ROBOTICS

Application manual
Spot options
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 Application manual
Spot options
RobotWare 6.07

Document ID: 3HAC050979-001

Revision: G

© Copyright 2004-2018 ABB. All rights reserved.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.

© Copyright 2004-2018 ABB. All rights reserved.

ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden
 Table of contents

Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 12
Safety ................................................................................................................................................ 14

1 Introduction to RobotWare Spot 15

1.1 Spot option and features .................................................................................... 15
1.2 Principles of the Spot option ................................................................................ 18
1.3 Programming principles ..................................................................................... 19

2 Configuration 21
2.1 Spot process configuration ................................................................................. 21
2.1.1 The type Spot System .............................................................................. 23
2.1.2 The type Spot Error Handling .................................................................... 25
2.1.3 The type Spot Equipments ........................................................................ 26
2.1.4 The type Spot Weld Equipment .................................................................. 27
2.1.5 The type Spot Gun Equipment ................................................................... 31
2.1.6 The type Spot Media Equipment ................................................................ 37
2.1.7 The type Spot SoftWare Equalizing ............................................................. 39
2.1.8 The type Spot GUI ................................................................................... 41
2.2 Spot I/O configuration ........................................................................................ 42
2.2.1 Spot I/O configuration for single gun system ................................................ 43
2.2.2 Spot I/O configuration multiple guns system ................................................. 47
2.2.3 Spot I/O configuration for MultiMove / MultiProcess systems ........................... 51
2.3 Spot Weld timer configuration options ................................................................... 55
2.3.1 782-1 Bosch DeviceNet AC and 782-7 Bosch DeviceNet MFDC ........................ 55
2.3.2 782-11 Bosch PROFINET MFDC ................................................................ 59

3 Programming 63
3.1 Quick start for servo gun .................................................................................... 64
3.2 Spot weld instructions and data ........................................................................... 65
3.3 Testing spot weld instructions in simulated mode .................................................... 72
3.4 Gun control ...................................................................................................... 73
3.5 Manual actions ................................................................................................. 74
3.6 Process sequence and error handling ................................................................... 76
3.7 Weld process timing .......................................................................................... 88
3.8 Miscellaneous information .................................................................................. 91
3.8.1 Jogging the robot after unintentional servo gun disconnection ......................... 91
3.8.2 Tip dressing for servo guns ....................................................................... 92
3.8.3 Pneumatic spot welding gun and gripper ..................................................... 93
3.9 Supervision task SW_SUP .................................................................................. 94

4 RAPID references 95
4.1 Instructions ...................................................................................................... 95
4.1.1 SpotL/SpotJ - The basic spot welding instructions ......................................... 95
4.1.2 SpotML/SpotMJ - Spot welding with multiple guns ......................................... 100
4.1.3 SetForce - Close and Open a gun with desired force and time ......................... 104
4.1.4 CalibL/CalibJ - Calibrate a servo gun during robot movement .......................... 108
4.1.5 Calibrate - Calibrate a servo gun ................................................................ 114
4.1.6 MeasureWearL - Measure current electrode wear and recalculate the TCP ........ 118
4.1.7 ReCalcTCP - Calculate current electrode wear and recalculate the TCP ............ 126
4.1.8 IndGunMove - Activates independent mode for a servo gun ............................ 130
4.1.9 IndGunMoveReset - Resets servo gun from independent mode ....................... 132
4.1.10 OpenHighLift/CloseHighLift - Control the position of a pneumatic gun ............... 133
4.2 Data types ....................................................................................................... 135
4.2.1 gundata - Equipment specific weld data ....................................................... 135

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Table of contents

4.2.2 spotdata - Spot weld data ......................................................................... 140

4.2.3 forcedata - Spot gun force data .................................................................. 143
4.2.4 simdata - Simulation data ......................................................................... 146
4.2.5 smeqdata - SoftMove Equalizing data ......................................................... 148
4.3 Global instructions and functions ......................................................................... 150
4.3.1 SwGetCurrTargetName - Get the current robtarget name ................................ 150
4.3.2 SwGetCurrSpotName - Get the current spotdata name ................................... 151
4.3.3 SwSetIntSpotData - Set the internal spotdata ............................................... 152
4.3.4 SwSetIntForceData - Set the internal forcedata ............................................. 153
4.3.5 SwSetIntGunData - Set the internal gundata ................................................. 154
4.3.6 SwSetIntSimData - Set the internal simdata .................................................. 155
4.3.7 SwGetCalibData - Get the latest total tip wear and position adjustment ............. 156
4.3.8 SwGetFixTipData - Get the latest fixed tip wear and position adjustment ........... 157
4.4 System modules ............................................................................................... 158
4.4.1 SWUSER ............................................................................................... 158
4.4.2 SWUSRM .............................................................................................. 164
4.4.3 ............................................................................................................ 168

5 Software Equalizing 169

5.1 Introduction to Software Equalizing ...................................................................... 169
5.2 Some basic definitions ....................................................................................... 171
5.3 Weld position Touch Up ..................................................................................... 173
5.4 Releasing of the fixed gun arm and gun opening ..................................................... 175
5.5 Gun arm deflection compensation ........................................................................ 177
5.6 Tip wear compensation ...................................................................................... 180
5.7 SoftMove Equalizing .......................................................................................... 185

6 Servo gun motion control 195

6.1 Servo gun introduction ....................................................................................... 195
6.2 General motion control for servo guns .................................................................. 196
6.3 Asynchronous movements with force control ......................................................... 198
6.4 Tip management ............................................................................................... 200
6.5 Installation and service ....................................................................................... 202
6.6 Stationary gun .................................................................................................. 210
6.7 Servo tool change ............................................................................................. 211

7 FlexPendant Interface 215

7.1 Application Overview ......................................................................................... 215
7.2 Main View ........................................................................................................ 217
7.3 Process Signals ................................................................................................ 220
7.4 Process Data .................................................................................................... 223
7.5 Manual Actions ................................................................................................. 226
7.6 Customizing the GUI .......................................................................................... 227

8 Bosch FlexPendant Interface 229

8.1 Application Overview ......................................................................................... 229
8.2 Pre Warning ..................................................................................................... 232
8.3 Weld Fault ....................................................................................................... 233
8.4 Last Weld ........................................................................................................ 234
8.5 Weld Parameters .............................................................................................. 235
8.6 Communication and configuration ........................................................................ 246

9 Customizing RobotWare-Spot 247

9.1 Introduction ...................................................................................................... 247
9.2 Files to be changed during customizing ................................................................. 248
9.3 Customizing guides ........................................................................................... 250
9.3.1 How to remove not used signals from the process sequence ........................... 250
9.3.2 How to remove not used process hooks ...................................................... 251

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9.3.3 How to change the number of guns equipments to be used ............................. 252
9.3.4 How to define max/min values for data components ...................................... 254
9.3.5 How to change the Spot data types ............................................................. 255
9.3.6 How to add functionality in the process sequence ......................................... 256
9.3.7 How to use spot data programmed in the weld timer ...................................... 258
9.3.8 How to set the number of automatic rewelds after weld error ........................... 260
9.3.9 How to package and install the result from the customizing ............................. 261

Index 263

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 Overview of this manual

Overview of this manual

About this manual
This manual describes the RobotWare option Spot and it's configurations Spot
Pneumatic, Spot Servo, and Spot Servo Equalizing, and contains instructions for
use of the software and configuration.

Usage
This manual should be used during installation and configuration of the RobotWare
option Spot.

Who should read this manual?

