spot time.
Arc spot condition
(Unit: Second (sec))

Arc spot current Sets weld current in arc spot welding.
(Unit: Ampere (A))
Arc spot voltage Sets weld voltage in arc spot welding.
(Unit: Volt (V))
Sets ratio of negative-positive polarity energizing.
Polarity Ratio (Option)
(16 steps from 0 to 15)
5-5
5.2 TEACHING FOR ARC WELDING
This section describes teaching operations specific to arc welding application. For standard
teaching methods, refer to Operation Manual for E series controller- 5.0 Teaching.
5.2.1 CREATING A PROGRAM SHEET
Once the teaching contents are determined, fill in the auxiliary data on program sheet.
The following sheet shows a sample program for teaching horizontal fillet welding. Teaching
operation of this program is explained in 5.2.4 Teaching Operation. A blank program sheet is
attached in Appendix 1. Program Sheet; make copies of use for when planning programs.
Program Name Machine No. Date prepared: Revision

2011
1998-5-18
PG10
Applicable Work Prepared by:
work001 Taro Kawasaki
S Teaching Type Welding

Weld Condition Arc Spot
Air- Accu- Timer OX
Typeofof Inter- Speed WX Jump Condition option
T point teach polation cut
teaching racy /End Direct Direct
E In- In-
P point
point speed direct SP A V WV f PN CtCACVdirect t A V
11 P0 AC JOINT 9 2 0
22 P1 WS LINEAR 9 - 0
3 P2 WC LINEAR - - - 0
4 P3 WE LINEAR - - - 0
5 P4 AC LINEAR 9 2 0
6 P5 AC JOINT 9 2 0
[ NOTE ]
When using RPS function, teach End at last step.
5-6
5.2.2 PREPARATION FOR TEACHING
To teach a program, first determine the work to be performed, then create a program sheet.
Before starting the teaching process, check the following two items.
1. Registration of tool transformation value for torch
Set the tool transformation value for the torch. When using a standard torch, refer to Aux.1405
in 8.0 Auxiliary Functions.
[ NOTE ]
No registration is need when robot and torch are purchased

together from Kawasaki, as tool transformation value is already
registered at time of factory shipment.
2. Setting of wire extension
When executing arc welding, set the wire extension length (mm) according to welding posture
and leg length. For details, refer to Aux.1405 in 8.0 Auxiliary Functions.
5-7
5.2.3 CONFIGURATION OF TEACH SCREEN
The configuration of the teach screen for arc welding is as shown in the figures below. To
switch between screens, press A + → or ←. For more details about using teaching screens,
refer to Operation Manual for E series controller- 5.0 Teaching.
1. Displays weld condition No. (0 - 99) or D (Direct) 2. Refer to 5.3.1 Setting

per how weld conditions were set, indirect/direct. Option Switches.
3. Displays weld conditions. [PO] means Polarity Ratio.
* *
5-8
NOTE* [PO (Polarity Ratio)] and [Weaving Pattern] are Options.
5-9
5.2.4 TEACHING OPERATION
This section describes how to teach the robot to perform horizontal fillet welding via the five
points shown in Figure 5.1 below.
P4
Escape point
(Air cut point)
P0
Work start point
＆ P2
P5 (Weld continue
Work end point point)
P3 (Weld end point)
P1
(Weld start point)
Figure 5.1
Teaching procedure
1. First, set the program name to be edited. The teach screen in Figure 5.2 below displays the
setting of program pg10.
Figure 5.2
5-10
2. The contents to be taught are listed in the table below.
Teaching point Teaching contents

Step1 Point for starting operations (P0).
Step2 Moves from P0 to P1 by linear interpolation. Generates arc at P1 and
starts welding.
Step3 Moves from P1 to P2 welding horizontal fillet of 5 mm leg length.
Arc is not OFF at P2.
Step4 Moves from P2 to P3 welding horizontal fillet of 5 mm leg length.
Cuts OFF arc after crater operation at P3.
Step5 Moves from P3 (Weld end point) to P4 (Escape point) by linear
interpolation.
Step6 Moves from P4 to P5 (Work end point), and completes teaching.
[ NOTE ]
Conditions for teaching operation:

1. Work to be welded is set in a jig manually.
2. Input/output of signals between robot and welding devices are automatically
set during the teaching process.
3. Teach step1.
P0
P5
P2 ・P
4
P1 P3
(1) Jog the torch tip to P0 by +/-.
5-11
(2) Set the auxiliary data, the instruction* to AC, the interpolation to joint, the speed to 9, the
accuracy to 2 and the timer to 0.**
NOTE* To set the instruction:
Move cursor to the auxiliary data title row by pressing either A + INSTR. or by → or ←.
⇓
Pressing ↵ changes the instruction setting on the edit row as “AC (Air Cut point (point not
welded)) → WS (Weld Start point) → WC (Weld Continue point) → WE (Weld End point) →
AS (Arc Spot point)”.
⇓
When the desired instruction appears (in this case, AC), then the instruction setting is complete.
NOTE** To set the interpolation, speed, accuracy and timer, refer to Operation Manual for E
series controller- 5.3 Element Instruction and Their Parameters. Note some
interpolation modes may not be available for an instruction as shown below.
Instruction Interpolation modes avail. to be set

AC, WS, AS Joint → Linear → Joint
WC Linear → Circular 1 → Circular 2 → Linear
WE Linear → Circular 2 → Linear
(3) Press RECORD to teach the pose and the auxiliary data of step1 at the same time. The teach
screen will appear as shown in Figure 5.3.
Figure 5.3
5-12
4. Teach step2.
Switch to inching
Set torch angle (θ1) mode when torch
approx. 45° at P1. is set close to P1.
P1
θ1= approx. 45°
Keep approx. 1mm
from corner.
(1) Press INTER and select base mode, then TEACH SPEED to select desired speed.
(2) Move torch tip near P1 by +/-. Then press TEACH SPEED to select the inching mode
(Speed 1), and move the robot at very slow speed to set the torch tip to P1 accurately.
(3) Set the auxiliary data, the instruction to WS, the interpolation to linear, the speed to 9, and the
timer to 0.
Figure 5.4
5. Teach step3.
P’2
Approx.
P’1 θ1=approx. 45°
1mm
P2 At P2, set torch posture by
torch angle θ1 and angle with
θ2=approx. 45° vertical plate θ2 to be approx.
P1 45° respectively.
Approx.
1mm
5-13
(1) Press INTER and select tool mode.
(2) Press Z- to evacuate the torch from P1 to P’1 temporarily.
(3) Press INTER and select base mode.
(4) Move the torch tip to P’2 near P2 by +/-. Then press TEACH SPEED and select the inching
mode (Speed 1). Move the robot at very slow speed to set the torch tip to P2 accurately.
(5) Set the auxiliary data, the instruction to WC, the interpolation to linear, and the weld condition
number* to 0. (In this example, weld condition No. 0 contains the data for welding
horizontal fillet with leg length/thickness of 5mm. For more details, refer to Aux.1401 (Arc
Weld Condition in 8.0 Auxiliary Functions).)
NOTE* To set the weld condition number,
Move cursor to Weld Condition Number on the auxiliary data title row by pressing either A +
CND.NUM. or by → or ←. The screen below appears, so input the desired weld condition No.
and press ↵. Input range for weld condition No. is from 0 to 99. Input 100 to directly specify
the weld condition. (In this example, 0 is specified).
Pressing <Setting> in the above screen changes the display to screen for Aux. 1401 Arc Weld
Condition. The weld conditions can be set in that screen.
(6) Press RECORD to teach the pose and the auxiliary data of step 3 at the same time. The
teach screen will appear as shown in Figure 5.5.
Figure 5.5
5-14
6. Teach step4.
Same as P2, set the torch tip to P3

accurately. This point is also welded
P2 by horizontal fillet. Set torch angle
θ1 to be approx. 45°.
θ1=approx. 45° P3
Approx. 1mm
(1) Set the auxiliary data, the instruction to WE, the interpolation to linear, and the weld condition
number to 0. (In this example, weld condition No. 0 contains the data for welding horizontal
fillet with leg length/thickness of 5mm, and crater condition. For more details, refer to
Aux.1401 (Arc Weld Condition).)
Weld condition numbers are the same for P1→P2 and P2→P3, thus step4 is automatically set
with the same conditions as in step3. Take note that crater treatment condition is only
reflected in weld end step.
Figure 5.6
5-15
7. Teach step5.
Same as P3, press Z- in tool

mode to evacuate the torch and
move it to the escape point P4.
P3
P4
(1) Set the auxiliary data, the instruction to AC, the interpolation to linear, the speed to 9, the
accuracy to 2 and the timer to 0.
Figure 5.7
8. Teach step6 by following the same procedure used in 3. above where P0 is taught. (See page
5-10 for procedure No. 3.)
5-16
5.3 SETTING OTHER AUXILIARY DATA
In arc welding specification, the following auxiliary data can be set in addition to those described
above.
J/E Refer to Operation Manual for E series controller-

5.3.8 Jump/End (J /E) Instruction.
Option Switch Refer to 5.3.1 Setting Option Switches.
Comment Comment can be input by moving the cursor to
Comment on the auxiliary data title row by pressing
→ or ←.the Refer to Operation Manual for E
series controller- 2.7.1- 6. PG Comment Input.
Weld Condition Refer to 5.3.2 Setting Weld Conditions.
(Spd Amp Vlt PO* Tmr Amp Vlt PO*)
WV Refer to 5.3.2 Setting Weld Conditions.
(Width Frequency Pattern*)
Special Condition Refer to 5.3.3 Setting Special Conditions.
OX Refer to Operation Manual for E series controller-
5.3.9 Output (O) Instruction.
WX Refer to Operation Manual for E series controller-
5.3.10 Output (O) Instructions.
NOTE* PO (polarity ratio) and weaving pattern are Options.
5-17
5.3.1 SETTING OPTION SWITCHES
When Option functions are installed, option switches can be set in AC, WS and WE steps. For
details about the setting of these switches, refer to related option manual and 9.0 Touch Sensing
Function (Option).
5.3.2 SETTING WELD CONDITIONS
1. In WC or WE steps press <Setting> in the screen that appears after pressing A + WELD CND.,
or move cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*) on the auxiliary
data title row by pressing → or ←, and press ↵. Aux. Function 1401 Arc Weld Condition is
displayed. For details about making settings on this screen, refer to Aux.1401 in 8.0
2. In AS (Arc Spot) steps, press <Setting> in the screen that appears after pressing A +
WELD CND., or move cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*) on
the auxiliary data title row by pressing → or ←, and press ↵. Aux. Function 1402 Arc Spot
Weld Condition is displayed. For details about making settings on this screen, refer to Aux.
1402 in 8.0 Auxiliary Functions.
NOTE* PO (polarity ratio) is Option.
5.3.3 SETTING SPECIAL CONDITIONS
In WC or WE steps, move cursor to Special Condition on the auxiliary data title row by pressing
either A + SPEC.CND. or by → or ←, and press ↵. Aux. Function 1401 Arc Weld Condition
is displayed. For details about making settings on this screen, refer to Aux. 1401 in 8.0
5-18
5.4 REAL TIME WELD CONDITION MODIFICATION FUNCTION
Using the real time weld condition modification function, weld speed, current, and voltage can be
changed during check operation. Any changes made to the weld conditions can then be
overwritten onto taught data in check mode. This function is also available in repeat operation
although overwriting is not allowed.
1. Press A + WELD ON/OFF to turn ON welding and start check operation.
2. In WC or WE steps, press A + CND.CHG. or F key <Real Time Condition> to display the real
time condition modify screen in C area as shown in the figure below.
Weld Speed Sets speed in welding.

(cm/min) Pressing <+> increases weld speed by 1cm/min increment.
(Max.: 999cm/min)
Pressing <-> decreases weld speed by 1cm/min increment.
(Min.: 1cm/min)
Weld Curr. (A) Sets current in welding.
Pressing <+> increases weld current by 1A increment. (Max.: 999A)
Pressing <-> decreases weld current by 1A increment. (Min.: 0A)
Weld Volt (V) Sets voltage in welding.
Pressing <+> increases weld voltage 0.1V increment. (Max.: 99.9V)
Pressing <-> decreases weld voltage 0.1V increment. (Min.: 0.0V)
Press <Data Set> at check operation to record changes to weld speed,
current, voltage and overwrite the weld condition data for that step.
Press <Undo Data> to set back values to the currently registered weld
conditions.
5-19
[ NOTE ]
1. During weld ON, weld speed, current, and voltage can be modified. To
overwrite weld condition data with the current changes, press <Data Set>.
During weld OFF, weld conditions cannot be modified.
2. When the taught data is overwritten in this manner, the weld condition is
considered to be direct setting even though it was originally indirect setting.
3. Real time condition modification for crater treatment and arc spot welding
is not possible at WE step.
！ WARNING
If you watch the weld bead while using the real time weld
condition modification function, use face shield without fail,
and avoid looking directly at the arc.
5-20
E Series Controller 6. Repeat Operation
6.0 REPEAT OPERATION
Repeat operation plays back and executes the contents of a program that was taught to the robot.
This chapter describes the functions available for arc welding application during repeat operation.
For details about standard repeat operation procedure, refer to Operation Manual for E series
controller- 6.0 Repeat Operation.
6.1 REAL TIME WELD CONDITION MODIFICATION FUNCTION
Using the real time weld condition modification function, weld speed, current, and voltage can be
changed during repeat operation. However, the changed weld conditions cannot be overwritten
onto taught data. Overwriting is possible in check mode. Refer to 5.4 Real Time Weld
Condition Modification Function for more details.
[ NOTE ]
1. During weld ON, weld speed, current, and voltage can be modified.
During weld OFF, only the weld speed can be changed.
2. Real time condition modification for crater condition and arc spot
condition is not possible at WE step.
！ WARNING
If you watch the weld bead while using the real time weld
condition modification function, do not fail to use face shield,
and avoid looking at the arc directly.
6-1
E Series Controller 6. Repeat Operation
6-2
E Series Controller 7.0 Program Modification
7.0 PROGRAM MODIFICATION
This chapter explains about the program editing screen for arc welding specification. For general
operations of the program editing screen, see the Operation Manual for E series controller- 7.3
Edit on the Program Edit Screen.
7.1 PROGRAM EDITING SCREEN
7.1.1 STEP MODIFICATION ON PROGRAM EDIT SCREEN
This section explains the procedures to edit the program steps.
7.1.1.1 POSE DATA AND AUXILIARY DATA MODIFICATION
The taught data are modified via the edit screen as follows:
1. Pressing A＋←/→ scrolls the page and displays the data as shown in the figures below.
7-1
2. Move the cursor to the item to modify.
3. Modify each data using the Number keys. Modification procedure differs according to the type
of data as 1 and 2 below.
1. Entering values other than for option switch, weld condition, WV, special conditions , Output(O),
input (I), and comment:
1) Move the cursor to the desired item.
2) Enter the necessary values according to the explanation in the chart below.
Item Explanation
Instruction Specify the instruction. (0:AC, 1:Start, 2：Midpoint, 3:End, 4：AS）
*
Interpolation Specify the interpolation mode. Refer to the Operation Manual for E Controller
7.3.3 Step Data Modification on Edit Screen.
No Specify the weld condition number. 0 – 99: Condition number, 100：Direct
input.
Speed Specify the speed. Refer to the Operation Manual for E Controller 7.3.3 Step
Data Modification on Edit Screen.
Accuracy Specify the accuracy. Refer to the Operation Manual for E Controller 7.3.3
Step Data Modification on Edit Screen.
Timer Specify the timer. Refer to the Operation Manual for E Controller 7.3.3 Step
Data Modification on Edit Screen.
J/E Specify the J/E instruction. Refer to the Operation Manual for E Controller
7.3.3 Step Data Modification on Edit Screen.
Pose data Specify the pose data. Refer to the Operation Manual for E Controller 7.3.3
Step Data Modification on Edit Screen.
3） Press ↵ after entering each value. When all the necessary items are input, press <ENTER>
to register.
NOTE* Interpolation setting that can be used depend on the instruction mode, as shown below.
Instruction Interpolation setting

AC, Start, AS Joint→Linear→Joint
Midpoint Linear→Circular 1→Circular 2→ Linear
End Linear→ Circular 2→ Linear
2. Entering values for option switch, weld condition, WV, special conditions , Output(O), input (I),
and comment:
1) Move the cursor to the desired item and press ↵.
7-2
2) The screen for data setting is display, so enter the values and comments to modify. See the
table below for how to input the values.
Item Explanation
Option Switch See 5.3.1 Setting Option Switches.
Weld condition See 5.3.2 Setting Weld Conditions.

