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Program Objective
To provide technical training and information of robotic
weld operations and provide a first response contact for
robotic or weld related issues.
As a Weld Tech you will be the first point of contact for robot and
robotic weld cell malfunction.
As a Weld Tech you will be expected to provide robotic support for
maintenance when malfunctions require the assistance of the
maintenance staff to repair.
In addition to robotic troubleshooting as a Weld Tech you will be
required to document any issues you encountered and the time it
took you to resolve those issues.
As a Weld Tech you will report to the engineer or supervisor any and
all issues encounter during the shift and any measures or corrective
action taken to resolve those issues.
As a Weld Tech you will agree to rapidly respond to all robotic weld
cell issues minimizing downtime from those issues and helping to
ensure the dept meets its daily production schedule.
Course Content
1.
2.
3.
4.
5.
6.
7.
8.
9.
Safety
Robot anatomy
Teach pendent, Controls and Motion
Robot problems
Stud welding problems
Weld cell problems
Weld Tech specifics
Engineering problems
Preventative maintenance
Safety
Definitions
Work Envelope: The area within maximum extension of either the
robot and or the positioner, fixture, and part.
Pinch Point: Any area 2ft or less between a hard surface and the work
envelope.
TCP: The Tool Center Point is the very end of the robot tool, in the case
of a weld gun the TCP is the tip of the wire.
Maximum rotational
motion
Maximum height
This is the working
envelope of the robot
arm or its potential
range of motion.
Maximum
horizontal reach.
Indicates the
rotational
envelope of
the fixture
Indicates the
working
envelope
restricted by
Indicates
vertical
rotational
envelope of
the Positioner
Indicates the
horizontal
envelope of
the robot
Potential pinch
points are
highlighted
Electrical Hazards
Emergency Stops
There are 5 manually
activated emergency
stops located around
the cell, become very
familiar with them.
On the operator podium
Robot Anatomy
Joint 6: Roll axis-rotates the tool.
Joint 5: Pitch axis-angles the tool in or
out
Joint 4: Yaw axis-angles the tool left or
right
Joint 3: Z axis-moves the tool up and
down
Joint 2: Y axis-moves the tool forward
or back
Joint 1: X axis-moves the tool left or
right
Tool: Attachment on the end of the
robot, i.e.. stud gun, weld gun.
Tool changer: mounted to the end of
joint 6
Home limit switch: indicates the robot
is in the home position and will not run
a new program in automatic unless the
switch is depressed
Controller
Hour meter: records the operating
hours of the robot.
Speed limiting switch: Allows the
operator to choose between automatic
mode, full speed teach mode, and
limited speed teach mode.
User Buttons: Allows operator to set
up specific setting for individual users.
Fault Reset: Resets current faults on
the robot after issue has been
resolved.
Cycle start: initiates cycle start in
automatic mode.
ON/OFF Button: powers up an down
the robot.
Emergency Stop: stops the robot and
activates all axis brakes.
Disconnect switch: cuts all power to
the controller.
Teach Pendant
and Controls
Emergency Stop: shuts down all power to the robot
internal and external axis, and applies the brakes to
all axis.
On/Off switch: activates teach pendent to for robot
control
Operating screen: show current running program,
speed, errors, activated signals, program name, and
motion type.
Menu Key: opens a list of menus such as utilities,
alarms, I/Os, files, status, user ,etc. Primary use of
this button for weld techs will be to view I/Os and
clear alarms, and enter passwords.
Function Key: opens supplementary menu with
options to abort current program or change group.
Cursor keys: used to scroll and navigate menus or
programs.
Shift key: must be held to allow motion in teach
modes, jog the robot, or skip multiple pages of a
menu, program or screen.
Next/Previous: moves forward or backwards through
menus or screens.
Reset: used to reset faults or clear errors.
Motion Keys: while holding shift this allows you to jog the
robot through a program. Shift key must be held through
entire motion.
Coordinate Key: changes the motion type of the robot,
between world, joint, tool, user, jog frame, and path.
Speed Keys: Changes the speed off the robot by
percentage of the programmed motion speed.
Jog Keys: Allows you to jog the robot in the direction
specified or the joint type specified by the key. This
movement is determined by the Coordinate motion that is
selected.
Dead Man Switch: This is a safety device used to E stop
the robot while in a teach mode. If too little pressure is
applied the robot will e stop if too much pressure is
applied the robot will e stop. Only one needs to be
depressed.
Motion Types
Motion types for the robot can be changed by using the COORD key on the
teach pendent. Below are the most common motion types and a description
of there movements.