This manual is intended for:
• Commissioning personnel
• Service engineers
• Robot programmers
• Personnel responsible for installations and configurations of fieldbus
hardware/software
• Personnel responsible for system configuration
• System integrators

Prerequisites
The reader should have the required knowledge of:
• IRC5 programming and usage
• System parameter configuration
• Mechanical installation work
• Electrical installation work
• System parameters and be used to editing these, either via RobotStudio or
via cfg-files

References

References Document ID
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Operating manual - RobotStudio 3HAC032104-001
Product manual - IRC5 3HAC021313-001
Product specification - Controller IRC5 with FlexPendant 3HAC041344-001
Technical reference manual - System parameters 3HAC050948-001
Technical reference manual - RAPID Instructions, Functions 3HAC050917-001
and Data types
Technical reference manual - RAPID overview 3HAC050947-001
Application manual - Additional axes and stand alone con- 3HAC051016-001
troller
Application manual - Servo Gun Setup 3HAC065014-001

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Overview of this manual
Continued

References Document ID
Application manual - SoftMove 3HAC050977-001
Application manual - RobotWare Add-Ins 3HAC051193-001
Application manual - DeviceNet Master/Slave 3HAC050992-001
Application manual - PROFINET Controller/Device 3HAC050969-001

Revisions

Revision Description
- Released with RobotWare 6.0.
A Released with RobotWare 6.01.
A Released with RobotWare 6.01.
• Updated the path to the template files, see 782-11 Bosch PROFINET
MFDC on page 59.
B Released with RobotWare 6.02.
• Possibility to configure supervision task SW_SUP, Supervision task
SW_SUP on page 94.
• Added possibility to use sensor search in MeasureWearL, see Meas-
ureWearL - Measure current electrode wear and recalculate the TCP
on page 118.
• Added possibility to perform a test weld in the CalibL and CalibJ instruc-
tions, see CalibL/CalibJ - Calibrate a servo gun during robot movement
on page 108.
• Added possibility to use dual forces in the SetForce instruction, see
SetForce - Close and Open a gun with desired force and time on page 104
• Added support for Spot in a MultiProcess configuration on 2 robots.
C Released with RobotWare 6.03.
• Changed template I/O naming for MultiGun and MultiMove configura-
tions, see Spot I/O configuration on page 42.
D Released with RobotWare 6.04.
• Changed template gun names in the SWUSER modules, see gundata
- Equipment specific weld data on page 135.
• Improved information on how to define TCP, see How to define the TCP
on page 171.
• Improved handling of independent gun mode in SetForce, see SetForce
- Close and Open a gun with desired force and time on page 104.
• Improved gun force gravity compensation, see Servo gun force gravity
compensation on page 204
• General improvements.
E Released with RobotWare 6.05.
• Added possibility to handle tip change and tip wear supervision errors
in the MeasureWearL and ReCalcTCP instructions in the user defined
error handling.
• Added supervision of force calibration status of used gun, and also a
possibility to create a default force table in the ManualForceCalib
and ManualServiceCalib service routines.
F Released with RobotWare 6.06.
• Limitations regarding servo tool change has been updated.
• Water flow supervision information improved.
• Added possibility to configure gun deflection parameters via system
parameters.

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Continued

Revision Description
G Released with RobotWare 6.07.
• References to the new manual Application manual - Servo Gun Setup,
that replace the old Application manual - Servo Gun Tuning.
• Added possibility to configure gun force unit, see The type Spot System
on page 23
• Misc. information improvements.

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© Copyright 2004-2018 ABB. All rights reserved.
Product documentation

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com.

Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.

Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.

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 Product documentation
Continued

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.

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Safety

Safety
Safety of personnel
When working inside the robot controller it is necessary to be aware of
voltage-related risks.
A danger of high voltage is associated with the following parts:
• Devices inside the controller, for example I/O devices, can be supplied with
power from an external source.
• The mains supply/mains switch.
• The power unit.
• The power supply unit for the computer system (230 VAC).
• The rectifier unit (400-480 VAC and 700 VDC). Capacitors!
• The drive unit (700 VDC).
• The service outlets (115/230 VAC).
• The power supply unit for tools, or special power supply units for the
machining process.
• The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.
• Additional connections.
Therefore, it is important that all safety regulations are followed when doing
mechanical and electrical installation work.

Safety regulations
Before beginning mechanical and/or electrical installations, ensure you are familiar
with the safety regulations described in Operating manual - General safety
information 1 .

1 This manual contains all safety instructions from the product manuals for the manipulators and the controllers.

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 1 Introduction to RobotWare Spot
1.1 Spot option and features

1 Introduction to RobotWare Spot

1.1 Spot option and features

The Spot option

The Spot option is a general and flexible software platform for creation of
customized and easy to use function packages for different types of spot welding
systems and process equipment.
There are three different main Spot configurations supporting spot welding, two
for servo guns and one for pneumatic guns.
• The Spot Pneu configuration provides support for sequential welding with
one gun equipment. For this configuration it is also possible to select a
multiple gun configuration when configuring the system, with support for
welding with four pneumatic guns at the same time.
• The Spot Servo configuration provides support for sequential welding with
one gun equipment. For this configuration it is also possible to select a
multiple gun configuration when configuring the system, with support for
welding with four servo guns at the same time.
• The Spot Servo Equalizing configuration has the same functionality as the
basic Spot Servo configuration, but can also be used for guns without
mechanical equalizing systems.
All Spot configurations provides dedicated spot welding instructions for fast and
accurate positioning combined with gun manipulation, process start and supervision
of the different gun equipment.
Communication with the external welding equipment is done with digital signals.
The Spot option is general and can be extensively customized. The three main
configurations have a default "template" functionality after installation, that can
easily be customized to fit the surrounding equipment(s) by changing I/O signals,
configuration data, RAPID data, and RAPID routines from RobotStudio for example.

Note

Some functionality may not be available from one software version to another,
e.g 5.15 vs 6.0.

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1 Introduction to RobotWare Spot
1.1 Spot option and features
Continued

Overview of the Spot option

As mentioned above it is possible to customize the Spot option to handle different
types of equipment, and this picture below shows a schematic example of a spot
welding system and the Spot option software.

Spot options

Robot controller

RobotWare

The Spot options

Program Spot weld equipment

memory Kernel
Spot weld equipment 1

User Gun1
modules

System Proc, Eio, Moc,

parameters Sys
Gun2

xx1200000682

Spot features
The Spot option package contains the following features:
• Fast and accurate positioning using the unique QuickMove and TrueMove
concept.
• Gun pre-closing, gun closing will be synchronized with robot reaching the
weld position to save cycle time.
• Support for mechanical gun equalizing systems.
• Software equalizing functions (if the Spot Servo Equalizing configuration is
installed).
• Constant or variable tip force during welding for servo guns.
• Detect missing or improper plates for servo guns.
• Reverse execution with gun control
• Gun calibration functions for servo guns.
• Manual actions for welding and gun control.
• Welding with up to four guns at the same time.
• Several simulation possibilities for test purposes.

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 1 Introduction to RobotWare Spot
1.1 Spot option and features
Continued

• Weld error recovery with automatic rewelding.

• Default "ready to use" functionality directly after installation if SpotPack
configuration is selected.
• Wide customizing possibilities, process data types, spotdata, gundata, such
as weld counters and tip wear data, for each used gun.
• User-defined supervision and error recovery.
• Fast switch between two servo guns with a tool changer. Note that this
requires the option Servo Tool Change.
• A dedicated Spot operator interface on the FlexPendant.
• Integrated weld timer fault management (for the options 782-x Bosch Weld
timer)
• RobotWare Spot can be applied on two robots robots in a MultiMove system,
and run semi coordinated using WaitSyncTask. Option 634-1 MultiProcess
is required for more than one robot.

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1 Introduction to RobotWare Spot
1.2 Principles of the Spot option

1.2 Principles of the Spot option

Process tasks
The spot welding process will be controlled by separate internal hidden semi static
tasks, which will run independently from the motion task.
The robot movements, the spot welding process and the continuous supervision
will be handled in different independent tasks. This means that if for example the
program execution and thus the robot movements is stopped, then the welding
and supervision will continue until they come to a well defined process stop.
For example, the welding process will carry on and finish the weld and open the
gun, although the program has been stopped during the weld phase.
The tasks running the spot weld processes are hidden and will not be visible on
the FlexPendant or in RobotStudio. Only the motion task and the default supervision
task are visible.

User routines and modules

At well defined places in the welding sequence, customizable user routines (hooks)
will be executed. This offers the possibility to adapt the software to different
preconditions and environments other than the default behaviour.
A number of customizable data types are also available to shape the behavior of
the spot weld instructions.