(Spd Amp Vlt PO* Tmr
Amp Vlt PO*)
WV (Width Frequency See 5.3.2 Setting Weld Conditions.
Pattern*)
Special condition See 5.3.3 Setting Special Conditions.
Output (O) The current setting is displayed. Refer to the Operation

Manual for E Controller 7.3.3 Step Data Modification on Edit
Screen.
Input (I) The current setting is displayed. Refer to the Operation
Manual for E Controller 7.3.3 Step Data Modification on Edit
Screen.
Comment Pressing ↵ displays the comment input screen. Refer to the
Operation Manual for E Controller 7.3.3 Step Data
Modification on Edit Screen.
NOTE* PO (Polarity ratio) and weaving patterns are options.
3) Press ↵ after entering each value. When all the necessary items are input, press <ENTER>
to register.
7-3
7.2 ONLINE EDITING FUNCTION
Using this function enables modification of programs that are in repeat operation, although with some
restrictions. This section explains about the online editing function for arc weld specification. For
online operations common to all specifications, refer to the Operation Manual for E controller 7.3 Edit
on the Program Edit Screen
7.2.1 SCREENS THAT CAN USE ONLINE EDITING FUNCTION
The following screens can be edited via the online editing function.
1．Programs that are already registered.

2．Subroutine programs that are being executed.
7.2.2 FUNCTIONS USED IN ONLINE EDITING SCREEN
1. Editing
Basically is the same as explained in 7.1 Program Editing Screen, but there are few data that
cannot be changed in online program editing. For details, see “2. Save as” below.
2. Save as
In online program editing, the following data cannot be modified: instruction. Interpolation,
No, option switch, weld condition, WV, special condition, pose and comment. (Weld
condition may be changed when specified in the program as weld condition number and not
specified by direct number). When any of these are changed, save the program with a new
name following the procedure described in the Operation Manual for E Controller 7.4.2 Functions
on Online Edit Screen.
7-4
E Series Controller 8. Auxiliary Functions
8.0 AUXILIARY FUNCTIONS
This chapter describes auxiliary functions specific to arc welding specification.
！ WARNING
Auxiliary functions are a kind of teaching. Their usage is

limited to only those who have completed special training
and are qualified for teaching or supervising robot
operations.
8.1 OVERVIEW OF AUXILIARY FUNCTION
Use auxiliary functions for arc welding specification in the following cases.
1. Confirmation and setting of various kinds of data for arc welding.

2. Confirmation and setting of robot installation
3. Confirmation and setting of arc weld torch dimensions
4. Other settings
Only auxiliary functions related arc welding are described here. For other auxiliary functions,
refer to Operation Manual for E series controller- 8.0 Auxiliary Functions, and for methods on
calling up the auxiliary function screen, see 8.2 How to Use Auxiliary Functions.
Select [14. Arc Weld] in the auxiliary function screen to call up the arc welding auxiliary function
list as shown below.
8-1
8.2 AUXILIARY FUNCTION LIST
No. Function Name Function Description
1401 ARC WELD CONDITION Displays and sets arc weld condition data.
ARC SPOT WELD Displays and sets arc spot weld condition data.
1402
CONDITION
ARC WELD CONDITION Displays and sets arc weld condition database.
1403
DATABASE
1404 ARC WELD SETTING Displays and sets various kinds of data for arc welding.
ARC WELD TORCH Displays and sets arc weld torch dimensions.
1405
DIMENSION
ARC WELD CONDITION Changes arc weld conditions for specified steps. (direct
1406
MODIFY teaching method)
ARC SPOT WELD Changes arc spot weld conditions for specified steps.
1407
CONDITION MODIFY (direct teaching method)
8-2
AUX.1401 ARC WELD CONDITION
1. Input desired weld condition

number by Number (0-9) and
press ↵.
2. Move cursor to each item and

input required data by Number
(0-9). If the setting is correct,
press ↵.
Press <Next Page> and <Prev

Page> to display the setting screens
for weld condition No. 0 to 99.
To refer to the arc weld condition database screen, press <Auto Set>. For details about the
screen, refer to Aux.1403.
3. When “Setting complete.” is displayed, the setting is done.
8-3
[ NOTE ]
1. [Pole Ratio] and [Weaving Data- Pattern] are displayed only when Option is installed.
2. Direct setting screen for arc weld conditions is not displayed. To specify or display the arc
weld condition of direct setting, see 3. below and set by Aux.1401 or Aux.1406.
3. In WC or WE steps, move cursor to “No.” on auxiliary data title row and press ↵ to display
the weld condition number input screen as shown in 5.2.4 (5) . Enter 100 and press
<Setting> to display the screen above. Directly input the condition number in this screen.
To select the weld condition No., refer to 5.2.4 Teaching Operation. (This method is also
available for indirect setting.) (Auxiliary function screen is also called up by moving
cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*) WV (Wid Freq Pat*),
and then pressing ↵.) At this time,
(1) the screen can be called up only in teach mode with teach lock ON.
(2) arc weld condition data set by direct method cannot be seen in repeat mode.
NOTE* Displayed only when Option is installed.
8-4
AUX.1402 ARC SPOT WELD CONDITION
1. Input desired arc spot weld

condition number by Number
(0-9) and press ↵.

press ↵.
Press <Next Page> and <Prev

Page> to display the setting screens
for arc spot weld condition No. 0 to
99.
3. When “Setting complete.” is

displayed, the setting is done.
[ NOTE ]
1. [Pole Ratio] is displayed only when Option is installed.
2. Direct setting screen for arc spot weld condition is not displayed. To specify or display the
arc spot weld condition of direct setting, see 3. below and set by Aux.1402 or Aux.1407.
3. In AS (Arc Spot) steps, move cursor to “No.” on auxiliary data title row and press ↵ to
display the weld condition number input screen as shown in 5.2.4 (5) . Enter 100 and
press <Setting> to display the screen above. Directly input the condition number in this
screen. To select the weld condition No., refer to 5.2.4 Teaching Operation. (This
method is also available for indirect setting.) (Auxiliary function screen is also called up
by moving cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*), and then
pressing ↵.) At this time,
(1) the screen can be called up only in teach mode with teach lock ON.
(2) arc spot weld condition data set by direct method cannot be seen in repeat mode.
NOTE* Displayed only when Option is installed.
8-5
AUX.1403 ARC WELD CONDITION DATABASE
In the arc weld condition database, weld data (speed, current, voltage, polarity ratio*), crater
treatment data (time, current, voltage) and weaving data (width, frequency, pattern*) can be set
and modified for each weld joint shape and leg length/thickness. This database provides a
convenient means of calling up data when setting weld conditions by either the direct or indirect
teaching Aux. screens.
As shown in the figures below, move cursor to [Big Category] to display big category items and
to [Small Category] to display small category items which correspond to the selected big category
items. Select the desired item for each category by Number (0-9).
Big category items Small category items
Pressing <Display> displays the weld condition data for the selected big/small category items on
the right half of the screen. In the figures above, weld condition data is for [1. H FILLET] of
[Big Category] and [1. 3mm] of [Small Category].
1. Horizontal fillet 2. Flat fillet 3. Lap fillet
4. Corner fillet 5. Butt I fillet 6. Downhill fillet
8-6
1. To change data, input required data

and press ↵ to display the setting
screen on the left. Move cursor to
each item and input required data
by Number (0-9). If the setting is
correct, press ↵.

NOTE* [Pole Ratio] and [Weaving Data- Pattern] are displayed only when Option is installed.
Setting item Setting range Unit

Speed 1 to 999 cm/min
Current 0 to 999 A
Weld data
Voltage 0.0 to 99.9 V
Polarity ratio (Option) 0 to 15 -
Time 0.0 to 9.9 sec
Crater weld data Current 0 to 999 A
Voltage 0.0 to 99.9 V
Width 0.0 to 40.0 mm
Weaving data Frequency 0.0 to 4.0 Hz
Pattern (Option) 0 to 10 -
！ CAUTION
Database described in the Appendix is pre-installed at

time of factory shipment.
8-7
AUX.1404 ARC WELD SETTING
This function sets various kinds of data for arc welding operation.
Move the cursor to [1404. Arc Weld Setting] in the auxiliary function screen to display the
auxiliary function list as shown in the figure below. Some menu items are Options and may not
be shown depending on robot specification.
Overview of each function is shown in the table on next page. The subsections hereafter
describe each of these functions.
8-8
Linearization Weld current/voltage characteristics in arc weld machines differ

depending on its manufacturer/model, weld gas, wire type, etc.
To match these characteristics, linearization table is prepared
inside the robot controller. By editing this table, it is possible
to match the set current/voltage with actual current/voltage and
to make control of weld conditions easier.
Offset/Gain For example, when a weld machine breaks, some characteristics
between old and new machines may differ. Use Offset/Gain to
correct these differences instead of re-editing the linearization
set above.
Weld machine
command
Set current/voltage
Weld Start Sequence Sets various kinds of data for arc weld sequence and enables
changing of the weld sequence.
Software Slow Down Sets weld conditions for the time up until arc is generated at arc
start. Enables superior arc start settings.
Weld Stuck Cancel Sets various kinds of data to automatically release when weld
Sequence wire is stuck.
Arc Spot Sequence Sets various kinds of data for arc spot weld sequence.
Preflow/Afterflow Sets time for preflow/afterflow.
Wire Inching/Retract Sets speed for inching/retracting weld wire.
Weld ON/OFF in Check Sets weld ON/OFF at check operation.
Touch Sensing (Option) Sets various kinds of data for touch sensing function. For more
details, see also 8.0 Touch Sensing Function (Option).
Special Pattern Weaving Enables registration of special weaving patterns for reference
(Option) during program execution. For more details, see also 9.0
Special Pattern Weaving Function (Option).
Servo Torch (Option) Sets various kinds of data for servo torch function. For more
details, see also 10.0 Servo Torch Function (Option).
8-9
AUX.1404-1 LINEARIZATION
This function calibrates the absolute values for current/voltage for each weld method, wire
diameter, wire extension length, wire type, and weld machine with the voltage that is actually
commanded to weld machine.
Setting item Description Setting range

Weld Current Sets the command voltage (mV) from controller to 0 to 999A
weld machine necessary for realizing command 0 to 15000mV
weld current.
Weld Voltage Sets the command voltage (mV) from controller to 0 to 99.9V
weld machine necessary for realizing command 0 to 15000mV
weld voltage.
Maximum Output Voltage Some weld machines receive only 15V or less of 0.0 to 15.0V
output voltage as a command value from robot
controller. For these machines, the max. voltage
output value from controller can be restricted.
！ CAUTION
1. No adjustment is needed when both robot and weld machine are

purchased from Kawasaki, as correct values are already
2. Consult Kawasaki before changing these set values.
8-10
Weld current
press ↵.
Press <Graph> to display the graph

showing the set data.

Weld voltage
press ↵.


Once setting is complete, weld current/voltage values are sorted in ascending order when the
setting screen is displayed again.
8-11
Maximum output voltage

1. Input required data by Number
(0-9), and if the setting is correct,
press ↵.

When current/voltage are set for the weld condition, the voltage value to be sent to weld machine
is then determined by linearization as per the linearization data. For example, the command
value to weld machine is as follows when setting the weld current/voltage value in the figure on
the previous page (outputs 4.74V by 224A and 7.967V by 19.2V, and outputs 3.53V by 192A and
6.639V by 16V) and executing welding of 210A and 18V.
Current 3530 + 4740-3530 × (210-192)

224-192
= 4210mV
Voltage 6639 + 7967-6639 × (18-16)

19.2-16
= 7469mV
8-12
Aux.1404-2 OFFSET/GAIN
In order to realize the specified current/voltage during actual welds, this function sets offset and
gain values for adjusting the standard linearization characteristics.

Current/Voltage offset Sets constant value (mV) to be added to -9999 to
command value from controller to weld machine. 9999
Current/Voltage gain Sets a multiplier value (unit 0.001) to command 0 to 9.999
value (mV) from controller to weld machine.
！ CAUTION


press ↵.

[ NOTE ]
Command voltage Value calculated

＝ × Gain + Offset
output from controller by linearization
8-13
Aux.1404-3 WELD START SEQUENCE

Threshold for scratch/ Sets threshold distance for switching 0 to 999
Standstill start scratch/standstill start. When the distance between
real taught points is larger than the set value, scratch
start is selected, and if not, stand still is selected.
Scratch start Sets distance/area in which robot will not move back 0 to 99
Keep welding to weld start point even after arc generation at scratch
distance start.
Scratch start Sets distance/area in which robot moves back to 0 to 99
Turn back distance weld start point after arc generation at scratch start.
Standstill start Sets standstill time at stand still start. 0.0 to 9.9
Standstill time
Weld start retry Sets No. of times for retrying weld start sequence 0 to 9
Number of times when arc is not generated.
Weld start retry Sets time for retracting wire before performing arc 0.0 to 9.9
Retract time start retry.
Weld start retry Sets speed for retracting wire before performing arc 0 to 100
Retract speed start retry by ratio to the Aux.1404-1-3 Maximum
Output Voltage. For servo torch spec. (Option),
sets the speed by ratio to the max. rotation speed set
in Aux.1404-16-1 Linearization.
Turn back speed Sets speed by which the torch moves back to weld 1 to 999
start point at scratch start, arc start retry, etc.
Overlap distance in Sets distance for overlap weld at restart. Setting -1 -1 to 99
restart automatically calculates the distance according to the
weld conditions.

input required data* by Number
press ↵.

NOTE* Values set here are standard parameter values of Kawasaki.
8-14
REMARKS: Weld Start Sequence
1. Weld start sequence
To start welding more smoothly, the following two types of weld start sequences have been
provided.
(1) Scratch start
Robot moves to the next teach point from weld start point during which time arc is generated.
This is called scratch start as it looks like the torch scratches the work, and it is used mainly for
welding a long weld line. This robot motion is further classified into two types depending on
the distance between taught weld start point and the point the arc is actually generated.
Weld continue point

Weld start point (A) (B) Weld end point
1) Distance from start point to arc generating point is less than [Keep Welding Distance (A)]
If arc is generated within (A) distance, welding continues toward the next weld continue (end)
point.
Arc generating point
Weld continue point

8-15
2) Distance to arc generating point after passing (A) is less than [Turn Back Distance (B)]
If arc is generated within (B) distance, robot welds moving backwards to the weld start point, and
continues welding toward the next weld continue (end) point. When no arc is generated even
after passing (B) distance, error occurs.
Arc generating point
Weld continue point

(2) Standstill start
Robot stops at weld start point until arc is generated. After arc generation, welding continues
toward the next weld continue (end) point. Standstill time is variable and when arc is not
generated within the set time, an error occurs.
2. Restart sequence
This sequence is used for restarting the welding after robot stops welding for some reason.
e.g.) After arc deficiency by tip friction, etc. After holding.
Scratch start or standstill start can be executed in restart sequence. However, in order to bury the
crater caused by the weld stop, robot moves back to the point where welding stops after arc
generation and to restart welding with an overlap welding.
e.g.) After calculating remaining distance and restarting by a scratch start
Weld start point Arc generating point
Overlap welding distance
3. Arc start retry
Normally when No. of times for retry is not set, an error occurs if arc is not generated. However,
if set, the weld start sequence (scratch start/standstill start) will be attempted the set No. of times.
Wire can be retracted before the retry, and retract time and No. of times for retract can be set or
modified.
8-16
AUX.1404-4 SOFTWARE SLOW DOWN
This function changes weld conditions for the time up until arc is generated. For example, when
the base metal surface is resistant to current flow and generation of arc is difficult, weave for
increased generation until the arc is actually applied to the surface.

Software slow down Enable
Disable
Weld current Sets weld current (A) at arc start until arc is 0 to 999
generated.
Weld voltage Sets weld voltage (V) at arc start until arc is 0 to 99.9
generated.
Pre-heat time Sets for the time (s) to operate keeping the
conditions set in this screen after arc is generated
at arc start.
Polarity ratio (Option) Sets polarity ratio at arc start until arc is 0 to 15
generated.
Weaving width Sets weaving width (mm) at arc start until arc is 0 to 40.0
generated.
Weaving frequency Sets weaving frequency (Hz) at arc start until arc 0 to 4.0
is generated.
Weaving pattern Sets weaving pattern at arc start until arc is 0 to 10
(Option) generated.

press ↵. ([Pole Ratio] and
[Weaving Data- Pattern] are
displayed only when Option is
installed.

8-17
AUX.1404-5 WELD STUCK CANCEL SEQUENCE
After crater treatment or arc spot welding at weld end point, weld stuck detecting is executed
automatically. When wire is stuck, this condition is automatically released by arc generation
under the crater/arc spot conditions (Weld Stuck Cancel Sequence). When weld stuck cancel
does not succeed after attempting sequence set No. of Detecting Times, error occurs. Note
that cancel sequence is not possible if crater treatment was not executed.

Number of Set No. of times for repeating detecting wire stuck → arc 0 to 9
detecting times ON after arc OFF.
Detecting wire Sets waiting time for detecting weld stuck after arc OFF. 0.0 to 9.9
stuck waiting time
Detecting wire Sets time for detecting wire stuck. Receiving stuck 0.0 to 9.9
stuck time signal within this time, it is considered as weld stuck.
Welding time Sets arc ON time to cancel weld stuck. 0.0 to 9.9

press ↵.