Joint: this mode allows you to control each joint independently. For every axis on the robot
there are corresponding jog keys to move in the positive or negative directions. A
demonstration will be provided.
World: this mode allows you to move the three lower axis, or major axis, according to the
Cartesian coordinate system (X,Y,Z) while the three upper axis, or minor axis (x,y,z), are
used to control the orientation of the TCP. Note, that by moving in either of the three
direction (X,Y,Z) the robot will move all axis needed to perform that motion. A demonstration
will be provided.
Tool: this mode allows you to move the robot about its TCP. Like the world mode the three
minor axis control the orientation of the TCP and the major axis still move relative to the
Cartesian coordinate system, however the difference is that the Cartesian coordinate
system changes to match the orientation of the TCP. A demonstration will be provided.
External Axis
External Axis: Any axis not used
in conjunction with the robot, but is
not a part of the robots original
design. i.e. positioners
To control an external axis press
the function key on the teach
pendant, and select change group
from the menu. The robot is
defaulted to group one and any
positioners are setup to be
additional groups. By changing the
group you will no longer have
control of the robot, but instead the
positioner. The top jog keys will
control the major axis of the
second group and additional axis
will be controlled by additional jog
keys.
I/O Menus
I/O menu: The I/O menu can be found by
pressing the menu button on the teach pendent
scroll using the arrow keys to the I/O menu and
then scrolling over to the digital menu. This will
bring up all digital inputs and outputs triggered
with in the program logic of the RSR. As a weld
tech your only need to be in this menu is to
trigger an one of the I/Os manually. For
example if the weld cell has completed welding
the cab and does not unclamp and the door
does not open, you may need to manually
trigger the signal for cycle complete. To trigger
the I/O you will need to enter the password first
under the setup menu and then go to the I/O
menu to trigger the input. Do this by
highlighting the status next to the input, and
press the F key that corresponds with the green
on button, then immediately turn it off again, by
pressing the F key corresponding to the red off
button. Most I/O have separate macro
programs that can be ran to trigger them with
out having to go to this menu and without
requiring a pass word. A demonstration will be
provided.
In most situations there is no need to shut down the robot cells unless
maintenance needs to be performed, thereby maintenance will
perform the shutdown, or the weld tech is instructed by the Engineer
or Supervisor to shutdown for special purposes (ex. power outages,
and power surges). To shut down the cell: 1) turn the teach pendent
off via the switch, if it is not already off. 2) Turn the controller off, by
pressing the on/off button. 3) Turn the main breaker off on the
controller. 4) and lastly turn the main buss breaker off on the back of
the weld cell. Use proper lock out procedures of process when
performing. To power up the cell repeat the steps in reverse order.
When at all possible ensure the robot and positioners or in there
home position before shutting down the robot or weld cell.
4)
2)
3)
No Contact
Feeder low
Collision Detect
Control Stop
Wrong stud
T1 or T2 selected
External E-Stop
Hand Broken
Cause:
This error occurs when one of the robot motors cause the drive chain to slip. This is usually
random and rarely occurs
Remedy:
Cause:
This error is caused when the robot goes to initiate the arc and burns back the wire or the
wire sticks to the work piece.
Remedy:
Verify if it is a wire stick or burn back. If it is a wire stick trim the wire if possible and restart
the cycle. If it is a burn back proceed with the following steps
Turn the controller to T1 mode and turn on the teach pendant
Press the Coordinate button to change the motion type to TOOL
Press and hold shift while pressing the J3+ key to move the robot away from the part far
enough to change the tip if needed
Remove the gas nozzle and clean or replace the contact tip and diffuser if needed.
Once the tip is cleaned or changed, scroll up in the program using the arrow keys to the arc
start line of the weld that was about to be made.
Turn the pendant off, and the controller to auto mode and restart the cycle. The robot may
not go, if this is the case, look at the pendant. A yellow box will appear asking if you would
like to move to this line in the program. Highlight yes and hit enter.
Hit the cycle start button on the operator podium again to start the cycle
Collision Detect
Cause:
This error is caused because the robot has collided with an object in its motion path. This is
usually a piece of tooling that never closed, or a foreign object that was left In the cell, or a
part that was not located properly
Remedy:
Put the controller into T1 mode and turn the teach pendent on.