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 1 Introduction to RobotWare Spot
1.3 Programming principles

1.3 Programming principles

Introduction
Both the robot movement and the control of the spot weld equipment are embedded
in the basic spot weld instructions SpotL and SpotJ. These are used for sequential
welding and are available in all spot welding options. If there is a need to weld with
several guns simultaneously then the instructions SpotML or SpotMJ are availble
for that purpose. See RAPID references on page 95.
• Each spot welding process is specified by:
• spotdata: spot weld process data. See spotdata - Spot weld data on page 140.
• gundata: spot weld equipment data. See gundata - Equipment specific weld
data on page 135.
• The system module SWUSRM: Process data and RAPID routines for data
transfer between user code and kernel code. See SWUSRM on page 164.
• The system module SWUSER: RAPID routines for customization of the
process behavior, checking the additional external equipments etc. See
SWUSER on page 158.
• System parameters: the I/O signal configuration and the manipulator
configuration. See Configuration on page 21 and Installation and service on
page 202.
• See Operating manual - IRC5 with FlexPendant and Technical reference
manual - System parameters.

Spot instructions
Both the robot movement and the control of the spot weld equipment are embedded
in the basic spot weld instructions SpotL and SpotJ. These are used for sequential
welding and are available in all spot welding options. If welding with several guns
simultaneously then SpotML or SpotMJ has to be used.

Instruction Used to
SpotL Control the motion, gun closure/opening and the welding process.
Move the TCP along a linear path and perform a spot welding at the
end position.
SpotJ Control the motion, gun closure/opening and the welding process.
Move the TCP along a non-linear path and perform a spot welding
at the end position.
SpotML Control the motion, gun closure/opening and 1 - 4 welding processes.
Move the TCP along a linear path and perform spot welding with 1
- 4 gun equipments at the end position. Only available if MultiGun
Configuration is installed.
SpotMJ Control the motion, gun closure/opening and 1 - 4 welding processes.
Move the TCP along a non-linear path and perform spot welding
with 1 - 4 gun equipments at the end position. Only available if
MultiGun Configuration is installed.
IndGunMove Set the servo gun in independent mode and thereafter move the
gun to a specific independent position.
IndGunMoveReset Reset the independent mode for servo gun.

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1 Introduction to RobotWare Spot
1.3 Programming principles
Continued

Instruction Used to
SetForce Close the gun a predefined time then open the gun.
OpenHighLift Open the pneumatic gun to the highlift position (large gap).
CloseHighLift Close the pneumatic gun to the work stroke position (small gap).
CalibL Calibrate the servo gun during linear movement to the programmed
position.
CalibJ Calibrate the servo gun during non-linear movement to the pro-
grammed position.
Calibrate Calibrate the servo gun in current position without movement.
STTune Tune motion parameters for the servo gun.
STTuneReset Reset tuned motion parameters for the servo gun.
MeasureWearL Measure the tip wear and recalculates the TCP. Only available if
Spot Servo Equalizing is installed.
ReCalcTCP Calculates the tip wear and recalculates the TCP. Only available if
Spot Servo Equalizing is installed.

Spot welding data types

Data type Used to define

spotdata The spot welding process, weld program number, gun force etc.
gundata The spot welding equipment, gun name, weld counters etc.
forcedata The SetForce process, gun force etc.
simdata Simulation modes, controller simulation, timer simulation etc.

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 2 Configuration
2.1 Spot process configuration

2 Configuration
2.1 Spot process configuration

Introduction
This chapter describes the process configuration options that are available for the
Spot options, and information about the signals and parameters that are used.
The parameters that are used for the Spot options are configured in the system
parameters. From the ABB menu on the FlexPendant:
1 Tap Control Panel.
2 Tap Configuration.
3 Tap Topics and select Process.
The Process configuration can also be accessed from RobotStudio.
The Spot option can be configured for different equipment setups, but the default
setup for a basic Spot configuration is for one gun equipment.
Not used equipments can also be removed completely if not needed, in the Spot
Equipments type.

Spot process configuration types

The system parameters for RobotWare Spot are divided in the following types.
• Spot System
• Spot Error Handling
• Spot Equipments
• Spot Weld Equipment
• Spot Gun Equipment
• Spot Media Equipment
• Spot Equalizing
• Spot GUI

Configuration types

Configuration types Definitions

Spot System Configuration of Spot system specific data.
Spot Error Handling Configuration of Spot error handling.
Spot Equipments Defines the number of used spot welding equipment
and equipment specific data.
Spot Weld Equipment Configuration of the spot welding equipment, setup
data, and the signals needed in the process and in
the Spot GUI.
Spot Gun Equipment Configuration of the spot gun equipment, setup data,
and the signals needed in the process and in the
Spot GUI.
Spot Media Equipment Configuration of the spot media equipment, setup
data, and the signals needed in the process and in
the Spot GUI.

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2 Configuration
2.1 Spot process configuration
Continued

Configuration types Definitions

Spot Equalizing Configuration of Software Equalizing, setup data.
Spot GUI Configuration of the Spot GUI.

Configuration files

Note

Configuration files and backups shall not be loaded into systems running an
older RobotWare version than in which they were created.
Configuration files and backups are not guaranteed to be compatible between
major releases of RobotWare and may need to be migrated after a RobotWare
upgrade.

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 2 Configuration
2.1.1 The type Spot System

2.1.1 The type Spot System

Description
The top level of configuration parameters for RobotWare Spot is Spot System. The
settings of Spot System is valid for the whole robot system.

xx1400002066

Parameters
The following parameters are used to define the system settings in RobotWare
Spot.

Note

Settings are dependent on actual spot configuration.

Parameter Default value Data type Note

Name spot_system string The name of the system.
Gun force unit N string The used gun force unit type. (Newtons [N],
type Decanewtons [daN] or Pounds Force [lbf]).

Note

Default value is Newton, the configured value

is used as a string to present the actual gun
force values shown on the FlexPendant.
No automatic recalculations of any force val-
ues will be done if this parameter is changed,
it is up to the user to specify correct force
unit type and corresponding force values.
Force calibration is needed if values is
changed. See Servo gun force calibration on
page 203

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2 Configuration
2.1.1 The type Spot System
Continued

Parameter Default value Data type Note

Min gun force 1000 N num The minimum allowed gun force used for
welding. (1-2000).
This value will be set to 20% of the entered
max gun force when performing a force calib-
ration of the gun.

Note

This value will be checked before weld in or-

der to prevent too low forces.

Min force time 1 s num The minimum allowed gun force time in Set-
Force. (0-2 s)
Max force 10 s num The maximum allowed gun force time in
time SetForce. (0-15 s)
Max simula- 10 s num The maximum allowed simulation time if
tion time simulated weld mode. (0-15 s)
Max plate 40 mm num The maximum allowed plate thickness in the
thickness system. (0-100 mm)
Max plate tol- 1 mm num The maximum allowed plate tolerance in the
erance system. (0-10 mm)
Min allowed 10 kg num The minimum allowed tool weight when run-
tool weight ning spot instructions. (0.5-800 kg)
No. of force 2 num The number of force calibration measure-
calibration ments in the ManualForceCalib service
measure- routine. (2-10)
ments
Sensor thick- 10 mm num The thickness of the force sensor used when
ness for force performing a force calibration with the
calibration ManualForceCalib service routine. (0-50 mm)
Squeeze time 2 s num The squeeze time when when performing a
for force calib- force calibration with the ManualForceCalib
ration service routine. (1-10 s)
Motion task SWUS- string The name of the user module running in the
user module RM.SYS motion task only.
name
All task user SWUSER.SYS string The name of the user module running in all
module name tasks.
Spot user HOME:/Spot string The location and file path of the spot user
modules file modules. Used when saving user data in the
path calibration and measurement routines, e.g
CalibL, MeasureWearL etc.
Use Spot spotequip- string The name of the used spot equipment(s)
Equipment1 - ment1 used in the system. Max number of spot
10 equipments are 10.

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 2 Configuration
2.1.2 The type Spot Error Handling

2.1.2 The type Spot Error Handling

Description
The Spot Error Handling contains parameters for the global error handling settings.