Crater treatment/arc spot weld
Detecting Wire Stuck Waiting Time
Weld stuck? No
(Detecting)
Yes To next step
Detecting times ≥ Yes

set detecting times
No
Error
Arc ON
8-18
AUX.1404-6 ARC SPOT SEQUENCE
This function sets various parameters for arc spot welding.
Setting item Setting

Description
range
Retry Number of times Sets max. No. of times for repeating arc 0 to 9
spot when current detect signal is not
returned from weld machine at time of arc
spot weld (that is, weld is not executed).
Wire retract time Sets time for retracting wire until arc spot 0.0 to 9.9
weld is executed at retry.
Wire retract speed Sets speed for retracting wire before 0 to 100
performing arc spot weld at retry by ratio to
the Aux.1404-1-3 Maximum Output
Voltage. For servo torch spec. (Option),
sets the speed by ratio to the max. rotation
speed set in Aux.1404-16-1 Linearization.
After arc spot Wire retract time Sets time for retracting wire after arc spot 0.0 to 9.9
weld was executed.
Wire retract speed Sets speed for retracting wire after 0 to 100
performing arc spot weld by ratio to the
Aux.1404-1-3 Maximum Output Voltage.
For servo torch spec. (Option), sets the
speed by ratio to the max. rotation speed set
in Aux.1404-16-1 Linearization.

press ↵.

8-19
AUX.1404-7 PREFLOW/AFTERFLOW

Preflow time Sets time to turn Arc ON 0∼9.9
ON gas before arc Gas ON
generation. Preflow time
Afterflow time Sets delay time for Arc ON 0∼9.9

Gas ON
turning OFF gas after
arc generation. Afterflow time

press ↵.

1. Preflow Air cut point

When preflow time is set, shield gas is turned ON for
the set time before robot arrives at weld start point.
If weld start point and its previous taught point are
close and robot moves within the set time, preflow is
executed only during the time robot moves.
Moving distance Weld start point Weld continue (end) point

determined by the set time
2. Afterflow When afterflow time is set, robot stops and shield

gas is turned ON for the set time after crater
treatment at weld end point. Afterflow is not
Air cut point
executed if crater treatment is not executed.
Weld start point Weld continue (end) point

8-20
AUX.1404-8 WIRE INCHING/RETRACT
This function inches/retracts wire during air cut operation. This is executed in 0.5 sec
increments as robot moves per the air cut instruction taught this setting.

Wire retract speed Sets speed at time of wire retract by ratio to the 0 to 100
Aux.1404-1-3 Maximum Output Voltage. For servo
torch spec. (Option), sets the speed by ratio to the max.
rotation speed set in Aux.1404-16-1 Linearization
Wire inching speed Sets speed at time of wire inching by ratio to the 0 to 100
Aux.1404-1-3 Maximum Output Voltage. For servo
torch spec. (Option), sets the speed by ratio to the max.
rotation speed set in Aux.1404-16-1 Linearization.

press ↵.

Air cut point

Air cut point
Inching
Air cut point

Air cut point Retract
8-21
AUX.1404-9 WELD ON/OFF IN CHECK
This switch enables execution of real welding during check operation.
Setting item Description

Weld in check ON Welding can be executed during check operation when
weld status is ON.
Weld in check OFF Welding cannot be executed during check operation
regardless of weld ON/OFF status.
1. Select [ON] or [OFF] of [Weld in

Check] and press ↵.*

8-22
AUX.1404-10 TOUCH SENSING (OPTION)

Touch sensing Distance* Sets wire sensing distance. 0 to 300
Speed* Sets wire sensing speed. 0 to 100
Wire check Retract speed Sets retract speed at wire check. 0 to 100
Inching speed Sets inching speed at wire check. 0 to 100
NOTE* For touch sensing distance and speed.

Teach point
A
z
Touch sensing speed
Sensing start point

B’
z Teach point
B
z
Sensing end point
zB’’
Touch sensing distance
(1) In the setting above, distances between B’ and B, and B and B’’ are both 20mm.
(2) The faster the sensing speed, the greater the weld wire bends at touch and then correcting
accuracy becomes decreased. However, wire bend varies depending on sensing direction,
wire diameter, material, etc.
(3) These parameters are provided for the work detection and work position compensation
functions. For more details, see 8.3 Work Detection Function and 8.4 Compensation
Function for Work Deviation.

input required data** by Number
press ↵.

NOTE** Values set here are standard parameter values of Kawasaki.
8-23
AUX.1404-11 SPECIAL PATTERN WEAVING (OPTION)

Time Sets time ratio. 0 to 100
X Sets robot motion increment ratio for back and forth. -100 to 100
Y Sets robot motion increment ratio for right and left. -100 to 100
Z Sets robot motion increment ratio for upper and lower. -100 to 100
Angle Sets posture changing angle for pendulum weaving. -10.0 to 10.0
Current Sets current increment ratio for boost. -100 to 100
Voltage Sets voltage increment ratio for boost. -100 to 100
1. Input desired weaving pattern

number by Number (0-9) and
press ↵.

press ↵. Press <Next Page> to
display the setting screen for
patterns 9 to 15.

8-24
AUX.1404-16 SERVO TORCH (OPTION)
This function sets various kinds of data for servo torch function.
Select [16. Servo torch] in [1404. Arc Weld Setting] to display the auxiliary function list shown in
the figure below.
Overview of each function is shown in the table below. The subsections hereafter describe each
of these functions.
Linearization Sets the relation between weld current command values (A) and wire
feeding speeds (rpm).
Torch data Sets the speed reduction ratio, number of bits changed per encoder
rotation and direction of motor rotation for the servo torch.
Servo adjustment Adjusts the servo parameters that control the feeding.
Inching speed Registers the wire inching/retract speed that corresponds to each
teach speed, set by pressing TEACH SPEED.
Start/End sequence Sets the parameters that control the wire feeding at weld start/end.
8-25
AUX.1404-16-1 LINEARIZATION
This function sets the relation between weld current command values (A) and wire feeding
speeds (rpm) for each weld method, wire diameter, wire extension length, wire type, and weld
machine.

Linearization Sets the value to transform weld current 0 to 999A
command value (A) to wire feeding speed (rpm). 0 to 999rpm
！ CAUTION


press ↵.


8-26
When current/voltage are set for the weld condition, the rotation speed to be sent to servo torch
motor is then determined by linearization as per the linearization data. For example, the
command rotation speed to servo torch is as follows when setting the weld current value in the
figure on the previous page (outputs 102rpm by 250A and 81rpm by 200A) and executing
welding of 210A and 18V.
Rotation speed 81 + 102-81 × (210-200)

250-200
=85.2rpm
Note that max. command rotation speed cannot exceed the max. value set in this linearization
table.
8-27
AUX.1404-16-2 TORCH DATA
This function sets the speed reduction ratio, number of bits changed per encoder rotation and
direction of motor rotation for servo torch.

Reduction ratio Sets the speed reduction ratio for the servo torch. n1: 1 to 100000
n2: 1 to 1000
Bits per encoder Sets number of bits per one encoder rotation. 1 to 9999
rotation
Rotary direction Sets plus or minus for direction of motor rotation.
of motor

press ↵.

8-28
AUX.1404-16-3 SERVO ADJUSTMENT
This function adjusts the servo parameters that control the wire feeding. The following three
setting items can also be set in Aux.2007-2 External Axis Servo Parameter- Full Spec Tuning.
In that auxiliary function screen, Servo gain is KVP, Torque limit (plus direction) is IQCLP, and
Torque limit (minus direction) is IQCLM.

Servo gain Sets the feedback gain of servo torch motor. 0 to 32767
Torque limit Sets the upper limit of max. output current of servo 0 to 32767
(plus direction) torch motor.
Torque limit Sets the upper limit of max. output current of servo 0 to 32767
(minus direction) torch motor.

press ↵.

8-29
AUX.1404-16-4 INCHING SPEED
This function registers the wire inching/retract speed that corresponds to each teach speed, set by
pressing TEACH SPEED.

Inching/Retract Sets the rotation speed when inching at wire inching 1 to 100
speed 1 speed 1.
Inching/Retract Sets the rotation speed for wire inching speed 2. 1 to 100
speed 2
Inching/Retract Sets the rotation speed for wire inching speed 3. 1 to 100
speed 3

press ↵.

8-30
AUX.1404-16-5 START/END SEQUENCE
This function sets the parameters that control the wire feeding at weld start/end.

Start Wire feeder on delay After Arc ON signal turns ON, delays the start 0 to 999
of the wire feeding by set value.
Slow down speed Sets wire feeding speed to turn WCR signal ON 1 to 999
after Arc ON signal turns ON.
Hot start 1 Sets the wire feeding time at slow down speed 0 to 999
after WCR signal turns ON.
Hot start 2 Sets the time to change from slow down speed 0 to 999
to wire feeding speed at welding after Hot start
1 described above.
End Wire feeder off delay After Arc ON signal turns OFF, delays the start 0 to 999
of the deceleration of the wire feeding by set
value.
Flare up time Sets time to decelerate from wire feeding speed 0 to 999
to 0, after Wire feeder off delay has elapsed.
Feeder waiting time Sets the time to start wire feeding after wire is 0 to 999
after Stuck cancel detected not to be stuck.
Time of wire feed Sets the wire feeding time after weld stuck is 0 to 999
after Stuck cancel canceled.
Feeder speed after Sets the wire feeding speed after wire stuck is 1 to 999
Stuck cancel canceled.

press ↵.

8-31
Wire feeding speed (rpm)
Wire feeding
speed at welding
Slow down speed
Weld in progress
Time (t)
Wire feeder Waiting WCR Hot start 1 Hot start 2
on delay detection
WCR
Arc ON signal
At start of welding
8-32
Wire feeding speed (rpm)
Wire feeding
speed at welding
Arc ON signal
Time t
Wire feeder off delay Flare up time
(1) When wire stuck is not detected.
Time1: Wire feeder off delay

Time2: Flare up time
Wire feeding speed (rpm) Time3: Feeder waiting time after Stuck cancel
Time4: Time of wire feed after Stuck cancel
Speed at welding Speed: Feeder speed after Stuck cancel
Speed
Time t
Time1 Time2 Time3 Time4
Detecting weld
stuck
Arc ON signal
Weld stuck detected Weld stuck not detected
(2) When wire stuck is detected.

At end of welding
8-33
AUX.1405 ARC WELD TORCH DIMENSION
When using a standard arc weld torch as shown below, tool transformation values can be set by
registering length of the weld torch, torch installation angle and wire extension length.

press ↵.


Length Length (A) in 0 to 999
the figure left
Angle Angle (B) in 0 to 180
the figure left
Wire Length (C) in 0 to 999
(A) extension the figure left
Tool Y direction
(B) No registration is needed when robot and

Tool X direction
torch are purchased together from Kawasaki,
as the values are already registered at time of
Tool Z direction
factory shipment.
End of tool
(C)
Rotation center of JT6
！ CAUTION
Attach the torch to the robot by setting wire extension length to

15 mm and the wire end to be on the rotation center of JT6 as
shown above. If wire extension length is not 15 mm, set the
torch by the same procedure above. Then, register the desired
wire extension length and cut the wire to that length.
8-34
AUX.1406 ARC WELD CONDITION MODIFY
This function changes the weld conditions for a block of weld continue or weld end points that
were taught by direct teaching method. To change the weld conditions for a range of points
taught by indirect method, use Aux.1401.
1. Move cursor to <Program Name>

and set the desired program name.
For more details about selecting a
program name, refer to Operation
Manual for E series controller-
2.7.1.1 Program/ Comment Area.
2. Input required data, and press ↵.
[ NOTE ]
Designation of step No.;

When the end step is 0, only start step is processed.
When 0 is designated for start step, input error is returned.
When specified number of steps is greater than the last step of designated
program, changes are applied up until the last step.
Example of input:
Start step No. 0 0 1 3
End step No. 0 5 0 3
↓ ↓ ↓ ↓
Error Error Execute only Execute only
step1 step 3
8-35
3. Condition setting screen* as

shown on left is displayed. Move
cursor to each item and input
required data by Number (0-9).
If the setting is correct, press ↵.

NOTE* From the range of selected steps, the data of the step first taught by direct teaching
method is displayed in this screen.
Press <Auto Set> to refer to the arc weld condition database screen. For details about
this screen, refer to Aux.1403.
[Pole Ratio] and [Weaving Data- Pattern] are displayed only when Option is installed.
[ NOTE ]
1. Changes apply only to the weld continue or weld end points in the specified
range that were taught by direct teaching method. Data of other steps in
the range are not affected.
2. To change weld conditions in weld continue or end points taught by indirect
method, see Aux.1401 Arc Weld Condition.
8-36
AUX.1407 ARC SPOT WELD CONDITION MODIFY
This function changes the weld conditions for a block of arc spot weld points that were taught by
direct teaching method. To change the arc spot weld conditions for a range of points taught by
indirect method, use Aux.1402.
1. Move cursor to <Program Name>

and set the desired program name.
For more details about selecting a
program name, refer to Operation
Manual for E series controller-
2.7.1.1 Program/ Comment Area.
2. Input required data, and press ↵.
[ NOTE ]
Designation of step No.;

When the end step is 0, only start step is processed.
When 0 is designated for start step, input error is returned.
When specified number of steps is greater than the last step of designated
program, changes are applied up until the last step.
Example of input:
Start step No. 0 0 1 3
End step No. 0 5 0 3
↓ ↓ ↓ ↓
Error Error Execute only Execute only
step1 step 3
8-37
3. Condition setting screen* as

shown on left is displayed. Move
cursor to each item and input
required data by Number (0-9).
If the setting is correct, press ↵.

NOTE* From the range of selected steps, the data of the arc spot step first taught by direct
teaching method is displayed in this screen.
[Pole Ratio] is displayed only when Option is installed.
[ NOTE ]
1. Changes apply only to the arc spot points in the specified range that were
taught by direct teaching method. Data of other arc spot steps in the range
are not effected.
2. To change AS (Arc Spot) weld conditions in arc spot points taught by
indirect method, see Aux.1402 Arc Spot Weld Condition.
8-38
E Series Controller 9. Touch Sensing Function (Option)
9.0 TOUCH SENSING FUNCTION (OPTION)
This chapter describes touch sensing function by optional specification and the teaching
operation.
9.1 OVERVIEW OF TOUCH SENSING FUNCTION
9.1.1 FEATURES OF TOUCH SENSING OPTION FUNCTION
When using the robot to weld, good positioning accuracy is required for both workpiece and for
arc torch relative to the workpiece. However, at the weld production site, perfect accuracy
cannot always be guaranteed. Thus, to achieve better, more consistent accuracy, use the touch
sensing function in the following situations.
1. When wire extension length must be accurate. → Wire check function

2. When confirmation is needed to check if workpiece is set correctly. → Workpiece detection
function
3. When positioning accuracy of the workpiece is not ensured. → Compensation for workpiece
deviation
1. Wire check function
In automatic weld operation, wire extension length

may vary from the set length after welding. This
function can be used to keep the wire length constant. Work-
piece
To check if wire is the set length, robot stops and only Weld wire is
wire is inched. inched as
robot stops.
2. Workpiece detection function
Typically in auto weld operation, workpiece placement

is checked via sensors (limit switches, photocells).
Touch sensing eliminates the need for sensors. Robot
checks correct placement automatically before welding Starts
Work-
piece detecting
by moving torch from its position and using the torch workpiece
tip to detect presence of the workpiece. from this point.
9-1
3. Compensation for workpiece deviation
In robot weld operation, this function compares taught Work-

point with the point where workpiece was detected at piece
repeat operation, and automatically corrects for

differences; weld can be executed accurately Corrects tip pose
automatically
considering workpiece set deviation. Torch tip moves when workpiece
according to the set sensing pattern. is not set
correctly.
9.1.2 SENSING PATTERNS FOR COMPENSATION OF WORKPIECE DEVIATION
When planning a weld operation, determine beforehand the direction in which the workpiece may
deviate. In addition, one must be considered the kind of workpiece to be welded, and workpiece
deviation amount.
This section describes seven kinds of sensing patterns by which workpiece deviation
compensation are made. Sensing patterns can be used alone or in combination (max. of three
patterns).
9-2
Pattern Pattern 1 Pattern 2 Pattern 3 Pattern 4 Pattern 5 Pattern 6 Pattern 7

Item
Types of sensing
No. of sensing pts

1 2 3 3 4 3 3
(teaching points)
Direction of Translational Translational Translationa

workpiece deviation movement in movement in l movement Movement Movement Movement on Movement
1 direction 2 directions in 3 on surface on surface surface on surface
directions
Shape of workpiece No need to be

Flat Flat Flat Flat Cylinder Flat
control surface flat
Relation between
workpiece deviation No need to be No need to No need to No need to be No need to
Vertical Vertical
direction and control vertical be vertical be vertical vertical be vertical
surface
Relation between Center line of

control surface and No need to be cylinder
Vertical Vertical Vertical Vertical Vertical
set surface vertical vertical to set
surface
st st st st st
Relation between 1 surface: 1 surface: 1 surface: 1 surface: 1 surface: Outer or inner 1st surface:
control surface and 1 point 1 point 1 point 2 points 2 points surfaces of 2 points
nd nd nd nd nd
sensing point 2 surface: 2 surface: 2 surface: 2 surface: cylinder 2 surface:
(teaching point) 1 point 1 point 1 point 2 points whose section 1 point
3rd surface: becomes
1 point perfect circle:
3 points
Relative relation of 2
control surfaces 2 orthogonal 3 orthogonal orthogonal 2 orthogonal
⎯ ⎯ ⎯
flat surfaces flat surfaces flat flat surfaces
surfaces
Order of teaching
⎯ ⎯ ⎯ Specified Specified Specified Specified
points
9-3
Each sensing pattern is described below.
1. Pattern 1: Workpiece may deviate in only one direction
(1) Condition of workpiece

Workpiece moves to only one direction
parallel.
Workpiece
(2) Sensing point

B1
B
Execute sensing of one point which the

Stopper
workpiece moves toward, B1 in left figure.
A1
(3) Teaching point

Direction of workpiece Control surface
deviation Teach A1 and B1 as line A1B1 parallel to
B
the direction in which workpiece deviates.
2. Pattern 2: Workpiece may deviate parallel to flat surface.