Clear the error by hitting the reset Button on the control pendent
Move the robot so that it clears the obstruction
Remove the obstruction or fix the problem what ever it is
Press the step key to activate the single step function
Jog the robot to the point it was heading to before the collision
Turn the step function off
Turn the teach pendant off and the controller to auto and restart the cycle
Cause:
This error is caused when one of the external entry device is active, such as the garage door
is open, or access door is open or the hold button on the pendant was pressed. This will
cause the robot motion to come to a controlled stop, but not activate the axis brakes
Remedy:
Check all doors and entry devices and verify that they have been close and there are no
obstructions
Press the reset button on the teach pendant and restart the cycle
T1 or T2 selected
Cause:
This is caused when the robot controller is still in T1 or T2 speed control while the teach
pendant is turned off
If trying to put the robot into a teach mode turn the teach pendent on, reset the error and
resume.
If trying to turn the robot into auto mode, turn the controller key to auto and reset the error
Cause:
This error is caused when trying to perform a function or move the robot while the teach
pendant is off
Remedy:
Cause:
This error occurs when you are trying to run two programs at the same time. When
attempting to reset a program and return all groups to their home position, this error may
occur if the original program is not aborted
Remedy:
If the robot is not already in teach mode, turn the controller to T1 and turn the teach pendant
on.
Press the FTCN button on the teach pendent to bring up a menu
Select the abort all function and press enter to abort the current program
By doing this you can not return to that place in the original program unless the line of the program is
noted before aborting. Re-running the aborted program will cause it to run from the start of the
program
Once the existing program is aborted, new programs can be selected from the select menu
by highlighting and pressing enter
Once the program is selected press and hold shift and then press the FWD button to run the
program. Continue to hold shift while program is running.
Cause:
This error is caused when there is an error in the Device net System of the PLC. This error
usually requires an electrician or Electrical Engineer to repair the error.
Remedy:
To clear this error once the repair is made, hit the reset button on the teach pendant.
Some suggested things to have the electrician check to speed up the repair include
24 volt fuse located in the rear relay box on the back of the cell
Power supply in the robot controller
Sick relays in the relay panel
Cause:
This error occurs when external emergency stop is activated. There are three external e
stops not including dead man switches which produce a different error. One is located on
the operator podium, a second on the teach pendant, and a third on the robot controller.
Remedy:
Check the three E-Stops and reset them as necessary. To reset some require a simple pull
of the button while others require you to twist the button.
Cause:
This is the most common error on the stud welder and occurs when the stud welder does not sense the
contact between the stud and the work piece. There are several reason for this such as miss fed stud, no
ground, oil on the base metal, broken cables on the grounding side, or broken cable on the stud gun side,
and finally circuit board needs to be reset.
Remedy:
Grab the pendant for the stud welder and perform the following
Reset any errors by pressing the menu button on the pendant, highlight actual errors and hit enter. From
this screen press the reset button several times until the error is cleared. Press the function button to return
to the main screen.
Check and make sure there is a stud fed through the collet
If there is not a stud press the feed stud button on the pendent to feed another stud
Remove the isolation tube that hold the outer collet on and remove any studs jammed in the outer collet( this may require you
to move the robot to accomplish)
Press the feed stud button again to clear any other studs In the head.
Attach the outer collet and the isolation tube to the head and press the feed stud button again to feed another stud
If needed, jog the robot back to the stud location and press the cycle start button on the stud pendent and hit enter to fire the
stud.
If it does feed a stud press the cycle start button on the stud pendent and press enter to fire the stud
If there is a stud present in the collet, check and make sure the ground cables are attached and have good
contact
Lower the head by pressing the head advance button on the pendant and hitting enter
Press the start weld button on the pendent and then hit enter
Press the head retract button and hit enter, than do it a second time.
Finally press the stud feed button and press enter
Call maintenance to have them check the large black cable packs running from the stud gun to the feeder unit.
Once a stud has been fired leave the cell, close all doors and reset any errors on the robot
Arrow down one line in the robot program and hit the cycle start button on the operator podium. Return to
the pendant and answer yes to the yellow box asking you to start from this new location in the program.
Return to the podium and press the cycle start again. The robot should resume.
If maintenance is called, notify the supervisor. If maintenance can not fix the issue Contact the ME.
Feeder low
Cause:
This error occurs when the feeder is running low on studs. This error does not usually stop
the robot until a miss feed.
Remedy:
Cause:
This error is cause when the a weld is made outside the parameter set within the program
Remedy:
Press the soft key that corresponds with the FK button in the lower right hand corner of the
screen. The robot should continue running.