Parameters
The following parameters and signals are used to define the error handling in
RobotWare Spot.
Parameter Default value Data type Note
Name spot_error_hand- string The name of the error handling in-
ling stance.
Number of auto- no reweld num Automatic reweld: Number of auto-
matic rewelds matic tries to reweld after weld
complete timeout, 0-3 are possible
to configure.
Show 'skip' but- No bool Show skip button in the error dia-
ton in auto mode logs on the TPU in automatic oprat-
ing mode, Yes/No.
Show 'skip' but- Yes bool Show skip button in the error dia-
ton in manual logs on the TPU in manual oprating
mode mode, Yes/No.
Show 'ignore' No bool Show ignore button in the error dia-
button in auto logs on the TPU in automatic oprat-
mode ing mode, Yes/No.
Show 'ignore' Yes bool Show ignore button in the error dia-
button in manual logs on the TPU in manual oprating
mode mode, Yes/No.
Error dialog ack. skip_proc signaldi The digital input signal that may in-
for 'Skip' terrupt the operator dialog, connec-
ted to the 'Skip' button.
Error dialog ack. reweld_proc signaldi The digital input signal that may in-
for 'Retry' terrupt the operator dialog, connec-
ted to the 'Retry' button.
Error dialog ack. ext_override signaldi The digital input signal that may in-
for 'Skip' or terrupt the operator dialog, connec-
'Retry' ted to the 'Skip' and 'Retry' button.
User defined er- No bool User defined error handling. The
ror handling error handling routine
SwErrorRecover in SWUSER is
called instead of the built in error
handling if this parameter is set to
Yes.

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2 Configuration
2.1.3 The type Spot Equipments

2.1.3 The type Spot Equipments

Description
The Spot Equipments defines the number of spot equipments defined in the system.
Max number of instances are 10.

Parameters
The following parameters and signals are used to define the equipments in
RobotWare Spot.

Note

Settings are dependent on actual spot configuration.

Parameter Default value Data type Note

Name Spot Equipment1 string The name of the spot equipment in-
stance.
Use Weld Equip- weldtimer1 string Pointer to the used weld eqipment.
ment
Use Gun Equip- servogun1 string Pointer to the used gun equipment.
ment
Use Media mediapanel1 string Pointer to the used media equip-
Equipment ment.
Spot GUI equip- diEquipmentOk signaldi Spot GUI equipment OK status sig-
ment OK nal.
Spot process doProcessRun signaldo Spot process running signal, set
running high during the spot process.
Spot process doProcessFault signaldo Spot process fault signal, set high
fault if a process fault occur during pro-
cess..

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 2 Configuration
2.1.4 The type Spot Weld Equipment

2.1.4 The type Spot Weld Equipment

Description
The Spot Weld Equiment contains parameters for the connected weld equipment(s).
This instance can be multiplied.

Parameters
The following parameters and signals are used to define the weld equipments in
RobotWare Spot and signals visible in the Spot GUI.
Parameter Default value Data type Note
Name weldtimer1 string The name of the weld timer in-
stance.
Weld process doStartWeld signaldo Used to configure the weld start
start [DO] signal for the timer. Signal will be
set when gun is closed and the ro-
bot is in position.
This signal is required.
Weld process diWeldComplete signaldi Used to configure the weld com-
complete [DI] plete signal for the timer. Signal will
be set by the timer when the current
weld is ready.
This signal is required.
Weld timeout 2s num The max time waiting for the weld
process complete signal, after this
time the error handling is activated.
(0-10 s)

Note

If the auto reweld function is activ-

ated, the weld will be restarted
automatically the specified times
before the error handling is activ-
ated, see The type Spot Error
Handling on page 25

Enable current doEnableCurrent signaldo Used to configure the weld current

[DO] enable signal. This signal will only
be set if no simulation is activated.
If no signal name is specified here,
there will be no function.
Timer ready to diTimerReady signaldi Used to configure the weld timer
weld [DI] ready signal. This signal will only be
set if no simulation is activated.
Signal will be set by the timer if no
error is present.
If no signal name is specified here,
there will be no function.
Timer ready 2s num The max time waiting for the weld
timeout timer ready signal, after this time
the error handling is activated. (0-5
s)

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2 Configuration
2.1.4 The type Spot Weld Equipment
Continued

Parameter Default value Data type Note

Stop weld pro- diWeldFault signaldi Used to configure the stop weld
cess [DI] process signal. This signal can be
set by the timer if an error is detec-
ted during the weld sequence. If set
the current weld will be stopped.
If no signal name is specified here,
there will be no function.
Weld program goWeldProgram signalgo Used to configure the weld program
group [GO] group signal. This signal will be set
at the beginning of a spot instruc-
tion.
If no signal name is specified here,
there will be no function.
New program se- doNewProgram signado Used to configure the new weld
lection [DO] program selection signal. This sig-
nal will be set just after the weld
program group signal is set.
If no signal name is specified here,
there will be no function.
Weld program diProgSelectVal- signaldi Used to configure the weld program
valid [DI] id vaild signal. This signal will be set
by the timer when a vaild weld pro-
gram is selected. It will be checked
during the process before the weld
is started.
If no signal name is specified here,
no check will be done.
Weld program 2s num The max time waiting for the valid
valid timeout weld program signal, after this time
the error handling is activated. (0-5
s)
Reset timer fault doResetFault signaldo Used to configure the reset timer
[DO] fault signal. This signal can reset
timer faults before a reweld is done.
If no signal name is specified here,
there will be no function.
Reset fault time 2s num The length of the reset fault signal
pulse to reset the timer. (0-2 s)
Wait time after 2s num Wait time after the reset fault pulse
reset fault before program execution contin-
ues. (0-2 s)
Weld contactor doWeldPower- signaldo Used to configure the weld contact-
on [DO] Contact or signal. This signal will be set by
a cross connection in the I/O config-
uration, as a result of the motor_on,
doEnableCurrent and doProcess-
Fault inverted.
Weld contactor diWeldContact signaldi Used to configure the weld contact-
on [DI] or activated signal. This signal is
normally set by the weld contactor
if a contactor is used. If not set be-
fore the weld, the error handling will
be activated.
If no signal name is specified here,
there will be no function.

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 2 Configuration
2.1.4 The type Spot Weld Equipment
Continued

Parameter Default value Data type Note

Gun force from giGunForce signalgi Used to configure the gun force
timer [GI] group signal. This signal can be
used if external gun force data from
the weld timer is required.
If no signal name is specified here,
there will be no function.

Note

To activate the use of the timer input

signals the corresponding paramet-
er in spotdata must be set to -1, e.g.
my_spot.tip_force := -1;

Force calculation 40 num Gun force factor when using extern-

factor al force from weld timer. (0-100)
Example with 8 bit group input, 255
* 39.2 ~ 10000 N Max in timer.
Plate thickness giPlateThickness signalgi Used to configure the plate thick-
from timer [GI] ness group signal. This signal can
be used if external plate thickness
data from the weld timer is required.
If no signal name is specified here,
there will be no function.

Note

To activate the use of the timer input

signals the corresponding paramet-
er in spotdata must be set to -1, e.g.
my_spot.plate_thickness := -1;

Thickness calcu- 0.1 num Plate thickness factor when using

lation factor external data from weld timer. (0-
100)
Example with 8 bit group input, 255
* 0.1 = 25.5mm max thickness.
Plate tolerance giPlateTolerance signalgi Used to configure the plate toler-
from timer [GI] ance group signal. This signal can
be used if external plate tolerance
data from the weld timer is required.
If no signal name is specified here,
there will be no function.

Note

To activate the use of the timer input

signals the corresponding paramet-
er in spotdata must be set to -1, e.g.
my_spot.plate_tolerance := -1;

Tolerance calcula- 0.1 num Plate tolerance factor when using

tion factor external data from weld timer. (0-
100)
Example with 8 bit group input, 255
* 0.1 = 25.5 max tolerance.

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2 Configuration
2.1.4 The type Spot Weld Equipment
Continued

Parameter Default value Data type Note

Timer status [GI] giTimerStatus signalgi Used to configure the timer status
group signal. This signal is used to
check the timer status when a weld
fault has occured.
If no signal name is specified here,
there will be no function.
Reset fault with signaldo Used to configure the reset timer
reweld [DO] fault with reweld functionality.
This signal can be used to enable a
reweld in KSR mode in a Bosch
weld timer when performing a re-
weld in adaptive weld mode. If used
the normal start weld signal will be
set to 1 during the reweld sequence,
and this signal will reset the timer
fault and perform the reweld. The
normal reset fault signal will not be
used.
If no signal name is specified here,
there will be no function.
User defined gui string Used to configure user defined sig-
signal1-10 nals that should be visible in the
Spot GUI process cabinet view. Not
used in process.

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 2 Configuration
2.1.5 The type Spot Gun Equipment

2.1.5 The type Spot Gun Equipment

Description
The Spot Gun Equipment contains parameters for the connected gun equipment(s).
This instance can be multiplied.