1) Workpiece moves parallel to the flat
Direction of workpiece surface.
deviation
2) Control surfaces (1 and 2) are flat and
A2
intersect at 90°.
3) Directions in which workpiece deviates
are vertical to each control surface.
Control B2 B
Workpiece
surface 1
(2) Sensing point
Control
surface 2 B1 B
Stopper Execute sensing of two points which the
workpiece moves toward, B1 and B2 in
A1 left figure.
Direction of workpiece Deviation

deviation B1 A1 direction (3) Teaching point
Control Teach A1, B1, A2, and B2 as lines A1B1
surface
B
and A2B2 parallel to the directions in

B
which workpiece deviates.
9-4
3. Pattern 3: Workpiece may deviate parallel in space.
Direction of
workpiece deviation (1) Condition of workpiece
Control
surface 2 1) Workpiece moves parallel in space (in
three directions).
A2 2) Control surfaces (1, 2 and 3) are flat
Control
surface 3
and orthogonal to each other.
BB22 B
3) Directions in which workpiece deviates

Workpice
A3 B3
B
are vertical to each control surface.
Direction of
workpiece deviation
BB11
B
(2) Sensing point
Execute sensing of three points which the
A1 workpiece moves toward, B1, B2 and B3 in
Control
surface 1 left figure.
Direction of Deviation
workpiece deviation B1 A1 direction
Control (3) Teaching point
surface
Teach A1, B1, A2, B2, A3, and B3 as lines
A1B1, A2B2 and A3B3 parallel to the
B B B
directions in which workpiece deviates.
9-5
4. Pattern 4: Workpiece may deviate arbitrarily on a flat surface.

surface on which it is placed.
intersect at 90°.
Work
3) The two control surfaces are vertical to
the flat surface on which the workpiece
moves.
B3 A3
B1 B2
(2) Sensing point
Control 1) Execute sensing of two points on one
surface 2
A1 A2 Control Deviation
sensing surface and one point on the
Control
surface 1 surface direction
B1 A1 other surface, B1, B2, and B3 in left
Set surface
figure.
2) B1 and B2 are on the same surface.
(3) Teaching point

Teach the points in order of A1, B1 →A2,
B2 → A3, B3 with the following
B
conditions.
1) Lines A1B1, A2B2, and A3B3 are
B B B
parallel to the workpiece setting

surface.
2) Angle between lines A1B1 and A3B3 is
B B
30° to 150° (90° is desirable).

3) Distance between B1 and B2 is 10mm or
more.
9-6

2) Control surfaces (1 and 2) are flat.
Work B4 3) The two control surfaces are vertical to
B1 A4
B3 moves.
B2
A3 (2) Sensing point

A1
Control 1) Execute sensing of four points (two
A2 Control surface 2
surface 1 points on each surface), B1, B2, B3, and
B4 in left figure.
B
2) B1 and B2 are on control surface 1 and

Control
surface Deviation B3 and B4, on control surface 2, as in
direction
B
B1
left figure.
Set surface
(3) Teaching point

B2 → A3, B3 → A4, B4 with the
B
following conditions.
1) Lines A1B1 and A3B3 are parallel to the
B B
workpiece setting surface.

2) Angles between lines A1B1 and A3B3/
B B
lines A2B2 and A4B4 are 30° to 150°

B B
(90° is desirable).
3) Distances between B1 and B2/B3 and B4
are 10 mm or more.
9-7
6. Pattern 6: Cylinder workpiece may deviate on a flat surface.
Centerline of cylinder (1) Condition of workpiece

1) Workpiece is cylinder.
2) Workpiece moves parallel on a flat
Workpiece
A3 surface which is 90° to the centerline
of the cylinder.
B3B
(2) Sensing point

1) Execute sensing of three points.
B1
B
B2
B
2) Execute sensing on outer or inner

A1 points of the cylinder whose section
A2
becomes a perfect circle, B1, B2, and
B3 in left figure.
B
Centerline (3) Teaching point

of cylinder
Set Deviation
surface direction B2 → A3, B3 with the following
B
conditions.
B B B

surface.
2) Angles between lines A1B1 and A2B2/
B B
lines A2B2 and A3B3 are 30° to 150°

B B
(90° is desirable).
9-8

intersect at 90°.
3) The two control surfaces are vertical to
B1
A1 moves.
A2
B2 (2) Sensing point
B3 1) Execute sensing of two points on one
Control sensing surface and one point on the
surface 1
other surface, B1, B2, and B3 in left
A3 Control Deviation
figure.
surface direction
Control B1 2) B1 and B2 are on the same surface.
surface 2
Set surface
(3) Teaching point
B2 → A3, B3 with the following
B
conditions.
B B B

surface.
2) Angle between lines A1B1 and A3B3 is
B B
30° to 150° (90° is desirable).

3) Distance between B1 and B2 is 10 mm
or more.
[ NOTE ]
Pattern 7 is different from pattern 4 in that A3 and B3 are compensated by

detecting B1 and B2; pattern 7 is suitable for sensing a thin work.
9-9
9.2 WIRE CHECK FUNCTION
！ WARNING
When wire check function is working, a

Torch
constant voltage (DC15V standard,
Weld
machine DC400V as Option) is applied between
Voltage Work
torch and base material as shown on the
+ -
Insulating left so that the contact position can be
sheet Set table/Base material
detected the instant a touch has been
Working table
made. Thus, beware the following items:
1. Avoid touching the base material or wire during touch sensing.
2. Do not fail to connect the work to be touched and the set table to the earth side.
Furthermore, the position to be touched should not be deviated and select the forged
surface. Execute the touch sensing on a firmly fixed set table.
Wire check function can be used in the following cases.
1. To keep a constant wire extension length without using wire cutter devices, etc.
2. At pre welding points, set the wire to the desired length in 1. above.
The following subsection describes the teaching operations. For standard teaching methods,
refer to 5.0 Teaching and Operation Manual for E series controller- 5.0 Teaching.
9.2.1 TEACHING FOR WIRE CHECK FUNCTION
Teach the movement in the right figure.
Point A
Inch wire and

touch the Point C
workpiece here.
Set length
Point B
Workpiece
9-10
[ NOTE ]
1. Only air cut points can be taught the wire check function.
2. Teach the wire check to the point where the wire is inched to the desired
length (Point B in figure on previous page).
1. Teach point A. As a general point

previous to teaching the wire check
function, move the torch tip to point A and
then teach air cut (AC) for instruction. If
setting is correct, press ↵.
A
Work
2. Teach point B; after moving the torch tip to

the point B, teach [Wire Check]. Set the
desired wire length and touch it to point B.
As exact positioning is required to point B,
set the accuracy to 1. Then move cursor
under Option Switch on the auxiliary data
B title row by pressing A + OPTION or by
→ or ←, and press ↵.
Workpiece
Nozzle
Tip
Wire
Extension
length
To set the desired wire
Workpiece extension length, use a scale
as shown here.
9-11
The setting screen appears as in Figure 8.1. Select [3. Wire Check] to [Touch Sensing] and
press ↵.
Figure 9.1
Press RECORD to teach the wire check in the Option Switch field. The teach screen appears as
in Figure 9.2.
Figure 9.2
3. Teach point C; move torch tip to point C

after touching the workpiece, and then
teach air cut (AC) for instruction. As
exact positioning is not required, set the
accuracy to 4 (2 or 3 is also possible). If
setting is correct, press RECORD.
Work
The setting of wire check function is complete.
9-12
9.2.2 WIRE CHECK FUNCTION AT REPEAT OPERATION
！ CAUTION
Wire check function is possible only when repeat mode and continuous step
are selected. Wire check function does not operate under any other
conditions. (Doing so only plays back taught contents.)
Robot moves as shown below when the program taught in 9.2.1 Teaching for Wire Check
Function is executed in repeat mode.
Point A Point C
Point B
0.5 sec Set length

ON Work Work
Wire retract signal
OFF at the moment of touch
Wire inching signal

ON for max. of 5 sec
1. When [Wire Check] is taught at point B, wire is retracted for 0.5 sec when robot starts moving
from point A to point B.
2. When arriving at point B, robot stops and inches the wire for 5 sec at a constant speed.
3. When wire tip touches the workpiece during wire inching, robot stops inching the wire and
starts moving to point C.
4. If wire tip does not touch the workpiece within 5 sec, robot outputs error- E6516 Wire check
failure.- and stops.
5. The speed for inching/retracting wire can be changed. (The time cannot be changed.) For
more details, refer to Aux.1404-8 in 8.0 Auxiliary Functions.
9-13
9.3 WORKPIECE DETECTION FUNCTION
！ WARNING
When workpiece detection function is

Torch
working, a constant voltage (DC15V
Weld
machine standard, DC400V as Option) is applied
Workpiece
Voltage between torch and base material as shown
+ -
Insulating on the left so that the contact position can
be detected the instant a touch has been
Working table
Workpiece detection function can check for presence of a workpiece on the set table thus
eliminating the need for sensors, switches, etc.
The following subsection describes the teaching operations. For standard teaching methods,
refer to 5.0 Teaching and Operation Manual for E series controller- 5.0 Teaching.
9.3.1 TEACHING FOR WORKPIECE DETECTION FUNCTION
Teach the movement in the figure below.
Point Ａ
Point Ｃ
Point B’
Workpiece
Point B
Touch the
workpiece here.
9-14
[ NOTE ]
1. Only air cut points can be taught the workpiece detection function.
2. Teach the workpiece detection to the point where the wire touches the work
(Point B in figure on previous page).
1. Teach point A. As a general point

previous to teaching the workpiece
detection function, move the torch tip to
point A and then teach air cut (AC) for
instruction. Note that point A defines the
A
sensing direction to the sensing point B
Workpiece
where workpiece detection is taught (that is,
robot moves A to B when sensing).
Recommended distance between A and B
is 100mm or more. If setting is correct,
press RECORD.
Case A 2. Teach point B; after moving the torch tip to

the point B, teach [Workpiece Detect].
When touching the torch tip to the
Extension length
(No need to workpiece, the desired torch angle can be
be accurate) B
selected as in case A, B and C on the left.
In case A, extension length need not be
accurate. In cases B and C, however, the
Case B extension length must correctly match the
set length.
B
As exact positioning is required to point B,
Extension length set the accuracy to 1. Then move cursor
(Needs to be accurate)
under Option Switch on the auxiliary data
title row by pressing A + OPTION or by
Case C
Extension length (Needs to be accurate) → or ←, and press ↵. The setting screen
appears as in Figure 8.1. Select [4.
B
Workpiece Detect] to [Touch Sensing] and
press ↵. Press RECORD to teach the
workpiece detection in the Option Switch
field. The teach screen appears as in
Figure 9.3.
9-15
Figure 9.3
Sensing start point Note that robot moves on line A to B at

B sensing as on the left even when point B
A
When point B was taught by joint interpolation. was taught by joint interpolation.
3. Teach point C; move torch tip to point C

after touching the workpiece, and then
teach air cut (AC) for instruction. As
exact positioning is not required, set the
accuracy to 4 (2 or 3 is also possible). If
C
setting is correct, press ↵.
Workpiece
The setting of workpiece detection function is complete.
9-16
9.3.2 WORKPIECE DETECTION FUNCTION AT REPEAT OPERATION
！ CAUTION
Workpiece detection function is possible only when repeat mode and

continuous step are selected. Workpiece detection function does not operate
under any other conditions. (Doing so only plays back taught contents.)
Robot moves as shown below when the program taught in 9.3.1 Teaching for Workpiece
Detection Function is executed in repeat mode.
Point C Detect the work
B’’’
Work
Point A Point B
B’ B’’
Sensing start point Sensing end point
Detection range
1. Register beforehand the distances between points B and B’ and points B and B’’ by
Aux.1404-10 in 8.0 Auxiliary Functions.
2. When [Workpiece Detect] is taught at point B, robot moves from point A to point B’ at the air
cut speed.
3. The wire tip moves detecting the workpiece at a constant speed from the point B’ to the point
B’’. Set this speed by Aux.1404-10 in 8.0 Auxiliary Functions.
4. When wire tip touches the workpiece (that is, workpiece detection) at point B’’’ during motion
from B’ to B’’, the robot moves to point C at the air cut speed.
5. When workpiece detection did not succeed even after arriving at point B’’, robot outputs error-
E6509 No work detected.- and stops.
9-17
9.4 COMPENSATION FUNCTION FOR WORKPIECE DEVIATION
9.4.1 COMBINATION OF SENSING PATTERNS
When compensating for deviations in workpiece position, the deviation amount must be acquired
correctly. In arc weld specification robot, sensing patterns for compensation are classified into
seven types as in the table below depending on shape of workpiece, deviate direction, etc. For
details on each pattern, see 9.1.2 Sensing Patterns for Compensation of Workpiece Deviation.
Pattern 1 Pattern 2 Pattern 3 Pattern 4 Pattern 5 Pattern 6 Pattern 7
It may be necessary to use a combination of two or three of the patterns above in order to
correctly acquire the deviation amounts. Apply any combination (max. of three patterns) as
needed to accommodate workpiece shape/size.
Two sample combining cases are described below.
1. Case 1
When the condition of the workpiece is as follows, combine pattern 1 (compensation in –

direction) and pattern 6 (compensation for cylinder). Then, compensate the deviation by the
following procedure and execute welding.
(2)
Executes circumferential fillet weld of the cylinder pipe to the Cylinder pipe (1)
square pipe as shown on the left.

(2) (2)
Height of the square pipe deviates a max. of ± 3mm. Weld line
Placing position of the cylinder deviates a max. of ± 5mm. Square pipe
Compensating procedure
Working table
(1) Compensate the deviation (height of square pipe) by pattern 1.
(2) Compensate the deviation (height of cylinder pipe) by pattern 6.
(3) Execute welding.
9-18
2. Case 2
When the condition of the workpiece is as follows, combine pattern 1 (compensation in –

direction) and pattern 4 (compensation on flat surface) to ensure accurate compensation for each
workpiece.
Weld workpiece B to workpiece A, and then workpiece C to workpiece B as shown below.