If this does not work, open the door and close it, arrow down to the next line od the robot
program and restart the cycle. You will get a a yellow box asking if this is okay, say yes, and
hit the cycle start again
Wrong Stud
Cause:
This error is cause when the gun conducts a push in to identify the stud or the ensure the
part is in the proper location.
Remedy:
Check the teach pendant and make sure the proper output is selected
Check to make sure the stud is in contact with the part and the part is not out of position
Reference the stud by pressing the reference button on the pendant and hit enter
Press the Cycle start button on the pendant and hit enter to fire the stud
Arrow down to the next line in the robot program and restart the robot.
If a clamp pressure not reach error shows on the operator podium perform the
following:
1.
2.
3.
2.
Unclamp the part, unload, and reload the part and attempt to clamp it again
If the first does not work call maintenance and notify the supervisor
If the maintenance can not resolve the issue notify the ME
If the Sick lights or light curtain are tripped while the cell is running
1.
2.
3.
Put the robot into T2 teach mode and run the remainder of the program in teach mode
When complete reset all errors and verify the next cycle start up
If all signals indicate green and no errors are shown, but the robot will not start
perform the following checks:
1.
Verify the sick lights indicate weld cell clear by displaying a yellow and green light
1.
2.
Verify all light curtains are aligned with reflectors indicated by a red and green light
1.
3.
If not, adjust the transmitter until the red and green lights are indicated
4.
If not, check for obstruction if any, or wipe the lens of the sick light with a clean dry cloth.
If not, turn the controller to teach mode and run the Home program (program name usually contain
the word home in it and is followed by and MR on the program select menu)
Check to see if the anti repeat is active by removing and replacing the cab (ensure the
cab has moved far enough such that the proximity switch is turned off)
If the operator is attempting to change over tooling and the positioner will not
rotate check the following
1.
Verify all clamp pressure has been reached for both sides
1.
2.
Ensure the robot is in the home position and the positioner is in the home position and
attempt to re-clamp
1.
3.
5.
If the clamp pressure has not been reached you will need to rotate the fixture manually and ensure
both side are clamped. If problem persists contact maintenance.
If the positioner is not home, use the teach pendant to rotate the positioner until the prox. switches
are lit.
Rotate the fixture manually using the teach pendant and then try to reset any errors
Remove the cab and check the prox. Switch for damage
1.
2.
Documentation
As a Weld tech you will have additional responsibilities above that of clearing robot faults
and errors. One of which includes assisting the Engineer in documenting and
resolving downtime issues. As a weld tech you will be responsible for recording any
and all issues that occurred though your shift, including robot error recoveries, tooling
repairs, program changes, maintenance issues, weld issues etc. At each robot
station there is a binder with record sheets. These sheets will need to be filled out for
each issue.
Sample Sheet: Downtime Tracking Sheet
At the end of the week they will be collected by the Engineer and tracked, generating a
pareto chart of the issues seen and rank by highest occurrence. From this chart the
engineer will consult with the weld techs possible solutions for these issues and CI
projects will be developed based on the findings.
If it appears that a weld is out of position or requires touch up in the weld program,
investigate the following prior to making any changes to the program.
1.
2.
Run the Torch mate program and check for any changes
1.
2.
3.
4.
5.
3.
Try a part from another batch or contico, does it still have the weld issue?
6.
Watch him load a few cabs, does it still have the same weld issue?
Watch another certified operator load the cab, does it still have the issue?
5.
4.
Check the next 3 cabs that come out of the weld cell, do they also have the same weld issue?
Check the previous 3 cabs, do they have the same weld issue?
If possible check the previous shifts cabs, do they have the same weld issue?
Check the downtime log to see if a change was made by another shift (also good to verify if other
shifts had the same problem and what measures were take to correct them).
Call a tool maker and together examine the tooling for changes, modifications, damage or just
loose locators and clamps.
If the weld issue still persists, document the problem and your findings from
following the procedure
1.
8.
Record the necessary information in the downtime tracking sheet and email or leave a note with
the engineer, a more detail record of your findings from the procedure
Document the changes in the downtime tracking sheet and the notes to the
engineer.
1.
Include detail such as program name, weld location and parts welded, and the line of the program
that was changed.
Again I must emphasize that policy dictates that if the decision is made to touch up a
weld, the shift in which the change was made will be expected to meet the daily
production schedule, and the weld tech must document all changes and findings
from following the procedures. If you do not feel that there is adequate time to
follow the procedure and make the change, than I would encourage you do the
alternative by documenting the issue and inform the Engineer or Supervisor who
will investigate the issue thoroughly.