Parameters
The following parameters and signals are used to define the gun equipments in
RobotWare Spot and signals visible in the Spot GUI.

Note

Settings are dependent on actual spot configuration.

Parameter Default value Data type Note

Name servogun1 string The name of the gun instance.
Selected gun Servo gun string Used to configure the gun type,
type possible values are Servo gun or
Pneu gun.
Gun trafo over- diTrafoTempOk signaldi Used to configure the transformer
temperature temperature sensor signal connec-
ted to the gun. Signal will be
checked during the spot process.
If no signal name is specified here,
no check will be done.
Gun opened diGunOpen signaldi Used to configure the gun opened
sensor signal for a pneumatic gun.
Signal will be checked during pro-
cess.
If no signal name is specified here,
no check will be done during pro-
cess.
Gun open 2s num The max time[s] waiting for the gun
timeout open signal after a pneumatic gun
has been opened, after this time the
error handling is activated. (0-10 s)
Gun highlift open diHighLiftOpen signaldi Used to configure the highlift open
sensor signal for a pneumatic gun.
Signal will be checked during the
spot process.
If no signal name is specified here,
no check will be done during pro-
cess.
Gun equalizing doEqualize signaldo Used to configure the gun equaliz-
ing signal for the gun. This signal
will be set when closing the gun and
reset when opening the gun after
weld.
If no signal name is specified here,
there will be no function.

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2 Configuration
2.1.5 The type Spot Gun Equipment
Continued

Parameter Default value Data type Note

Gun pre equaliz- 0 s num Time before gun in weld position,
ing time when the equalizing signal is set for
activation of a mechanical equaliz-
ing system in the gun, if used. (0-0.5
s)
Gun close doCloseGun signaldo Used to configure the gun close
signal for a pneumatic gun. This
signal will be set a predefined time
before the weld position, and reset
when the weld is completed.
If no signal name is specified here,
there will be no function.
Gun pre closing 0.1 s num Time before gun in weld position,
time when the asynchronous gun closure
is started. For pneumatic guns,
when the gun close signal is set. (0-
0.5 s)
This data is not used if Software
Equalizing is active. In this case the
preclosing is handled automatically
during the movement from the re-
lease distance to the weld position.
Gun close 2s num The max time waiting for gun open
timeout signal before closing a pneumatic
gun, after this time the error hand-
ling is activated. (0-10 s)
Gun open highlift doOpenHighLift signaldo Used to configure the open highlift
signal for a pneumatic gun. Signal
will be set during the spot process
if the optional argument \OpenHigh-
Lift is selected in the spot instruc-
tion. (Pneumatic guns only)
If no signal name is specified here,
there will be no function.
Gun close highlift doCloseHighLift signaldo Used to configure the close highlift
signal for a pneumatic gun. Signal
will be set during the spot process
if the optional argument \CloseHigh-
Lift is selected in the spot instruc-
tion. (Pneumatic guns only)
If no signal name is specified here,
there will be no function.
Gun pressure signalgo Used to configure the gun pressure
group group signal for a pneumatic gun.
Will be set to the value specified in
the tip force parameter in spotdata.
If no signal name is specified here,
there will be no function.
Gun pressure OK diPressureOk signaldi Used to configure the gun pressure
ok signal for a pneumatic gun.
If no signal name is specified here,
no check will be done during pro-
cess.
Gun pressure 2s num The max time waiting for gun pres-
timeout sure ok signal, after this time the
error handling is activated. (Pneu-
matic guns only). (0-10 s)

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 2 Configuration
2.1.5 The type Spot Gun Equipment
Continued

Parameter Default value Data type Note

Force complete force_complete signaldi Used to configure a gun force com-
plete signal that can be used in the
SetForce instruction.
If no signal name is specified here,
there will be no function.
Max allowed gun 5000 N num Maximum allowed tip force for each
force gun. This value can be set from the
ManualForceCalib service routine
when performing a force calibration
of the gun. (0-10000). See Available
service routines on page 74.

Note

Normally this data is supplied by the

gun manufacturer and the max al-
lowed gun force value should be
entered here.

Note

This parameter can also be con-

figured via system parameters, see
System Parameters, Topic Motion
and Type SG Process Technical
reference manual - System paramet-
ers. In this case this parameter has
to be set to Deactivated (-1) = Not
used.

Gun force normal Deactivated num Reference gun force when move-
orientation able gun arm is working with grav-
ity.
This parameter can be set from the
ManualForceCalib service
routine.
Example: Applied gun force 5000N
normal gun orientation, measured
force 5000N.
Deactivated (-1) = Not used.

Note

The max gun force will be used as

reference for the two gun positions.

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2 Configuration
2.1.5 The type Spot Gun Equipment
Continued

Parameter Default value Data type Note

Gun force inver- Deactivated num Reference gun force in when
ted orientation moveable gun arm is working
rotated 180° against gravity.
This parameter can be set from the
ManualForceCalib service
routine.
Example: Applied gun force 5000N
in inverted gun orientation, meas-
ured force 4500N.
If these parameters are used the
gun force will be compensated be-
fore weld depending on the current
angle of the gun in the specific pos-
ition.
Deactivated, (-1) = Not used.

Note

The max gun force will be used as

reference for the two gun positions.

Use SoftWare Yes bool Soft equalizing specific data.

equalizing This data has to be set to Yes to
activate the software equalizing
functions release of the fixed gun
arm and gun arm deflection com-
pensation. Yes/No
MeasureWearL signaldi Soft equalizing specific data.
search I/O Used to configure an input signal
that can be used instead of the ref-
erence plate for the search se-
quence in the MeasureWearL in-
struction.
If this signal is specified the search
will be done against a sensor signal
instead of a fixed reference surface.
Tip change super- 3 mm num Soft equalizing specific data.
vision value Tip change supervision value.
Max allowed digression [mm] in
positive and negative direction from
stored reference values. Default
value 3 mm.
This data is used to supervise a
missing tip or wrong size of the tip
and is used in the MeasureWearL
and Calibrate/CalibL/J instruc-
tions. (Max 10 mm)

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 2 Configuration
2.1.5 The type Spot Gun Equipment
Continued

Parameter Default value Data type Note

Tip wear supervi- 0.2 mm num Soft equalizing specific data.
sion value Tip wear supervision value.
Max allowed digression [mm] in
positive and negative direction since
last tip wear compensation. Default
value 0.2 mm.
This data is used to supervise the
tip wear and is used in the
MeasureWearL, ReCalcTCP and
Calibrate/CalibL/Jinstructions.
(Max 2 mm)
Tip wear ratio, Deactivated num Soft equalizing specific data.
fixed vs total The expected ratio [%] between the
wear tip wear for the fix tip related to the
total tip wear. This value has to be
set to a permitted value (between
0-100) if the calculation method
(ReCalcTCP) is used for the tip
wear compensation. The value can
be set in predefined steps of 10%.
Example: Fixed tip 60% of total wear
Indicates that the wear of the fixed
tip is 60% of the total tip wear, which
leaves 40% for the moving tip,
60/40.

Note

If the measuring method is used,

(MeasureWearL) this value has to
be set to Deactivated.

Opposite z-direc- No bool Soft equalizing specific data.

tion Defined z-direction for the TCP,
gives move direction for search and
compensations movements.
Yes/No.
No = positive z-direction out from
the fixed tip (Normal setting).
Yes = positive z-direction into the
fixed tip (Setting for stationary tools
to achieve the same jogging behavi-
or as with a robot held tool).
This parameter also influences the
direction of the gun arm deflection
compensation.
For more information, see How to
define the TCP on page 171.
MeasureWearL Deactivated num Soft equalizing specific data.
TouchUp force Contact force (in N) during tip
override measurement in the MeasureWearL
instruction, (typically between 50 -
150N).
This parameter will override the
global parameter in the Spot
Equalizing instance if used.
Deactivated = Not used.

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2 Configuration
2.1.5 The type Spot Gun Equipment
Continued

Parameter Default value Data type Note

Tip change fault signaldo Soft equalizing specific data.
Used to configure the tip change
fault signal. This signal will be set
when a tip wear error is detected in
the CalibL/J, MeasureWearL,
RecalcTCP instructions.
If no signal name is specified here,
there will be no function.
Tip wear fault signaldo Soft equalizing specific data.
Used to configure the tip wear fault
signal. This signal will be set when
a tip wear error is detected in the
MeasureWearL and ReCalcTCP in-
structions.
If no signal name is specified here,
there will be no function.
User defined gui string Used to configure user defined sig-
signal1-10 nals that should be visible in the
Spot GUI gun equipment view. Not
used in process.