Workpiece B deviates a max. of ± 2 mm up and down.
Placing position for workpiece C deviates a max. of ± 1 mm.
Compensate by the following procedure and then execute welding.
Compensating procedure Weld line 1
(1) Compensate the deviation in

(3)
workpiece B by pattern 1. (3)
(2) Keep weld line 1 between the (1)
(3) Work C
workpieces A and B. Work B
(3) Compensate the deviation of

workpiece C on the flat surface by Work A
Weld line 1
pattern 4.
(4) Keep weld line 2 between workpieces B and Weld line 2
C.
Using multiple patterns to compensate for workpiece deviation as above is called compensation
by combination of sensing patterns. The relation between patterns is explained below.
Work to be welded To combine patterns, first compensate to

the base, then distinguish second/third
compensations. These are called: mother
Baby work
workpiece compensation, daughter
Third compensation
Daughter work Second compensation
workpiece compensation and baby
workpiece compensation, respectively.
Mother work First compensation
Their relationships are demonstrated here,
Base with mother on base, daughter on mother,
baby on daughter, and the workpiece on
the baby’s back.
9-19
As shown in figure above, the workpiece to be welded can be compensated only after the
deviation of mother workpiece, daughter workpiece and baby workpiece are compensated in this
order.
[ NOTE ]
Compensation by combination
Z
Compensation by combination of sensing
patterns can be mathematically explained as
follows. To compensate the deviation of
coordinates systems, assume mother work
coordinates system (XM, YM, ZM) relative to
the robot base coordinates system (X, Y, Z),
daughter work coordinates system (XD, YD,
Y
ZM ZD) relative to the mother work coordinates
Mother work coordinates
YM
system (XM, YM, ZM), and baby work
Base coordinates
X ZD coordinates system (XB, YB, ZB) relative to
Daughter work coordinates
XM YD the daughter work coordinates system (XD,
XD ZB
YD, ZD) shown on left. Then obtain the
Baby work coordinates deviation of the coordinates systems and
YB
XB
compensate the deviation.
That is, compensation can be performed

correctly during repeat operation by
executing touch sensing to the coordinates
systems (XM, YM, ZM), (XD, YD, ZD) and (XB,
YB, ZB) specified at teaching, obtaining the
deviated coordinates systems (X’M, Y’M,
Z’M), (X’D, Y’D, Z’D) and (X’B, Y’B, Z’B), and
compensating each of the deviations in order
of mother, daughter and baby.
9-20
9.4.2 TEACHING- COMPENSATION FUNCTION FOR WORKPIECE DEVIATION- 1

(TEACHING FOR EACH SENSING PATTERN)
！ WARNING
When deviation compensation function is

Torch
Weld
Voltage Work
between torch and base material as shown
+ -
Working table
This section describes the teaching operations. For standard teaching methods, refer to 5.0
Teaching and Operation Manual for E series controller- 5.0 Teaching.
Deviation direction of cylinder work (7)
(5)
(6)
(2) (4)
(1) (3)
Cylinder work
(Mother work)
Part to be welded
9-21
[ NOTE ]
1. Only air cut points can be taught the deviation compensation function.
2. Teach points in order of (1)→(2)→…→(6)→(7). Execute the sensing to the
mother workpiece (cylinder workpiece) by pattern 6.
3. Teach angle made by lines (1)(2) and (3)(4) to be 30° to150° (90° is desirable).
[ NOTE ]
Direction of torch at teaching

1. Parallel to sensed surface 2. Oblique to sensed surface 3. Vertical to sensed surface
て垂直
Workpiece Workpiece Workpiece
When torch direction is parallel to the sensed surface, wire extension length need not be
accurate. However, when it is oblique or vertical, wire length must correctly match the
set length.
Teach the following data. (Weld conditions, OX, WX, etc. are omitted.)
Step Type of Motion

Inter- Accu- Touch
(Teaching teaching Speed Timer Contents of teaching point coordinates
polation racy sensing
point) point of robot
1 Air cut Linear 9 4 0 Workpiece

⎯ Base
reset mother
2 Air cut Linear 9 1 0 Workpiece Create mother workpiece

mother coordinates by sensing pattern
Pattern 6 6. (1st point)
3 Air cut Linear 9 4 0 ⎯ ⎯

Pattern 6 6. (2nd point)
5 Air cut Joint 9 4 0 ⎯ ⎯
9-22

Pattern 6 6. (3rd point)
7 Air cut Linear 9 4 0 Mother

⎯ ⎯
workpiece
1. Teach point (1). As a general point

previous to teaching the deviation
compensation function, move the torch tip
to point (1) and then teach air cut (AC) for
Cylinder work instruction, linear for interpolation, 9 for
(1)
speed, and 4 for accuracy.
Note that point (1) defines the sensing direction to the sensing point (2) where compensation
deviation is taught (that is, robot moves (1) to (2) when sensing). Recommended distance
between (1) and (2) is 100mm or more.
Then move cursor under Option Switch on the auxiliary data title row by pressing A + OPTION
or by → or ←, and press ↵. The setting screen appears as in Figure 8.1. Select [6. Workpiece
Reset] to [Touch Sensing]. Then move cursor to [Work] by → to display the setting screen as in
Figure 8.4. Select [1. Mother] and press ↵. Press RECORD to teach the workpiece reset
(Mother) in the Option Switch field. The teach screen appears as in Figure 8.5.
Figure 9.4
Figure 9.5
9-23
！ CAUTION
When teaching a program using combination of sensing patterns for the

workpiece deviation compensation function, be sure to set “Work Reset
Mother” in the first step for safety. (This clears all workpiece coordinates
systems and resets them to base coordinates system.) This prevents robot
from moving per the last workpiece coordinates set. Attempting to execute
the program from the beginning step after robot stops without “workpiece
reset” at the first step causes an error.
2. Teach point (2). Move the torch tip to the

point (2) and then teach [Workpiece
Modify].
(2)
Cylinder
workpiece
(1) Direction to
touch the
workpiece is
(1)→(2)
Teach air cut (AC) for instruction, linear for interpolation, 9 for speed. As exact positioning is
required to point (2), set the accuracy to 1. Then move cursor under Option Switch on the
auxiliary data title row by pressing A + OPTION or by → or ←, and press ↵. The setting
screen appears as in Figure 9.1. Select [5. Work(piece) Modify] for [Touch Sensing]. Then
move cursor to [Work] by → to display the setting screen as in Figure 9.6. Select [1. Mother].
Move cursor to [Pattern] by → to display the setting screen as in Figure 9.7. Select reset pattern
[6] and press ↵. Press RECORD to teach the workpiece modify (Mother, 6) in the Option
Switch field. The teach screen appears as in Figure 9.8.
Figure 9.6
9-24
Figure 9.7
Figure 9.8
3. Continue teaching points (3) to (7) following the same procedure described above. Note that
points (3) and (5) define the sensing direction to the sensing points (4) and (6) respectively
where deviation compensation is taught (that is, robot moves (3) to (4) and (5) to (6) when
sensing). Be sure to teach “workpiece mother, pattern 6” to points (2), (4), (6).
9-25
9.4.3 TEACHING- COMPENSATION FUNCTION FOR WORKPIECE DEVIATION- 2

(TEACHING FOR COMBINATION OF SENSING PATTERNS)
！ WARNING
When deviation compensation function is

Torch
Weld
Voltage Workpiece
between torch and base material as shown
+ -
Working table
2. Do not fail to connect the workpiece to be touched and the set table to the earth side.
This section describes the teaching operations. For standard teaching methods, refer to 5.0
Teaching and Operation Manual for E series controller- 5.0 Teaching.
(9)
Deviation direction of cylinder workpiece (7)
(8)
(6)
(4)
(3) Cylinder (5)
(1) workpiece
(Daughter Deviation direction of square pipe
workpiece)
(2) Part to be welded
Square workpiece
(Mother workpiece)
Working table
9-26
[ NOTE ]
1. Only air cut points can be taught the deviation compensation function.
2. Teach points in order of (1)→(2)→…→(8)→(9).
3. Execute the sensing to the mother workpiece (square workpiece) by pattern 1.
4. Execute the sensing to the daughter workpiece (cylinder workpiece) by pattern
6.
5. Teach angle made by lines (3)(4) and (5)(6) to be 30° to 150° (90° is desirable).
[ NOTE ]
Understanding of sensing patterns

Deviation
Cylinder pipe
Deviation
Square pipe
Up down deviation occurs in the square Horizontal deviation occurs in the cylinder
pipe. Compensate the height by pipe. Compensate the deviation by pattern
pattern 1. Height compensation of a 6. The square pipe on which cylinder pipe
square pipe should be executed first, is placed is compensated as mother
thus select [Mother work]. workpiece, thus the cylinder pipe becomes
the second compensation, then select
[Daughter work].
9-27
Teach the following data. (Weld conditions, OX, WX, etc. are omitted.)
Step Type of Motion

Inter- Accu-
(Teaching teaching Speed Timer Touch sensing Contents of teaching point coordinates
polation racy
point) point of robot
1 Air cut Linear 9 4 0 Workpiece

⎯
reset mother
2 Air cut Linear 9 1 0 Workpiece Create mother workpiece Base

Pattern 1 1.
3 Air cut Linear 9 4 0 ⎯ ⎯ Mother
4 Air cut Linear 9 1 0 Workpiece Create daughter workpiece workpiece
daughter coordinates by sensing pattern

Pattern 6 6. (1st point)
5 Air cut Linear 9 4 0 ⎯ ⎯

6 Air cut Linear 9 1 0 Workpiece Create daughter workpiece
Pattern 6 6. (2nd point)
7 Air cut Joint 9 4 0 ⎯ ⎯

8 Air cut Linear 9 1 0 Workpiece Create daughter workpiece
Pattern 6 6. (3rd point)
9 Air cut Linear 9 4 0 Daughter

⎯ ⎯
workpiece
1. Teach point (1). As a general point

previous to teaching the deviation
(1) Cylinder pipe compensation function, move the torch tip
to point (1) and then teach air cut (AC) for
Square pipe instruction, linear for interpolation, 9 for
speed, and 4 for accuracy. Note that point
(1) defines the sensing direction to the
sensing point (2) where compensation
deviation is taught (that is, robot moves (1)
to (2) when sensing). Recommended
distance between (1) and (2) is 100mm or
more.
9-28
or by → or ←, and press ↵. The setting screen appears as in Figure 9.1. Select
[6. Workpiece Reset] for [Touch Sensing]. Then move cursor to [Work] by → to display the
setting screen as in Figure 9.4. Select [1. Mother] and press ↵. Press RECORD to teach the
workpiece reset (Mother) in the Option Switch field. The teach screen appears as in Figure 9.5.
！ CAUTION
When teaching a program using combination of sensing patterns for the

workpiece deviation compensation function, be sure to set “Work Reset
Mother” in the first step for safety. (This clears all workpiece coordinates
systems and resets them to base coordinates system.) This prevents robot
from moving per the last workpiece coordinates set. Attempting to execute
the program from the beginning step after robot stops without “workpiece
reset” at the first step causes an error.
Direction to
touch the 2. First create mother workpiece coordinates
workpiece
(square pipe) by sensing pattern 1.
is (1)→(2).
Teach point (2). Move the torch tip to the

(1) Cylinder pipe
point (2) and then teach [Work Modify].
(2)
Square pipe
Teach air cut (AC) for instruction, linear
for interpolation, 9 for speed. As exact
positioning is required to point (2), set the
accuracy to 1.
Then move cursor under Option Switch on the auxiliary data title row by pressing A +
OPTION/C or by → or ←, and press ↵. The setting screen appears as in Figure 9.1. Select [5.
Work(piece) Modify] for [Touch Sensing]. Then move cursor to [Work] by → to display the
setting screen as in Figure 9.6. Select [1. Mother]. Move cursor to [Pattern] by → to display
the setting screen as in Figure 9.7. Select reset pattern [1] and press ↵. Press RECORD to
teach the workpiece modify (Mother, 1) in the Option Switch field. The teach screen appears as
in Figure 9.9.
9-29
Figure 9.9
Creating the mother workpiece coordinates by sensing pattern1 is complete.
3. Next create daughter workpiece coordinates

by sensing pattern 6.
(3)
Cylinder pipe Teach point (3). As a general point, move
the torch tip to point (3) and then teach air
(2) cut (AC) for instruction, linear for
Square pipe
interpolation, 9 for speed, and 4 for
accuracy. Note that point (3) defines the
sensing direction to the sensing point (4)
where compensation deviation is taught
(that is, robot moves (3) to (4) when
sensing). Recommended distance
between (3) and (4) is 100 mm or more.
If setting is correct, press ↵.
4. Teach point (4). Move the torch tip to the

point (4) and then teach [Work Modify].
(4) Teach air cut (AC) for instruction, linear

(3) for interpolation, 9 for speed. As exact
Direction to
touch the Cylinder pipe positioning is required to point (4), set the
workpiece
(cylinder pipe) accuracy to 1.
is (3)→ (4)
Square pipe
9-30
or by → or ←, and press ↵. The setting screen appears as in Figure 9.1. Select
[5. Work(piece) Modify] for [Touch Sensing]. Then move cursor to [Work] by → to display
the setting screen as in Figure 9.6. Select [2. Daughter]. Move cursor to [Pattern] by → to
display the setting screen as in Figure 9.10. Select reset pattern [6] and press ↵. Press
RECORD to teach the workpiece modify (Daughter, 6) in the Option Switch field. The teach
screen appears as in Figure 9.11.
Figure 9.10
Figure 9.11
5. Continue teaching points (5) to (9) following the same procedure described above. Note that
points (5) and (7) define the sensing direction to the sensing points (6) and (8) respectively
where deviation compensation is taught (that is, robot moves (5) to (6) and (7) to (8) when
sensing). Be sure to teach “workpiece daughter, pattern 6” to points (4), (6), (8).
The procedure is now complete. The teaching performed here creates the mother workpiece
coordinates by sensing pattern 1 and the daughter workpiece coordinates by sensing pattern 6.
9-31
9.4.4 COMPENSATION FOR WORKPIECE DEVIATION AT REPEAT OPERATION
！ CAUTION
Deviation compensation function is possible only when repeat mode and

continuous step are selected. Deviation compensation does not operate
under any other conditions. (Doing so only plays back taught contents.)
Robot moves as shown below when the program taught in 9.4.2 Teaching- Compensation
Function for Workpiece Deviation- 1 (Teaching for Each Sensing Pattern) is executed in repeat
mode.
Point (3)
Point (1)
Sensing the
workpiece
Cylinder
workpiece
Point (2)
Touch sensing distance
1. Register beforehand the touch sensing distance by Aux.1404-10 in 8.0 Auxiliary Functions.
2. The wire tip moves detecting the workpiece at a constant speed within the touch sensing
distance (sensing range). Set this speed by Aux.1404-10 in 8.0 Auxiliary Functions.
3. When wire tip touches the workpiece (that is, sensing) within the touch sensing distance
(sensing range), the robot moves to the next teaching point (point (3) in the figure above).
9-32
9.4.5 CONTINUATION AND RESET OF WORKPIECE DEVIATION COMPENSATION
9.4.5.1 CONTINUATION AND RESET OF COMPENSATION
The difference between continuation and reset of compensation are described in this section by
Figures 9.12 and 9.13 which demonstrates the welding a pipe on an iron plate. In Figure 9.12,
pipes are placed on the same iron plate and are considered to deviate in one direction on the plate.
In Figure 9.13, each pipe is on a separate iron plate but deviates in the same direction.
In the case of Figure 9.12, execute one direction compensation by pattern 1 before welding pipe
No.1, then weld No.1 → No.2 → No.3 in that compensated state. In the case of Figure 9.13, on
the other hand, weld pipe No.1 by executing one direction compensation by pattern 1, and reset
the compensation (that is, reset compensation when robot moves to next teaching point.).
Execute compensation by pattern 1 again before welding pipe No.2, and then execute the same
procedure to pipe No. 3.
Based on these examples, the compensation function can be performed once, compensating the
same deviation distance on multiple workpieces – “Continuous Compensated” state, or
compensation can be performed independently for each workpiece – “Reset Compensation” state.
(See program examples on next page.)
9-33
Guide
No.1 No.2 No.3 No.1 No.2 No.3

Deviation Deviation
Guide Iron plate Guide Iron plate
Figure 9.12 Figure 9.13
Flow of program Flow of program

(Continuous compensation) (Reset compensation)
Work reset mother … Sets initialization Work reset mother … Sets initialization
(Same state at (Same state at
teaching) teaching)
Work mother pattern 1 Work mother pattern 1
…Compensated state
Weld pipe No.1. Weld pipe No.1.
Weld pipe No.2. …Continuous Work reset mother …Reset compensation

compensated
state
Weld pipe No.3. Work mother pattern 1
Weld pipe No.2.
Work reset mother …Reset compensation
Work mother pattern 1

Weld pipe No.3.
9-34
9.4.5.2 CASES OF CONTINUING/RESETTING COMPENSATION
Cases for using continuous or reset compensation are classified in the table below.
When continuing use of

When resetting the compensation amt.
same compensation amt.
If nothing is done on Select compensation data to reset: workpiece mother,
program (not teaching daughter or baby on program.
reset of workpiece Workpiece mother reset: All compensations are reset.
Operation
mother, daughter, baby), Workpiece daughter reset: Only daughter workpiece
on
the previous and baby workpiece
program
compensation continues. compensations are reset.
Workpiece baby reset: Only baby workpiece
compensation is reset.
Reset compensation data when:
1. Selecting a program by teach pendant, etc.
2. Selecting a step by teach pendant, etc.
Others 3. Inserting, deleting or changing program by teach
pendant, etc.
4. External program reset is input by interlock, etc.
from outside.
9-35
9.5 PRECAUTIONS ON TEACHING
This section describes precautions when teaching a program that uses the touch sensing functions,
wire check, workpiece detection, and compensation for workpiece deviation. Note that incorrect
operation causes sensing error or defect.
！ WARNING
When touch sensing function is working,

Torch
a constant voltage (DC15V standard,
Weld
machine DC400V as Option) is applied between
Workpiece
Voltage torch and base material as shown on the
+ -
Insulating left. Avoid touching the base material or
the wire during teaching.
Working table
1. If tool dimensions are registered incorrectly, error results from the workpiece coordinates
acquired by sensing, even if workpiece is set correctly with no deviation. For more details,
see Aux.1405 in 8.0 Auxiliary Functions.
Dimensions for torch installation Registered torch dimensions
Aux. 1405 Arc Weld Torch Dimension

Different! Length 404mm
404mm Angle 55deg
Wire Extension 15mm
55°
One or some of these registered
values are incorrect.
15mm
9-36
2. During workpiece detection/compensation, if wire extension length is incorrect, error results

from the workpiece coordinates acquired by sensing regardless of the workpiece deviation.
However, if torch is parallel to the control surface when touching, error does not occur.
Therefore, ensure the same extension length in teaching and repeat operations using wire check
function, wire cutter, etc.
Extension length at teaching Extension length in repeat operation
Different!
E.g.
15mm 10mm
3. Confirm wire touches the control surface correctly and that there is conduction.
Correct teaching state Incorrect teaching state
Wire touches No conduction as

surface, and wire does not touch
there is a surface、or due to
conduction. forged surface even
when touched.
4. When condition of wire tip is not good, wire check, workpiece detection, compensation for
workpiece deviation may not be performed correctly.
Desirable wire tip Undesirable wire tip
The tip is cut by wire cutter, Wire tip has a lump, or spatter,
etc. and there is a good etc. adheres to the wire.
electrical contact.
9-37
5. In order to compensate correctly, execute touch sensing to the surface which deviates the same
as the weld line.
Incorrect touch sensing (1) Correct touch sensing
6. When sensing pattern and sensing order are not matched, an error occurs.
Correct sensing pattern

Incorrect touch sensing (2) and sensing order
3
1 2 1 2
[ NOTE ]
To compensate work deviations correctly, touch sensing function assumes that

the weld line on the work surface/area to be sensed is taught with a sufficiently
high accuracy level.
9-38
9.6 ERRORS AND COUNTERMEASURES FOR TOUCH SENSING FUNCTION
This section describes errors occurring during touch sensing operation and the error handling.
9.6.1 ERROR MESSAGE LIST
Error
Error message Main cause
code
E6509 No work detected. When sensing for workpiece detection or
compensation, wire did not touch the workpiece
after moving the touch sensing distance.
E6510 Undefined sensing When sensing for workpiece detection or
direction. compensation, no point was taught prior to the
sensing point, or Air Cut (defining the sensing
direction) was not taught in the prior point/step.
E6511 Insufficient sensing Weld was started before acquiring the No. of
points. sensing points specified by the pattern.
E6512 Undefined mother or Attempted to execute daughter or baby workpiece
daughter work. before mother workpiece was specified. Or,
attempted to execute baby workpiece before
daughter workpiece was specified.
E6513 Too many sensing Without reset, executed the same sensing to
points. workpiece for which sensing was already complete.
Or, executed sensing at more points than the No. of
sensing points specified by the pattern.
E6514 Work specification Before completing sensing of all the sensing points
incorrect. of the specified pattern, a different sensing pattern
was processed.
E6515 Incorrect sensing point During deviation compensation, sensing order or
specified. sensing locations were incorrect.
E6516 Wire check failure. During wire check, wire did not touch the
workpiece after inching the wire for 5 sec.
9-39
9.6.2 ERRORS AND COUNTERMEASURES
If the program taught with the touch sensing function suffers an error while it is running, execute
the recovery procedures detailed here and on the following pages.
1. E6509: No work detected.
When an error occurs, robot holds detection of the workpiece and stops at the place the error
occurred.
Main cause:
1. Workpiece deviated more than touch sensing distance registered in Aux. Function 1404-10.
2. Workpiece is not set.
Countermeasure:
Touch sensing distance may be short, set again with a longer touch sensing distance in Aux.
Function 1404-10. (Beware that setting a longer distance lengthens the touch sensing time.)
Or, when workpiece deviates too much, reset it to its set place.
Trajectory of robot torch tip from time of error occurrence to error handling
Error occurrence Torch tip motion Cycle start

A A A
z z z
Torch evacuation
P P
z point
z
zB’ zB’ zB’
(Sensing start
B point)
z B
z
B
z
zB’’ (Sensing end point) zB’’ zB’’

Place error
occurred
9-40
Remarks: If robot is stopped by turning RUN /HOLD to HOLD during sensing, the trajectory
of the robot torch tip is as shown below when restarting.
Pausing A
Cycle start
z A
z
A
z
Pausing zB’ zB’ zB’

(Sensing
location
B start point)
z B
z Pausing B
z
location
zB’’ (Sensing end point) zB’’ zB’’
Returns to B’ once. Then moves B → B’’.
！ CAUTION
If this error occurs when sensing the workpiece by deviation compensation

function, and then if the workpiece was moved for the error recovery, be
sure to execute sensing of the workpiece coordinates from the first
compensation (for mother workpiece, daughter workpiece, etc.). Also
beware that when selecting a particular step, all compensation amounts are
reset.
2. E6510: Undefined sensing direction.
When an error occurs, robot holds detection of the workpiece and stops in that step.
Main cause:
For example, when the error occurred in step 4 of the program below, the following are
considered probable causes.
1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET

2. WS LINEAR SPEED9 TIMER0
3. WE LINEAR WELD_CONDO
4. AC LINEAR SPEED9 ACCU4 TIMER0 WORK_DETECT
:
1. The previous step (step 3) is not an air cut point, which is necessary for using the workpiece
detection function in step 4.
2. When selecting a particular step as the start step wherein the sensing function is specified, for
9-41
example, if only step4 in the above program is selected for execution.
Countermeasure:
1. In the case of the program above, inset a new step containing an Air Cut point before step4
(which includes workpiece detection). (Sensing direction is determined by the point taught
sensing function and the air cut point.)
2. When selecting a particular step for execution, specify the step that precedes the step taught
workpiece detection function as a start step. For programs that frequently use touch sensing
functions, be sure to execute the program from the first step.
3. E6511: Insufficient sensing points.
When an error occurs, robot holds creation of the workpiece coordinates and stops in that step.
Main cause:
For example, when the error occurred in step2 of the program below, the following are

2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2
:
1. Although pattern 2 (with 2 sensing points) was set in step2 above, sensing was executed for
only one of the two sensing points, also a non-Air Cut instruction was specified in the next step
(step3).
Countermeasure:
1. In the case of the program above, insert new steps (steps 3, 4) for sensing the second of the two
sensing points as below. Ensure the number of steps used to execute workpiece deviation
compensation corresponds with the number of sensing points. (As in program example each
sensing point is taught by two steps, the first being an Air Cut step and the second being
MOTHER_WORK#, DAUGHTER_WORK#, etc.)

3. AC LINEAR SPEED9 ACCU4 TIMER0
9-42
4. E6512: Undefined mother or daughter work.
When an error occurs, robot holds creation of the workpiece coordinates and stops in that step.
Main cause:

2. AC LINEAR SPEED9 ACCU4 TIMER0 DAUGHTER_WORK2
:
1. Attempted creation of daughter workpiece coordinates in step2 without first making the mother
workpiece coordinates. Or, although mother workpiece is taught in the previous step,
attempted to start execution in repeat mode from the step containing daughter workpiece.
Countermeasure:
1. In the case of the program above, edit the step so as to ensure mother workpiece coordinates
are created first. Or, insert a new step creating mother workpiece coordinates.

When selecting a step from which to begin in repeat mode, avoid starting from step with
daughter workpiece or baby workpiece.
9-43
5. E6513: Too many sensing points.
When an error occurs, robot stops in the place the error occurred.
Main cause:

5. WE LINEAR WELD_COND0
1. Although workpiece coordinates have already been created (step 2), the workpiece coordinates
were to be created again (step 7). Or, the sensing was to be executed at a higher No. of
sensing points than specified in sensing pattern.
Countermeasure:
1. In the case of the program above, reset the workpiece coordinates (step6), and edit the step so
as to create the workpiece coordinates again. See below.
6. AC LINEAR SPEED9 ACCU4 TIMERO MOTHER_RESET

6. E6514: Work specification incorrect.
Robot stops in the step where error occurred.
Main cause:

9-44
1. After specifying the first point of two point sensing pattern in step3, different sensing pattern
was specified in step4.
Countermeasure:
1. In the case of the program above, specify the same sensing pattern to complete the workpiece
coordinates as below.
7. E6515: Incorrect sensing point specified.
Main cause:
1. Teaching order was incorrect, for example did not follow A1→B1→A2→B2→A3→B3.
B B B
2. The distance between two points taught on the same control surface was less than 10mm. Or,
angle made from the sensing directions for two different control surfaces was not within
30°∼150°.
Countermeasure:
1. Clear the error cause and teach again correctly.
8. E6516: Wire check failure.
Main cause:
1. The workpiece was too far from the teaching point.
2. Wire feeder did not inch weld wire due to cut OFF of power supply in weld machine, etc.
Countermeasure:
1. When teaching point and the workpiece are located far apart, teach again with the position
closer to the workpiece.
2. When weld wire was not inched, adjust and check the devices and press CYCLE START
button. Then, confirm wire is inched for the full 5 sec.
9-45
9-46
E Series Controller 10. Special Pattern Weaving Function (Option)
10.0 SPECIAL PATTERN WEAVING FUNCTION (OPTION)
This section describes special pattern weaving function, an optional specification.
10.1 OVERVIEW OF SPECIAL PATTERN WEAVING
10.1.1 SPECIAL PATTERN WEAVING
By using this special pattern weaving function, weaving shapes which are normally simple
harmonic can be created or changed freely.
1. Standard registration → Pattern No. (PN): Standard

2. Available only when Option (Special pattern weaving) is installed → Pattern No. (PN): 1∼10
PN=1 to PN=5: These patterns are already registered at time of factory shipment.
Original, newly created patterns can be also registered here.
PN=6 to PN=10: Registers original, newly created patterns.
(1) Pattern examples listed in this manual
Select and register the desired pattern from Appendix 3. Pattern
Example of Special Pattern Weaving (List).
(2) Register the newly created weaving patterns.
10-1
Pattern No. Pattern name Motion Motion of torch tip
Standard Simple harmonic
Simple harmonic
1
both ends stop
2 Triangular
Reciprocating
3
triangular
Circular
4
(Clockwise)
Circular
5
(Counterclockwise)
6 to 0 Unregistered ⎯ ⎯
10-2
10.1.2 PENDULUM WEAVING
For weaving in a narrow groove, the torch posture often needs to be changed during weaving
operation. With the special pattern weaving function, torch posture can be changed a max. of
±10°. This is called pendulum weaving.
+10° -10°
+50% -50%
！ CAUTION
Note that pendulum weaving sometimes induces large motions in the robot
even though the motion of the torch tip is small. Or, speed abnormality
may occur. In these cases, set pendulum angle smaller, or modify teaching
contents to make the motion of each robot axis smaller.
10.1.3 WELD CURRENT/ WELD VOLTAGE BOOSTS
For weaving in a narrow groove, etc., weld current or weld voltage often need to be changed to
enable high quality penetrating at both ends of the weave. Via the special pattern weaving
function, weld current or weld voltage can be changed a max. of ±100%. This is called weld
current/weld voltage boosts.
(%)
200
+100%
100 Weld condition set value
-100%
0
10-3
10.1.4 FLOW CHART FOR USING SPECIAL PATTERN WEAVING FUNCTION
To use special pattern weaving function, follow the flow chart described below.
Decide weaving pattern type to use.
Use a standard pattern. Use a pattern example listed in Make and use a new
(See 10.2 Standard this manual. (See Aux.1404-11 pattern. (See 10.4.2
Weaving Patterns Special Pattern Weaving (Option) Creating Weaving
Registered for Robot.) in 8.0 Auxiliary Functions). Patterns.)
(Specify one pattern from the five kinds of weaving patterns.)
Draw a figure of the

(Pattern example can be modified.)
movement in created
pattern.
Determine a position for

defining teaching origin and
weaving width.
Create expansion pattern

diagrams for back/forth,
lateral, and vertical
directions of the torch.
Fill in sheet used for Based on pattern diagrams,

registering pattern fill in sheet used for
data. registering pattern data.
Determine weaving
pattern No. and register
required data.
Specify weaving pattern

No. when teaching the
program.
10-4
10.2 STANDARD WEAVING PATTERNS REGISTERED FOR ROBOT
The standard weaving patterns registered in this function include: simple harmonic both ends stop
weaving, triangular weaving, reciprocating triangular weaving, circular weaving, etc.
This section describes the motion using solid figures and the expansion patterns for the weaving
patterns in back/forth, lateral, and vertical directions.
Vertical direction
Vertical direction:
Lateral direction Torch direction
Motion direction (+ moves upwards.)
Vertical plate
Lateral direction:
Direction vertical to torch
Back/forth direction
and traveling direction
Amplitude (+ moves towards vertical
(WV)
1 cycle (sec) plate (left))
Back/forth direction:
Horizontal plate
Motion direction of weld
Motion of torch tip (+ moves forward)
Relation between frequency and cycle is as shown in the graph below.

1 cycle
1 sec
Frequency
f=0.5Hz 2 sec
1 cycle
1 sec
f=1Hz 2 sec
1 cycle
1 sec
f=2Hz 2 sec
10-5
1. Pattern No. 1 (PN=1): Simple harmonic both ends stop weaving pattern
Motion of torch tip
Amplitude
(WV)
Motion direction
Forth
Time ratio in a cycle

Back
Lateral

Lateral (Torch moves left and right at amplitude
Up 100%. Pause at both ends.)

Down (Torch does not move in vertical direction.)
10-6
2. Pattern No. 2 (PN=2): Triangular weaving pattern
Motion of torch tip
Amplitude
(WV)
Motion direction
Forth
Back
Lateral

Lateral (Torch moves at amplitude 100 %.)
Up

Down (Torch also moves in vertical direction.)
10-7
3. Pattern No. 3 (PN=3): Reciprocating triangular weaving pattern- both ends stop, center stop
Motion of torch tip
Motion direction
Amplitude
(WV)
Forth

Back
Lateral

Lateral (Torch moves left and right at amplitude
Up 100 %. Pause at both ends and center.)

Down (Torch also moves in vertical direction.)
10-8
4. Pattern No. 4 (PN=4): Circular weaving pattern (1)- from vertical plate direction
Motion of torch tip
Amplitude
(WV)
Motion direction
Forth

Back (Torch displacement changes back and forth.)
Lateral

Lateral (Torch moves left and right at amplitude 100%.)
Up

Down
(Torch does not move in vertical direction.)
10-9
5. Pattern No. 5 (PN=5): Circular weaving pattern (2)- from horizontal plate direction
Motion of torch tip
Amplitude
(WV)
Motion direction
Forth

(Torch displacement changes back and
Back
forth.)
Lateral

(Torch moves left and right at amplitude
Lateral
100%.)
Up

(Torch does not move in vertical direction.)
Down
10-10
10.3 TEACHING OPERATION FOR SPECIAL PATTERN WEAVING
Point at teaching Weaving motion in repeat operation
Weld end point
Weld line
Weld start point
Teach the motion pattern at Welding executed by repeating the

weld end or weld continue points. specified motion pattern.
When using registered weaving patterns, there is no additional teaching procedure to use special
weaving function. Simply set the desired weaving pattern No. in the weld conditions.
For example, to use weaving pattern 4 in the arc spot weld condition of direct setting, set the
pattern No. as in Figure 10.1. ([Pole Ratio] shown only when Option is installed.)
Figure 10.1
Weaving patterns can be also set in the weld condition by the following auxiliary functions. For
details about the setting procedures of each function, see 8.0 Auxiliary Functions.
1. Aux. Function 1403: Arc Weld Condition Database

2. Aux. Function 1404-4: Software Slow Down
3. Aux. Function 1406: Arc Weld Condition Modify
10-11
10.4 CREATING A NEW WEAVING PATTERN
10.4.1 COORDINATES SYSTEM AND PARAMETERS WHEN CREATING WEAVING

PATTERN
When creating a new weaving pattern, keep in mind the torch movements defined in the figure
below, and be careful when specifying the plus (+) and minus (-) directions on this coordinates
system. To register created weaving patterns, see Aux.1404-11 in 8.0 Auxiliary Functions.
1. Back/forth direction of torch (X)

2. Lateral direction of torch (Y)
3. Vertical direction of torch (Z)
Torch
Up+
Lateral+ Down- Motion direction

(Vertical plate direction) Lateral- Forth+
Back-
Back/forth motion of torch (X) (forth: +, back: -)

Lateral motion of torch (Y) (vertical plate dir.: +, horizontal plate dir.: -)
Vertical motion of torch (Z) (up: +, down: -)
Amplitude(WV)=100%
When defining an amplitude and setting the (0) point for
50% 50%
teaching origin as shown on left, motion amounts of points (1)
and (2) are as follows.
Left Up Right Amount of oscillation for point (1):
(1) (2)
upward direction 50%, left direction 50%
50%
Amount of oscillation for point (2):
upward direction 50%, right direction -50%
Down (0)
When registering weaving patterns, specify the motion amount in each oscillation direction by
percentage (%) to the amplitude.
10-12
4. Torch angle rotation (pendulum weaving)
As robot travels along weld direction, this weaving rotates the torch vertical to surface of weld
with torch tip set as center of rotation. For angle, minus (–) direction is toward the vertical plate.
⎯
+
Vertical
plate
Angle can be set at a max. of ±10°. However, some

robot postures or weave frequencies may not allow
robot to move.
⊗
Motion direction
5. Weld current boost