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 2 Configuration
2.1.6 The type Spot Media Equipment

2.1.6 The type Spot Media Equipment

Description
The Spot Media Equipment contains parameters for the connected media
equipment(s). This instance can be multiplied.

Parameters
The following parameters and signals are used to define the media equipment
settings in RobotWare Spot and signals visible in the Spot GUI.
Parameter Default value Data type Note
Name mediapanel1 string The name of the media panel in-
stance.
Water flow diWaterFlow1Ok signaldi Used to configure the water flow
sensor1 sensor1 in the media panel. Signal
will be checked during the spot
process and from the supervision
task if configured.
If no signal name is specified here,
no check will be done.
Water flow diWaterFlow2Ok signaldi Used to configure the water flow
sensor2 sensor2 in the media panel. Signal
will be checked during the spot
process and from the supervision
task if configured.
If no signal name is specified here,
no check will be done.
Water sensor 2s num Used to configure the water flow
flow timeout timeout. If no water flow is detected
by the water flow sensors within the
specified time an operator error
dialog will take focus. (0-10 s)
Continuous water No = FALSE bool Used to configure the continuous
supervision water supervision in the SW_SUP
task.
If set to Yes, the SW_SUP task will
supervise the water flow continu-
ously if the system is in motors on
state, if an error is detected the ro-
bot movement will stop.

Note

Continuous water supervision will

only be active if the water ok sum-
mary signal is defined.

Air flow sensor diAirOk signaldi Used to configure the air flow signal
in the media panel. Signal will be
checked during the spot process.
If no signal name is specified here,
no check will be done.

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2 Configuration
2.1.6 The type Spot Media Equipment
Continued

Parameter Default value Data type Note

Water flow start doStartWater signaldo Used to configure the water start
signal in the media panel. This sig-
nal will be reset when a flow error
is detected. If a delay is configured
the signal is reset after the time has
passed.
If no signal name is specified here,
there will be no function.
Water turn off 1s num Used to configure a delay before the
delay water start signal is reset, can be
used as a filter to prevent air
bubbles causing false alarms. (0-2
s)
Water saver activ- No bool Used to configure water saver
ated function in the SW_SUP task. If set
to Yes, water will only start and be
supervised if the system is in cycle
on state and executing a program.
Water OK diWaterOk signaldi Used to configure the water ok
summary signal. This signal will be
checked during the process before
the weld start, and continuously
from the supervision task if con-
figured. The spot process will wait
for this signal the specified time in
water sensor flow timeout.
If no signal name is specified here,
the water flow sensor signals will be
checked independently.

Note

Make sure that the corresponding

cross connection is changed if only
one of the water flow sensor signals
are used, see Cross-connected sig-
nals on page 45

Note

Continuous water supervision can

not be used if this signal is un-
defined.

User defined gui string Used to configure user defined sig-

signal1-10 nals that should be visible in the
Spot GUI water and air unit view.
Not used in process.

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 2 Configuration
2.1.7 The type Spot SoftWare Equalizing

2.1.7 The type Spot SoftWare Equalizing

Description
The Spot Equalizing contains parameters for global software equalizing settings.

Parameters
The following parameters are used to define the software equalizing settings in
RobotWare Spot.
Parameter Default value Data type Note
Name spot_equalizing string The name of the software equalizing
instance.
MeasureWearL 5 mm/s num Search speed during tip measure-
search speed ment in the MeasureWearLinstruc-
tion, (between 1 - 5 mm/s)
MeasureWearL 100 N num Contact force (in N) during tip
TouchUp force measurement in the MeasureWearL
instruction, (typically between 50 -
150N).
-1 will deactivate this parameter and
use the override parameter in the
Spot Gun Equipment instance
instead.
MeasureWearL 10 mm num Maximal distance from programmed
movein distance point to search for reference surface
in the MeasureWearL instruction.
Max allowed re- 15 mm num Maximum allowed release distance.
lease distance (0-20 mm)
Max allowed de- 15 mm num Maximum allowed deflection dis-
flection value tance. (0-20 mm)
Min allowed 0.1 mm num Minimum allowed touch up step. (0-
TouchUp step 1 mm)
Max allowed 10 mm num Maximum allowed touch up step. (1-
TouchUp step 15 mm)
SoftMove offset 3 mm num Offset distance from the nominal
distance plate position when using SMEQ
(between 1 - 5 mm).

Note

When using SoftMove Equalizing

the teach_dist cannot be used.

SoftMove ap- 50 mm/s num Search speed (v_tcp) into nominal

proach speed position when using SoftMove
Equalizing (between 20 - 200 mm/s).

Note

A too high speed will influence the

"search" result negatively. Excess-
ive force may deform the plate.

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2 Configuration
2.1.7 The type Spot SoftWare Equalizing
Continued

Parameter Default value Data type Note

SoftMove gun 200 mm/s num Gun close speed (v_leax) to target
close speed position (plate thickness) when us-
ing SoftMove Equalizing (between
20 - 200 mm/s).
This parameter can be used to
change the gun closing speed if the
gun is impacting the plates, for ex-
ample if the location of the plates
are higher than the nominal posi-
tion.
SoftMove force Yes bool Enable or disable force_offset
offset auto tuning auto tuning.

40 Application manual - Spot options

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 2 Configuration
2.1.8 The type Spot GUI

2.1.8 The type Spot GUI

Description
The Spot GUI contains parameters for the spot gui settings.

Parameters
The following parameters are used to define the spot gui settings in RobotWare
Spot.
Parameter Default value Data type Note
Name spot_gui string The name of the spot gui instance.
Show Spot GUI No bool Used to define i the spot gui should
at startup be started automatically at system
startup, Yes/No.
Spot system type servo string Used to define the system type in
in Manual Ac- the Manual Action view, pneumat-
tions ic/servo/combined.
Show simdata in No bool Used to define if the simdata should
Process Data be visible in Process Data view.
Show forcedata Yes bool Used to define if the forcedata
in Process data should be visible in the Process
Data view.

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2 Configuration
2.2 Spot I/O configuration

2.2 Spot I/O configuration

Introduction
This chapter describes the different predefined I/O configurations that are available
for the Spot options, and information about the use of the signals.
The Spot package can be configured for different equipment setups. The default
I/O configurations should be seen as default templates, and the physical
connections and names can be changed freely and signals not in use can be
connected to simulated devices.
The signals used are configured in the system parameters. From the ABB menu
on the FlexPendant:
1 Tap Control Panel.
2 Tap Configuration.
3 Tap Topics and select I/O.
The I/O configuration can also be accessed from RobotStudio.

Note

The used signals names are also used in the process configuration. If the names
are changed, the corresponding names in the process configuration must be
changed also. For more information, see Spot process configuration on page 21.

Continues on next page

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 2 Configuration
2.2.1 Spot I/O configuration for single gun system

2.2.1 Spot I/O configuration for single gun system

Introduction
If a basic configuration is selected when building a spot welding system, the system
will be prepared with signals for one spot welding equipment on simulated I/O. It
is then easy to adapt the configuration to the surrounding equipment, e.g weld
timer, media panel etc.

Default configuration
The I/O configuration is prepared for one weld equipment. A set of customized
user modules are also installed if this configuration is selected.
The signals are connected to LOCAL devices by default, and can be changed to
any unit type if needed, for example PROFINET, DeviceNet, and so on.

Note

Some of the signals are only used in a Spot Pneumatic configuration.

Predefined I/O devices

There are three predefined I/O devices:
• One local device, named SW_TIMER, with signals for the weld timer.
• One local device, named SW_BOARD, with signals for the media panel and
the gun.
• One local device, named SW_SIM_BOARD with some internal or normally
not connected signals.
The devices are configured on a virtual network by default.