6. Weld voltage boost
Current and voltage values set in weld condition can be changed within a max. of ±100%.
(%)
200
+100%
100 Weld condition set value
-100%
0
10-13
10.4.2 CREATING WEAVING PATTERNS
1. Flow chart for creating a weaving pattern
When creating a weaving pattern, follow the procedure described in the flow chart below. A
blank program sheet is attached in Appendix 3. Pattern Example of Special Pattern Weaving
(List); make copies and use when creating weaving patterns.
(1) Draw a figure showing motion of desired weaving pattern.
(2) Determine a position for defining teaching origin and weaving width.
(3) Create expansion pattern diagrams for back/forth, lateral, vertical dir.
(4) Fill in sheet with the data from expansion pattern diagram in (3).
(5) Fill in the conditions.
(5)
(1)
(2)
(4)
(3)
10-14
2. Follow the flow chart steps to create weaving pattern.
(1) Draw a figure showing motion of desired weaving pattern.
Create a weaving pattern with a max. of

15 points (16 paths). (First point is not
included.) In this figure, there are 5
points; 6 points are possible including
the last point.
Draw a weaving pattern for

only one cycle.
Do not fail to set amplitude 0 in the
first and last points of weaving pattern.
(2) Determine a position for defining the teaching origin and weaving width.
1) Teaching origin: Be sure to match the teaching point and the teaching origin.
Case 1
Up
B C
A During weaving
Lateral+ Lateral-
operation, torch tip
Teaching origin
moves as
Down
A→B→C→A.
10-15
Case 2
Up
B C
Lateral+
During weaving
A D
operation, torch tip
moves as
Down Lateral- A→B→C→D→A.
Teaching origin
Case 3
Up
C D
During weaving
Lateral+ operation, torch tip
B A E moves as
A→B→C→D→E→
Lateral-
Down Teaching origin
A
2) Defining position for weaving width: Normally, weaving width (lateral direction) is set at 90°
to the torch axis. However, a root gap (or groove
dimension) can be used as basis for setting the weaving
width, as shown below right. Be careful as the
dimensions and directions set for the weaving width will
affect the weaving pattern that can be created.
Weaving width
(Groove dimension)
Left Right
Left
Right
Weaving width Weaving width

Weaving width
(Root gap)
10-16
(3) Create expansion pattern diagrams for the back/forth, lateral, and vertical directions. See
diagrams at bottom.
Case 1
Up
Stop time on vertical plate=26%
2
Weaving width=6mm (0)
1 (1)
(1) 3
(2) (2)
(1) 3mm (0) (2) 5
4 Stop time on horizontal
(0) plate=26%
Lateral+ Lateral-
(0)
In the groove in the figure above, set weaving In the weaving pattern in the figure above, set time
width 6 mm (100 %) between (1) and (2). (0) is ratio between paths in the case where stop time on
teaching origin. Note if weaving motion vertical plate=26 % and stop time on horizontal
component in any one (+/-) direction exceeds plate=26 %. Weaving speed in each path is
±200 %, an error occurs. considered to be the same.
0 mm to vertical dir. .........................0 % 100 % - ( 26 % + 26 %)
(0) = 12 %
0 mm to lateral dir. ...........................0 % 4
Then, time ratio in each point is as follows.
3 mm(3 mm/6 mm) upward.......... 50 %
(1) Time ratio at point 1: .................................. 12 %
3 mm(3 mm/6 mm) to left............. 50 %
Time ratio at point 2: 12 % + 26 %............ 38 %
3 mm(3 mm/6 mm) upward........... 50%
(2) Time ratio at point 3: 38 % +12 %............. 50 %
-3 mm(-3 mm/6 mm) to right........ -50%
Time ratio at point 4: 50 % + 12%............. 62 %
Time ratio at point 5: 62 %+26 %.............. 88 %
Forth+
1 2 3 4 5
0 Time ratio
12 38 50 62 88 100%
Back-
50 50
Lateral+
0 0% Time ratio
0
Lateral-
-50 -50
50 50 50 50
Up+
0 Time ratio
0 0%
Down-
10-17
Case 2
This example shows weaving with torch inclined 22.5° toward the groove: 45° horizontal and
bevel shape with 4mm root gap. Calculate the time, motion amount in vertical, lateral directions,
etc. in consideration of the 22.5° angle. When calculation seems too complicated, draw the
groove diagram in x10 scale, then use the expanded groove diagram to get the vertical, lateral
motion amounts.
When reading by scale
Approx. 6.9mm
(1) Up 2
(0)
22.5° Weaving width (2) (1)
=10mm 4 (3)
6 mm (3) 5
1 3
45°
Lateral+ (0) (3) (2)
(0)
Stop time=10%
4 mm Stop time=10%
Lateral-
Down
In the groove in the figure above, set weaving In weaving pattern above, set time ratio for each path
width 10 mm (100 %) among (0) to (3). (0) is assuming a 10 % stop time at bottom of each wall.
teaching origin. Note if weaving motion Weaving speed in each path is considered to be the
component in any one (+/-) direction exceeds same. Weaving motion is executed in 80% of
±200%, an error occurs. weaving cycle.
0mm to vertical dir. ...............................0％ Time ratio at point 1: .............................................. 10%
(0) 6mm
0mm to lateral dir. .................................0％ Time ratio at point 2: 10％＋80％× 28.5m ......26.8％
6cos22.5° mm upward.........................55％ 10mm
(1) Time ratio at point 3: 26.8％＋80％× 28.5m ...54.9％
6sin22.5° mm to left............................23％
6cos22.5°+10sin22.5° mm upward.....94％ 8.5mm
(2) Time ratio at point 4: 54.9％＋80％× 28.5m ...78.8％
6sin22.5°-10cos22.5° mm to right......69％
4sin22.5°mm upward ..........................15％ Time ratio at point 5: 78％＋10％ .....................88.8％
(3)
-4cos22.5°mm to right....................... -37％
Forth+
1 2 3 4 5
0 Time ratio
10 26.8 54.9 78.8 88.8 100
Back-
Lateral+
0 0%
23 Time ratio
0
-37 -37
Lateral- -69
Up+
94
55 15 15
0 0%
0 Time ratio
Down-
10-18
(4) Fill in sheet with the data from the expansion pattern diagram created in (3).
Using the expansion weaving pattern diagram created in Case 1 in (3) above, the data will be as
follows. When filling in data for each point, do not fill in the last point or specify all 0%.
Forth+ First point Last point
Point1 Point2 Point3 Point4 Point5

0 Time ratio
12 38 50 62 88 100%
Back-
50 50
Lateral+
0 0%
0 Time ratio
Lateral-
-50 -50
50 50 50 50
Up+
0 Time ratio
0 0%
Down-
Time B&F [X] Lateral [Y] Vertical [Z] Angle Current Voltage
Point
(%) (%) (%) (%) (°) (%) (%)
←Do not fill in the
1 12 0 50 50 0 0 0
first point (prior
2 38 0 50 50 0 0 0
to point 1).
3 50 0 0 0 0 0 0
4 62 0 -50 50 0 0 0
5 88 0 -50 50 0 0 0
6 (0) (0) (0) (0) (0) (0) (0) ←Do not fill in
¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ the last point, or
specify all 0%.
10-19
(5) Fill in the conditions.
For weaving patterns with stops at both ends or a center stop, do not fail to fill in the ratio of
stopping time.
3. Precautions on creating weaving patterns
(1) When specifying a big weaving width in a short time during weaving operation, an error
occurs. In this case, the torch tip speed became 100 mm/s or more, and error message
“(E1123) Speed error jtXX.” is displayed. (For some specific robots, this error may occur at
speeds less than100 mm/s.)
Time ratio is small and

weaving width is too big.
(2) In sequential steps, when time ratios of back/forth direction are the same, or when time ratio to
the next point is smaller than the time ratio to the last point, the last point becomes the final
point. (Point 3 is the final point in the following three examples.)
Point Time(%) Point Time(%) Point Time(%)

: : :
3 0 3 38 3 38
4 0 4 38 4 28
: : :
Time ratios are same. Time ratio to next point is smaller.
(3) When weaving motion component in back/forth, lateral, or vertical directions is 400 %
(200 % in either plus (+) or minus (-) direction) or more, an error occurs.
10-20
E Series Controller 11. Servo Torch Function (Option)
11.0 SERVO TORCH FUNCTION (OPTION)
This chapter describes servo torch function by optional specification and the teaching operation.
11.1 OVERVIEW OF SERVO TORCH FUNCTION
Typically when a robot and weld machine are used together to perform arc welding, the weld
machine controls the wire feeding. However, this system may not be effective for welding all
types of works. This is especially true if the weld machine lacks the sensitivity for feeding the
wire on to delicate works such as thin aluminum plates which can damage easily. Using this
servo torch function makes the following possible:
1. By controlling the wire feeding servo motor as robot-controller controlled external axis,
detailed weld conditions can be set and the welding of thin works/plates becomes possible with
much greater accuracy.
2. Features of servo adjusted by feedback gain of wire feeding servo motor, etc. and sequence at
weld start/end can be changed depending on its application condition.
11-1
11.2 PROCEDURE FOR SETTING SERVO TORCH AS EXTERNAL AXIS
This section describes the procedure for registering a servo torch as an external axis. For more
details on the procedure for setting external axes, refer to External Axis Addition of E Series
Controller, a separate volume.
As described in the External Axis Addition manual, select Aux.2002 External Axis to display the
screen below.
1. Input the largest number of

external axes by Number (0-9),
and press <Next page>.
！ CAUTION
Be sure to set the servo torch with the highest axis number
in the system. Failure to do so may cause malfunction.
2. Select [Servo torch] and press

<Next page>.
For settings made after pressing <Next Page>, see the External Axis Servo Parameter Setting
manual. Note that the number of setting items for [Servo torch] is smaller than those required
for [Linear Axis] or [Rotary Axis].
11-2
11.3 SERVO TORCH SPECIFICATION
11.3.1 AUXILIARY FUNCTIONS FOR SERVO TORCH
For details on auxiliary functions specific to the servo torch, see Aux.1404-16 in 8.0 Auxiliary
Functions.
11.3.2 DIFFERENCES: SERVO TORCH SPEC. VS. STANDARD ARC SPEC.
The differences between the servo torch specification and standard arc specification are explained
below. Take these characteristics into account when planning you system and the work required
for your application.
1. Wire inching/retract using teach pendant

As stated in 4.2 Inching Operation for Weld Wire, in the standard arc spec. the weld wire can
be fed or withdrawn by pressing WIRE INCHING or WIRE RETRACT. In this case,
inching operation is possible when both weld power supply and control power are ON
regardless of ON/OFF status of TRIGGER, TEACH LOCK, RUN/HOLD, etc. Inching
operation for servo torch spec., on the other hand, is possible only when TRIGGER,
TEACH LOCK and MOTOR ON are ON and RUN/HOLD is set to RUN in teach mode.
2. Speed of wire inching/retract

As stated in Aux.1404-3 Weld Start Sequence in 8.0 Auxiliary Functions, for standard arc spec.
set the inching/retract speed by ratio to the Aux.1404-1-3 Maximum Output Voltage. For
servo torch spec., set the speed by ratio to the max. rotation speed set in Aux.1404-16-1
Linearization.
11-3
11.4 ERROR HANDLING WHEN OPERATING SERVO TORCH FUNCTION
This section describes errors occurring during servo torch operation and the error handling.
11.4.1 ERROR MESSAGE LIST
Error
Error message Main cause
code
E6559 Wire feeding speed deviation Difference between command speed and actual wire
error. feeding speed exceeds allowable range.
11.4.2 ERRORS AND COUNTERMEASURES
If the program taught with the servo torch function suffers error E6559 while it is running,
execute the recovery procedures below.
1. E6559: Wire feeding speed deviation error.
Robot stops at the point where the error occurs.
Main cause:
1. Difference between the command speed and actual wire feeding speed exceeds the allowable
range.
Countermeasure:
1. Check if the power cable to the servo torch motor is disconnected. If disconnected, speed
command will still be output even though robot does not actually work and thus result in error.
2. Determine why the actual wire feeding speed has decreased. Check the system for possible
causes: the wire is being supplied correctly, etc.
11-4
E Series Controller 12. Error Message for Arc Weld Specification
12.0 ERROR MESSAGE FOR ARC WELD SPECIFICATION
This chapter describes errors occurring in arc weld specification robot. Some errors only occur
if optional functions for arc weld application are installed.
12-1
12.1 ERROR MESSAGE LIST
Error
Error message Option
code
P6502 No weld database. Standard
P6503 Cannot change weld condition. Standard
E6500 No welding Interface board. Standard
E6502 Arc failure. Standard
E6503 Wire stuck. Standard
E6505 Arc weld insulation defect. Standard
E6506 Torch interference. Standard
E6509 No work detected. Touch sensing
E6510 Undefined sensing direction. Touch sensing
E6511 Insufficient sensing points. Touch sensing
E6512 Undefined mother or daughter work. Touch sensing
E6513 Too many sensing points. Touch sensing
E6514 Work specification incorrect. Touch sensing
E6515 Incorrect sensing point specified. Touch sensing
E6516 Wire check failure. Touch sensing
E6517 Incorrect weld condition number. Standard
E6518 No weld data set. Standard
E6519 Weld data is out of range. Standard
E6533 No RTPM board. RTPM
E6534 Too many taught points for RTPM. RTPM
E6535 RTPM arc sensor error. RTPM
E6536 RTPM current deviation error. RTPM
E6537 RTPM tracking value is out of range. RTPM
E6538 Out of RTPM tracking capacity. RTPM
E6539 Out of AVC tracking value. AVC
E6540 Out of AVC tracking capacity. AVC
E6541 No AVC board. AVC
E6542 AVC voltage deviation error. AVC
E6543 Too many taught points for AVC. AVC
E6559 Wire feeding speed deviation error. Servo torch
E6562 Electric pole stuck. TIG welding
12-2
12.2 ERRORS AND COUNTERMEASURES
This section describes troubleshooting for standard errors occurring in arc specification. For
errors which occur in optional functions for arc welding, refer to the related Option Manuals.
1. E6502 Arc failure.
Main cause:
Signal showing welding in process (current detection: WCR) was not returned from weld
machine 1 sec (or more) after robot attempted to weld.
Countermeasure:
Some insulating object may interrupt arc generation at arc start point. Check for and remove
any foreign object, insulating item, etc. If this error occurred during welding, check if wire feed
has run out or tip is stuck.
12-3
2. E6503 Wire stuck.
Main cause:
Wire is stuck to the base material when welding has completed.
Countermeasure:
If wire is stuck to the base material, cut the wire. When wire is often stuck at the same point,
reexamine the weld conditions.
3. E6500 No welding Interface board.
After error reset, robot can be moved without welding.
Main cause:
When controller power was turned ON, interface board for arc welding was not detected.
Countermeasure:
Turn OFF the CONTROLLER POWER, and check whether weld interface board is mounted in
the card rack of the controller. When mounted, insert it correctly and firmly as the interface
board may be loose.
4. E6506 Torch interference.
After error reset, robot can be moved in teach mode. In repeat mode, operation is only possible
after setting the torch back to its original state.
Main cause:
Torch interfered with something, and limit switch in the torch bracket came off.
Countermeasure:
Reset the error, and move robot in teach mode to set the torch back to its original state. (Set the
limit switch back to the original state.)
12-4
5. E6505 Arc weld insulation defect.
Main cause:
Torch short-circuited to the work when INSUL_CHK instruction was executed.
Countermeasure:
Check and make the insulation as needed.
12-5
12-6
E Series Controller Appendix 1. Program Sheet
APPENDIX 1.0 PROGRAM SHEET
Once the robot operation is determined, fill in the contents to teach the robot on the program
sheet.
Instruction Interpolation Speed Accuracy Timer Weld condition Arc Spot condition
1 Air cut Joint 9 4 0
2 Weld start Joint 9 0
3 Weld continue Linear Direct
4 Weld end Linear Direct
5 Air cut Linear 9 4 0
6 Arc spot Joint 9 1 0 Direct
A-1
SHEET OF
Program Name Machine No. Date Prepared: Revision
Applicable Work Prepared By:
lding Condition
WeWeld Arc Spot Condition Option
Condition
E Series Controller
Typeofof Inter-
Step Teachcing Type Air
Speed Accu- Timer ＯＸＷＸ Jump
Point teaching
Teach polation Cut racy Direct Direct
/End In- In-
point
Point Speed direct
direct ｔ
SP A V WV f PN Ct CA CV A V
A-2
Appendix 1. Program Sheet
E Series Controller Appendix 2. Weld Database
APPENDIX 2.0 WELD DATABASE
[ NOTE ]
Database provided at time of factory shipment contains weld conditions whose
contents were tested and confirmed by Kawasaki. Be advised these
conditions may not be best for the planned work. Kawasaki cannot guarantee
that this database will provide the best possible welding operation and quality
for every work.
Preconditions for using this database with the standard arc specification:
Weld gas ........................ CO2
Wire diameter ................ 1.2φ
Wire extension length .... 15mm
Wire type ....................... Solid wire “JIS YGW12 (equivalent to KC-50T KAWASAKI
STEEL)”
Weld machine ................ DAIHEN CPVB350, CPVP350, etc.
(For other weld machines, please contact Kawasaki.)
If conditions differ from those described above, no data is stored in weld database at time of
factory shipment.
Weld types stored in the database are shown in table below.
Type of weld joint Leg length/Thickness (mm)

Horizontal fillet 3, 4, 5, 6, 7, 8
Flat fillet 3, 4, 5, 6, 7, 8
Lap fillet 1.2, 1.6, 2.3, 3.2, 4.5, 6.0
Corner fillet 1.2, 1.6, 2.3, 3.2, 4.5, 6.0
Butt I fillet 1.0, 1.2, 1.6, 2.0, 2.3, 3.2, 4.0, 4.5
Downhill fillet 3, 4, 5, 6
A-3
1. Horizontal fillet
Leg Crater Crater Crater Weaving Weaving

Speed Current Voltage Deviation
length time current voltage width frequency
(cm/min) (A) (V) (mm)
(mm) (sec) (A) (V) (mm) (Hz)
3 120 230 26.0 0.5 140 21.0 0 0 1.0
4 96 260 28.5 0.5 160 22.0 0 0 1.0
5 80 290 32.0 1.0 170 22.5 0 0 1.5
6 55 290 32.0 1.3 170 22.5 0 0 2.0
7 40 290 32.0 1.5 170 22.5 4 2 1.5
8 30 290 32.0 2.0 170 22.5 5 2 1.5
Teach the point as follows.