Weld timer signals

Name Type Information

diWeldComplete input Weld complete signal from the weld timer.
diWeldFault input Fault signal from the weld timer. If this signal is activated
during the weld process the weld error handling in Spot
is started without waiting for weld time out.
diTimerReady input The timer is ready to weld.
doTimerOn output 24V safety signal cross connected to motors on, can be
used to turn off the timer logic in motor off state.
doStartWeld output Start signal to the weld timer.
doEnableCurrent output Signal used for the weld simulation function (simtype =
2). See Simulation modes on page 72.
doResetFault output Reset signal. Can be used to reset the welding controller
after a weld error. The signal is pulsed with a user defined
pulse length before manual or automatic rewelding.
goWeldProgram output group Selected weld program number in weld timer, see spot-
data - Spot weld data on page 140. Default size is 8 bits,
0 - 255, 256 different programs. The maximum group size
can be configured up to 32 bits, seespotdata - Spot weld
data on page 140
Continues on next page
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2 Configuration
2.2.1 Spot I/O configuration for single gun system
Continued

Name Type Information

doNewProgram output This signal can be used as handshaking to let the timer
know a new program has been selected in the goWeldPro-
gram group.

Note

For some timers this signal must be set after a new pro-
gram number is set in goWeldProgram in order for the
timer to set the corresponding inputs giGunForce, giPlat-
eThickness, and giPlateTolerance.

diProgSelectValid input This signal can be used as handshaking to let spot know
that a valid program has been read by the timer and to
continue the execution and read the timer input groups,
force, thickness, etc.

Note

Some timers has the possibility to check if a valid weld

program selection has been done.
Valid program = 1, Not valid = 0
This signal is used by spot. If not set, a program valid
timeout will occur during execution.

giGunForce input group Gun force from weld timer if tip_force in spotdata is
-1.
giPlateThickness input group Plate thickness from weld timer if plate_thickness in
spotdata is -1.
giPlateTolerance input group Plate tolerance from weld timer if plate_tolerance in
spotdata is -1.
giTimerStatus input group Weld timer status code.

Gun and media signals

Name Type Information

diGunOpen input Signal indicating that a pneumatic gun is opened.
diHighLiftOpen input Signal indicating that a pneumatic gun has reached the
highlift position.
diPressureOk input Signal indicating that the right gun pressure is reached for
a pneumatic gun.
diTrafoTempOk input Signal indicating that the temperature is too high.
diWaterFlow1Ok input Signal that can be used to indicate problems with the water
supply in pipe 1.
diWaterFlow2Ok input Signal that can be used to indicate problems with the water
supply in pipe 2.
diAirOk input Signal indicating low air pressure in the equalize cylinder.
diWeldContact input Signal indicating the state of the weld contactor.
(0 = deactivated)
diEquipmentOk input Signal indicating the total gun status. A number of input
signals from the gun is cross connected to this signal.

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 2 Configuration
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Continued

Name Type Information

doEqualize output Gun equalizing signal if mechanical equalizing system are
used.
doCloseGun output Gun close signal for a pneumatic gun.
doOpenHighLift output Signal used to open a pneumatic gun to the highlift position.
doCloseHighLift output Signal used to close apneumatic gun from the highlift posi-
tion.
doStartWater output Signal used to activate the water cooling system.
This signal is set depending on status of several cross-
connected signals.
See Cross-connected signals on page 49.
doWeldPowerContact output Signal used to pull the weld contactor.
This signal is set depending on status of several cross-
connected signals
See Cross-connected signals on page 49.

Process status signals

Name Type Information

doProcessRun output Is set at motion start and is reset when the weld process is ready
and motion is released.
doProcessFault output Is set when an error situation occurs and the process is interrup-
ted.

Other signals

Name Type Information

force_complete input Can be used to interrupt the SetForce instruction before the pro-
grammed force time is elapsed for a servo gun.
reweld_proc input Can be used to answer a weld error dialog on the FlexPendant with
an input signal. The same as tapping Reweld.
skip_proc input Can be used to answer an error dialog on the FlexPendant with an
input signal. The same as tapping Skip. Only in manual operating
mode.

Cross-connected signals

Resultant Activator(s) Information

doStartWater motor_on AND Water start signal, if any of the activators are
doEnableCurrent AND not set the water start signal will be reset.
doProcessFault (Inverted)
doWeldPower- motor_on AND Weld contactor signal, if any of the activators
Contact doEnableCurrent AND are not set the weld contactor signal will be
reset.
doProcessFault (Inverted)
diEquipmentOk diWaterFlow1Ok AND Equipment status signal, if any of the activators
diWaterFlow2Ok AND are not set the equipment ok signal will be re-
set.
diAirOk AND
diTempOk AND
diTimerReady

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2.2.1 Spot I/O configuration for single gun system
Continued

Resultant Activator(s) Information

diWaterOk diWaterFlow1Ok AND Water status signal, if any of the activators are
diWaterFlow2Ok not set the water ok signal will be reset.

Note

This cross connection needs to be modified if

one of the actor signals are removed from the
process configuration, in order to get correct
functionality.
See The type Spot Media Equipment on
page 37.

ext_override skip_proc AND Reset signal. Can be used to reset the operator
reweld_proc error dialog on the FlexPendant when an error
occurs.
See Other signals on page 49.

Limitations
This configuration is only availible for single robot Spot systems, not in MultiProcess
systems with more than one Spot robot.

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 2 Configuration
2.2.2 Spot I/O configuration multiple guns system

2.2.2 Spot I/O configuration multiple guns system

Introduction
If a multiple gun configuration is selected when building a spot welding system,
the system will be prepared with signals for four spot welding equipments on
simulated I/O's. It is then easy to adapt the configuration to the surrounding
equipment, e.g weld timers, media panels etc.

Default configuration
The I/O configuration is prepared for four weld equipments. A set of customized
user modules are also installed if this configuration is selected.
The signals are connected to LOCAL devices by default, and can be changed to
any unit type if needed, for example PROFINET, DeviceNet, and so on.

Note

Some of the signals are only used in a Spot Pneumatic configuration.

Note

Signal names for gun equipment 2 are the same as for gun 1 but with the ending
G2, e.g. doStartWeldG2.

Predefined I/O devices

There are five predefined I/O devices if a multiple gun configuration is selected:
• One local device, named SW_BOARD1, with signals for gun equipment 1.
• One local device, named SW_BOARD2 with signals for gun equipment 2.
• One local device, named SW_BOARD3 with signals for gun equipment 3.
• One local device, named SW_BOARD4 with signals for gun equipment 4.
• One local device, named SW_SIM_BOARD with some internal or normally
not connected signals.
The devices are configured on a virtual network by default.

Weld timer signals for eqipment 1

Name Type Information

diWeldComplete input Weld complete signal from the weld timer.
diWeldFault input Fault signal from the weld timer. If this signal is activated
during the weld process the weld error handling in Spot
is started without waiting for weld time out.
diTimerReady input The timer is ready to weld.
doTimerOn output 24V safety signal cross connected to motors on, can be
used to turn off the timer logic in motor off state.
doStartWeld output Start signal to the weld timer.
doEnableCurrent output Signal used for the weld simulation function (simtype =
2). See Simulation modes on page 72.

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2 Configuration
2.2.2 Spot I/O configuration multiple guns system
Continued

Name Type Information

doResetFault output Reset signal. Can be used to reset the welding controller
after a weld error. The signal is pulsed with a user defined
pulse length before manual or automatic rewelding.
goWeldProgram output group Selected weld program number in weld timer, see spot-
data - Spot weld data on page 140. Default size is 8 bits,
0 - 255, 256 different programs. The maximum group size
can be configured up to 32 bits, seespotdata - Spot weld
data on page 140
doNewProgram output This signal can be used as handshaking to let the timer
know a new program has been selected in the goWeldPro-
gram group.

Note

For some timers this signal must be set after a new pro-
gram number is set in goWeldProgram in order for the
timer to set the corresponding inputs giGunForce, giPlat-
eThickness, and giPlateTolerance.

diProgSelectValid input This signal can be used as handshaking to let spot know
that a valid program has been read by the timer and to
continue the execution and read the timer input groups,
force, thickness, etc.

Note

Some timers has the possibility to check if a valid weld

program selection has been done.
Valid program = 1, Not valid = 0
This signal is used by spot. If not set, a program valid
timeout will occur during execution.

giGunForce input group Gun force from weld timer if tip_force in spotdata is
-1.
giPlateThickness input group Plate thickness from weld timer if plate_thickness in
spotdata is -1.
giPlateTolerance input group Plate tolerance from weld timer if plate_tolerance in
spotdata is -1.
giTimerStatus input group Weld timer status code.