(1) No sweep forward/back angles.
(2) Torch angle 45°.
45° (3) Offset from corner is required. (Necessary for
making uniform leg lengths.)
Offset
2. Flat fillet

Speed Current Voltage
(cm/min) (A) (V)
(mm) (sec) (A) (V) (mm) (Hz)
3 120 230 27.0 0.5 140 21.0 0 0
4 96 260 29.5 0.5 160 22.0 0 0
5 80 290 33.0 1.0 170 22.5 0 0
6 55 290 33.0 1.3 170 22.5 0 0
7 40 290 33.0 1.5 170 22.5 0 0
8 30 290 33.0 2.0 170 22.5 0 0

(2) Torch faces directly downward.
(3) Point at the corner
A-4
3. Lap fillet
Thick- Crater Crater Crater Weaving Weaving

ness time current voltage width frequency
(mm) (sec) (A) (V) (mm) (Hz)
1.2 100 120 18.5 0 0 0 0 0 0.3
1.6 80 120 19.0 0 0 0 0 0 0.5
2.3 120 190 22.5 0 0 0 0 0 0.8
3.2 110 230 26.0 0.5 140 21.0 0 0 1.0
4.5 80 260 28.5 0.5 160 22.0 0 0 1.5
6.0 50 260 28.5 1.0 160 22.0 0 0 2.0

(2) Torch angle 50°.
50°
(3) Offset from corner is required. (Necessary for
making uniform leg lengths.)
Offset
4. Corner fillet
Thick- Crater Crater Crater Weaving Weaving

ness time current voltage width frequency
(mm) (sec) (A) (V) (mm) (Hz)
1.2 100 120 18.5 0 0 0 0 0 0.3
1.6 80 120 19.0 0 0 0 0 0 0.5
2.3 120 190 22.5 0 0 0 0 0 0.8
3.2 110 230 26.0 0.5 140 21.0 0 0 1.0
4.5 80 260 28.5 0.5 160 22.0 0 0 1.5
6.0 50 260 28.5 1.0 160 22.0 0 0 2.0

40° (2) Torch angle 40°.
(3) Offset from corner is required. (Necessary for
Offset making uniform leg lengths.)
A-5
5. Butt I fillet
Thick- Crater Crater Crater Weaving Weaving Assumed

ness time current voltage width frequency gap
(cm/min) (A) (V)
(mm) (sec) (A) (V) (mm) (Hz) (mm)
1.0 110 85 17.5 0 0 0 0 0 0
1.2 95 85 17.5 0 0 0 0 0 0
1.6 75 110 18.5 0 0 0 0 0 0
2.0 65 110 18.0 0 0 0 0 0 0.8
2.3 60 110 18.0 0 0 0 0 0 1.0
3.2 60 140 20.5 0 0 0 0 0 1.2
4.0 60 170 22.0 0.5 100 17.5 0 0 1.2
4.5 60 185 23.5 0.5 100 18.5 0 0 1.2

(2) Torch faces directly downward.
(3) Center point when a gap exists.
(Assumed gap defined as an assumed root gap in
database wherein weld does not burn through
Assumed gap work and attains enough penetration.)
6. Downhill fillet

(cm/min) (A) (V)
(mm) (sec) (A) (V) (mm) (Hz)
3 100 205 24.0 0 0 0 0 0
4 80 230 25.0 0 0 0 0 0
5 60 230 25.0 0 0 0 0 0
6 42 230 23.0 0 0 0 0 0
45° Teach the point as follows.

(1) Sweep back angle 10° to 20°. (Slightly raised
torch tip.)
45°
(2) Point at the corner
A-6
E Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Kawasaki Robot Arc Welding Operation Manual (List)
APPENDIX 3.0 PATTERN EXAMPLE OF SPECIAL PATTERN WEAVING (LIST)
Weaving pattern name: Date prepared:

Triangular weaving with both ends stop Prepared by:
Joint type: Fillet Ver. plate stop time: 26%
Weaving pattern for 1 cycle Weld gas: CO2, MAG Center stop time: 0%
Weld posture: Horizon., Flat Hor. plate stop time: 26%
No. of points: 4 Remarks:
Teaching origin and amplitude:
Amplitude
Teaching origin
Points for weaving pattern
100%
B&F Lat. Vert.
F + Point
Time
X Y Z
Ang. Cur. Vol.
(%) (°) (%) (%)
50 (%) (%) (%)
0 Time ratio 1 12 0 50 50 0 0 0
12 38 62 88 100%
-50 2 38 0 50 50 0 0 0
B - -100 3 62 0 -50 50 0 0 0
4 88 0 -50 50 0 0 0
Lateral direction: 5 … … … … … … …
100% 6 … … … … … … …
Lat. + 50 50
50 7 … … … … … … …
0 Time ratio 8 … … … … … … …
0%
-50
9 … … … … … … …
-50 -50
Lat. - 10 … … … … … … …
-100
11 … … … … … … …
Vertical direction: 12 … … … … … … …
100% 13 … … … … … … …
Up + 50 50 50 50 14 … … … … … … …
50
15 … … … … … … …
0 Time ratio
0%
-50
Down - -100
A-7

Reciprocation triangular weaving without stop Prepared by:

Up
Amplitude
Teaching origin
100% B&F Lat. Vert.
Time Ang. Cur. Vol.
F + Point
(%)
X Y Z
(°) (%) (%)
50 (%) (%) (%)
0 Time ratio 1 25 0 50 50 0 0 0
25 50 75 100%
-50 2 50 0 0 0 0 0 0
B - -100
3 75 0 -50 50 0 0 0
4 … … … … … … …
100% 6 … … … … … … …
Lat. + 50
50
7 … … … … … … …
0
0 Time ratio
8 … … … … … … …
0%
9 … … … … … … …
-50
-50
10 … … … … … … …
Lat. - -100
11 … … … … … … …
12 … … … … … … …
Vertical direction:
13 … … … … … … …
100%
Up + 50 50 14 … … … … … … …
50
0 15 … … … … … … …
0 Time ratio
0%
-50
Down - -100
A-8

Horizontal triangular weaving for single bevel groove Prepared by:
Joint type: Bevel Groove Ver. plate stop time: 0%
Weld posture: Horizontal Hor. plate stop time: 0%

22.5° Up
22.5°
Down
Teaching origin
Amplitude
100% B&F Lat. Vert.
Time Ang. Cur. Vol.
F + Point
(%)
X Y Z
(°) (%) (%)
50 (%) (%) (%)
0 Time ratio 1 25 0 46 -19 0 0 0

25 50 75 100%
-50 2 50 0 0 0 0 0 0
B - -100
3 75 0 -46 19 0 0 0
4 … … … … … … …
100% 6 … … … … … … …
Lat. +
50
46 7 … … … … … … …
0
0 Time ratio
8 … … … … … … …
0%
9 … … … … … … …
-50
-46
10 … … … … … … …
Lat. - -100
11 … … … … … … …
12 … … … … … … …
Vertical direction:
13 … … … … … … …
50%
Up + 19 14 … … … … … … …
25
0 15 … … … … … … …
0 Time ratio
0%
-25
-19
Down - -50
A-9

Back and forth weaving Prepared by:

Motion dir.
Teaching origin
Amplitude
100% Point B&F Lat. Vert.
Time Ang. Cur. Vol.
F + 50 (%)
X Y Z
(°) (%) (%)
50 (%) (%) (%)
0 0%
0 Time ratio 1 25 50 0 0 0 0 0
25 50 75 100%
-50 2 50 0 0 0 0 0 0
-50
B - -100
3 75 -50 0 0 0 0 0
4 … … … … … … …
100% 6 … … … … … … …
Lat. +
50
7 … … … … … … …
0 Time ratio
8 … … … … … … …
0 0 0 0%
9 … … … … … … …
-50
10 … … … … … … …
Lat. - -100
11 … … … … … … …
12 … … … … … … …
Vertical direction:
13 … … … … … … …
100%
Up + 14 … … … … … … …
50
15 … … … … … … …
0 Time ratio
0 0 0 0%
-50
Down - -100
A-10

Horizontal weaving for bevel groove (pendulum weav.) Prepared by:
Torch angle Weld posture: Horizontal Hor. plate stop time: 0%

Incline torch 7.5°.
15°
30°
Incline torch 2.5°.

6mm 22.5° 20°
25°
45°
4mm
Teaching point
Weaving width is 10mm (100%).

Front + Time
B&F Lat. Vert.
Ang. Cur. Vol.
Point X Y Z
1 2 3 4 5 (%)
(%) (%) (%)
(°) (%) (%)
0 Time ratio
7 28 63 93 100%
1 7 0 18 -8 2.5 0 0
2 28 0 41 47 7.5 0 0
Back -
3 63 0 -50 86 -7.5 0 0
4 93 0 -18 8 -2.5 0 0
Lat. +
5 … … … … … … …
41
18
0 6 … … … … … … …
Time ratio 7 … … … … … … …
Lat. - -18
-50 8 … … … … … … …
9 … … … … … … …
Up + 47
86 10 … … … … … … …
8
11 … … … … … … …
0 Time ratio
-8 12 … … … … … … …
Down - 13 … … … … … … …
Angle + 14 … … … … … … …
7.5
2.5
15 … … … … … … …
0 Time ratio
-7.5 -2.5
Angle -
A-11
Weaving pattern name: Triangular weaving Date prepared:

with both ends stop (both ends current boost) Prepared by:
Amplitude
Teaching origin
Boost 20 % of current at both ends of

Simple harmonic both ends stop.
Point B&F Lat. Vert.
Time Ang. Cur. Vol.
X Y Z
(%) (°) (%) (%)
(%) (%) (%)
Lat. + 50 50
1 15 0 38 0 0.0 0 0
65 70 80 85 100% 2 20 0 50 0 0.0 20 0
0 Time ratio
15 20 30 35 50
3 30 0 50 0 0.0 20 0
-50 -50
Lat. - 4 35 0 38 0 0.0 0 0
5 50 0 0 0 0.0 0 0
Current + 20 30 20 20
6 65 0 -38 0 0.0 0 0
Time ratio
0 7 70 0 -50 0 0.0 20 0
8 80 0 -50 0 0.0 20 0
Voltage - 9 85 0 -38 0 0.0 0 0
10 … … … … … … …
11 … … … … … … …
12 … … … … … … …
13 … … … … … … …
14 … … … … … … …
15 … … … … … … …
A-12

Prepared by:
Joint type: Ver. plate stop time:
Weaving pattern for 1 cycle Weld gas: Center stop time:
Weld posture: Hor. plate stop time:
No. of points: Remarks:
100%
B&F Lat. Vert.
F + Point
Time
X Y Z
Ang. Cur. Vol.
(%) (°) (%) (%)
50 (%) (%) (%)
0 Time ratio 1
50 100%
-50 2
B - -100 3
4
Lateral direction:
5
100%
6
Lat. +
50 7
0 Time ratio 8
50 100%
-50 9
Lat. - 10
-100
11
Vertical direction: 12
100% 13
Up + 14
50
15
0 Time ratio
50 100%
-50
Down - -100
A-13

Prepared by:
Joint type: Ver. plate stop time:
Weaving pattern for 1 cycle Weld gas: Center stop time:
Weld posture: Hor. plate stop time:
No. of points: Remarks:
100%
B&F Lat. Vert.
F + Point
Time
X Y Z
Ang. Cur. Vol.
(%) (°) (%) (%)
50 (%) (%) (%)
0 Time ratio 1
50 100%
-50 2
B - -100 3
4
Lateral direction:
5
100%
6
Lat. +
50 7
0 Time ratio 8
50 100%
-50 9
Lat. - 10
-100
11
Vertical direction: 12
100% 13
Up + 14
50
15
0 Time ratio
50 100%
-50
Down - -100
A-14
Kawasaki Robot Controller E Series
ARC WELDING OPERATION MANUAL
May 2011 : 1st Edition
Published by KAWASAKI HEAVY INDUSTRIES, LTD.
90203-1036DEA
All rights reserved. Copyright © 2011 by KAWASAKI HEAVY INDUSTRIES, LTD.

Robot Manipulator Control Theory and Practice - Frank L.lewis

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Robot Manipulator Control Theory and Practice - Frank L.lewis

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Kawasaki Robot Controller

Kawasaki Heavy Industries, Ltd.

Failure to comply with indicated matters can result in

Denotes precautions regarding robot specification,

1. The accuracy and effectiveness of the diagrams, procedures, and detail

1. HARDWARE KEYS AND SWITCHES (BUTTON)

TEACH/REPEAT: indicates the mode switch “TEACH/REPEAT” on the operation panel.

2. SOFTWARE KEYS AND SWITCHES

2.0 Hardware Keys on Teach Pendant ·······················································································2-1

3.0 Instructions for Operating Screen on Teach Pendant···························································3-1

4.0 Manual Operation of Robot··································································································4-1

5.3.2 Setting Weld Conditions·····································································································5-18

6.0 Repeat Operation ··················································································································6-1

7.0 Program Modification···········································································································7-1

8.0 Auxiliary Functions ··············································································································8-1

9.0 Touch Sensing Function (Option)························································································9-1

9.5 Precautions on Teaching·····································································································9-36

10.0 Special Pattern Weaving Function (Option) ······································································10-1

11.0 Servo Torch Function (Option) ··························································································11-1

12.0 Error Message for Arc Weld Specification········································································12-1

Appendix 1.0 Program Sheet ···········································································································A-1

1.0 OVERVIEW OF ARC WELDING CONTROL

1.1 CONFIGURATION OF ARC WELDING ROBOT SYSTEM

1. Robot for arc welding (RA series robot, etc.)

Robot main body

Arc welding torch

1.2 E CONTROLLER SPECIFICATIONS FOR ARC WELDING

1. Necessary boards: Arc welding interface board (1TW/1GN boards)

3. Optional control function: Touch sensing, special pattern weaving, etc.

2.0 HARDWARE KEYS ON TEACH PENDANT

2.1 OVERVIEW OF TEACH PENDANT

2.2 HARDWARE KEYS ON TEACH PENDANT

A + INSTR. selects the instructions column under “Mtd” on block

A + CND.NUM. selects the weld condition number column on block

A + OPTION selects the option switch column on block teaching screen.

A + JT6 +/- executes 45° align operation while in base mode.

A + JT7 +/- executes 90° align operation while in base mode.

3.0 INSTRUCTIONS FOR OPERATING SCREEN ON TEACH PENDANT

3.1 STATUS AREA

When Weld ON:

Weld OFF :< Arc OFF>

When Weld OFF:

Weld ON: Icon lights up

3.2 F KEYS (FUNCTION KEYS)

Operation When pressed with A key

2 Displays the real time Displays the real time

3.3 MONITOR SCREEN

This screen displays the data of up to five PC programs.

3.3.2 ARC STATUS SCREEN

In Figure 3.3, Torch Interfere and Weld ON are ON.

3.3.3 STEP INFORMATION (AUXILIARY DATA) SCREEN

4.0 MANUAL OPERATION OF ROBOT

4.1 MANUAL OPERATION OF ROBOT

4.1.1 ALIGNING OPERATION

RX and RY rotate → parallel to Z axis.

1. Press INTER and select base mode.

Aligning operation is not possible in joint or tool modes.

45° alignment 90° alignment

4.1.2 SETTING FOR KEEPING BASE +Z DIRECTION

1. Display Aux. Function 0505

2. Move cursor to the desired item

4.2 INCHING OPERATION FOR WELD WIRE

4.3 ON/OFF OPERATION FOR SUPPLYING SHIELD GAS

5.1 OVERVIEW OF TEACHING OPERATION