Gun and media signals for equipment 1

Name Type Information

diGunOpen input Signal indicating that a pneumatic gun is opened.
diHighLiftOpen input Signal indicating that a pneumatic gun has reached the
highlift position.
diPressureOk input Signal indicating that the right gun pressure is reached for
a pneumatic gun.
diTrafoTempOk input Signal indicating that the temperature is too high.
diWaterFlow1Ok input Signal that can be used to indicate problems with the water
supply in pipe 1.
diWaterFlow2Ok input Signal that can be used to indicate problems with the water
supply in pipe 2.

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Continued

Name Type Information

diAirOk input Signal indicating low air pressure in the equalize cylinder.
diWeldContact input Signal indicating the state of the weld contactor.
(0 = deactivated)
diEquipmentOk input Signal indicating the total gun status. A number of input
signals from the gun is cross connected to this signal.
doEqualize output Gun equalizing signal if mechanical equalizing system are
used.
doCloseGun output Gun close signal for a pneumatic gun.
doOpenHighLift output Signal used to open a pneumatic gun to the highlift position.
doCloseHighLift output Signal used to close apneumatic gun from the highlift posi-
tion.
doStartWater output Signal used to activate the water cooling system.
This signal is set depending on status of several cross-
connected signals.
See Cross-connected signals on page 49.
doWeldPowerContact output Signal used to pull the weld contactor.
This signal is set depending on status of several cross-
connected signals
See Cross-connected signals on page 49.

Process status signals for equipment 1

Name Type Information

doProcessRun output Is set at motion start and is reset when the weld process is ready
and motion is released.
doProcessFault output Is set when an error situation occurs and the process is interrup-
ted.

Other signals

Name Type Information

force_complete input Can be used to interrupt the SetForce instruction before the pro-
grammed force time is elapsed for a servo gun.
reweld_proc input Can be used to answer a weld error dialog on the FlexPendant with
an input signal. The same as tapping Reweld.
skip_proc input Can be used to answer an error dialog on the FlexPendant with an
input signal. The same as tapping Skip. Only in manual operating
mode.

Cross-connected signals

Resultant Activator(s) Information

doStartWater motor_on AND Water start signal, if any of the activators are
doEnableCurrent AND not set the water start signal will be reset.
doProcessFault (Inverted)
doWeldPower- motor_on AND Weld contactor signal, if any of the activators
Contact doEnableCurrent AND are not set the weld contactor signal will be
reset.
doProcessFault (Inverted)

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2 Configuration
2.2.2 Spot I/O configuration multiple guns system
Continued

Resultant Activator(s) Information

diEquipmentOk diWaterFlow1Ok AND Equipment status signal, if any of the activat-
diWaterFlow2Ok AND ors are not set the equipment ok signal will
be reset.
diAirOk AND
diTempOk AND
diTimerReady
diWaterOk diWaterFlow1Ok AND Water status signal, if any of the activators
diWaterFlow2Ok are not set the water ok signal will be reset.

ext_override skip_proc AND Reset signal. Can be used to reset the oper-
reweld_proc ator error dialog on the FlexPendant when
an error occurs.
See Other signals on page 49.

Limitations
This configuration alternative can not be used together with the option 634-1
MultiProcess, not in MultiMove systems with more than one Spot robot.

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 2 Configuration
2.2.3 Spot I/O configuration for MultiMove / MultiProcess systems

2.2.3 Spot I/O configuration for MultiMove / MultiProcess systems

Introduction
If a Spot MultiMove and MultiProcess configuration for more than one robot is
selected when building a spot welding system, the system will be prepared with
signals for two spot welding equipments on simulated I/O's, one equipment per
robot. It is then easy to adapt the configuration to the surrounding equipment, e.g
weld timer, media panel etc.

Default configuration
The I/O configuration is prepared for two weld equipments. A set of customized
user modules are also installed if this configuration is selected.
The signals are connected to LOCAL devices by default, and can be changed to
any unit type if needed, for example PROFINET, DeviceNet, and so on.

Note

Some of the signals are only used in a Spot Pneumatic configuration.

Note

Signal names for gun equipment 2 are the same as for gun 1 but with the ending
G2, e.g. doStartWeldG2.

Predefined I/O devices

There are five predefined I/O devices if a MultiMove / MultiProcess configuration
is selected:
• One local device, named SW_TIMER1, with signals for weld timer1 (Robot
1).
• One local device, named SW_BOARD1, with signals for media panel and
gun1 (Robot 1).
• One local device, named SW_TIMER2, with signals for weld timer2 (Robot
2).
• One local device, named SW_BOARD2, with signals for media panel and
gun2 (Robot 2).
• One local device, named SW_SIM_BOARD with some internal or normally
not connected signals.
The devices are configured on a virtual network by default.

Weld timer signals

Name Type Information

diWeldComplete input Weld complete signal from the weld timer.
diWeldFault input Fault signal from the weld timer. If this signal is activated
during the weld process the weld error handling in Spot
is started without waiting for weld time out.

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2.2.3 Spot I/O configuration for MultiMove / MultiProcess systems
Continued

Name Type Information

diTimerReady input The timer is ready to weld.
doTimerOn output 24V safety signal cross connected to motors on, can be
used to turn off the timer logic in motor off state.
doStartWeld output Start signal to the weld timer.
doEnableCurrent output Signal used for the weld simulation function (simtype =
2). See Simulation modes on page 72.
doResetFault output Reset signal. Can be used to reset the welding controller
after a weld error. The signal is pulsed with a user defined
pulse length before manual or automatic rewelding.
goWeldProgram output group Selected weld program number in weld timer, see spot-
data - Spot weld data on page 140. Default size is 8 bits,
0 - 255, 256 different programs. The maximum group size
can be configured up to 32 bits, seespotdata - Spot weld
data on page 140
doNewProgram output This signal can be used as handshaking to let the timer
know a new program has been selected in the goWeldPro-
gram group.

Note

For some timers this signal must be set after a new pro-
gram number is set in goWeldProgram in order for the
timer to set the corresponding inputs giGunForce, giPlat-
eThickness, and giPlateTolerance.

diProgSelectValid input This signal can be used as handshaking to let spot know
that a valid program has been read by the timer and to
continue the execution and read the timer input groups,
force, thickness, etc.

Note

Some timers has the possibility to check if a valid weld

program selection has been done.
Valid program = 1, Not valid = 0
This signal is used by spot. If not set, a program valid
timeout will occur during execution.

giGunForce input group Gun force from weld timer if tip_force in spotdata is
-1.
giPlateThickness input group Plate thickness from weld timer if plate_thickness in
spotdata is -1.
giPlateTolerance input group Plate tolerance from weld timer if plate_tolerance in
spotdata is -1.
giTimerStatus input group Weld timer status code.

Gun and media signals

Name Type Information

diGunOpen input Signal indicating that the pneumatic gun is opened.
diHighLiftOpen input Signal indicating that the pneumatic gun has reached the
highlift position.

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Continued

Name Type Information

diPressureOk input Signal indicating that the right gun pressure is reached for
a pneumatic gun.
diTrafoTempOk input Signal indicating that the temperature is too high.
diWaterFlow1Ok input Signal that can be used to indicate problems with the water
supply in pipe 1.
diWaterFlow2Ok input Signal that can be used to indicate problems with the water
supply in pipe 2.
diAirOk input Signal indicating low air pressure in the equalize cylinder.
diWeldContact input Signal indicating the state of the weld contactor.
(0 = deactivated)
diEquipmentOk input Signal indicating the total gun status. A number of input
signals from the gun is cross connected to this signal.
doEqualize output Gun equalizing signal.
doCloseGun output Gun close signal for a the pneumatic gun.
doOpenHighLift output Signal used to open the pneumatic gun to the highlift posi-
tion.
doCloseHighLift output Signal used to close the pneumatic gun from the highlift
position.
doStartWater output Signal used to activate the water cooling system.
This signal is set depending on status of several cross-
connected signals.
See Cross-connected signals on page 49.
doWeldPowerContact output Signal used to pull the weld contactor.
This signal is set depending on status of several cross-
connected signals
See Cross-connected signals on page 49.

Process status signals

Name Type Information

doProcessRun output Is set at motion start and is reset when the weld process is ready
and motion is released.
doProcessFault output Is set when an error situation occurs and the process is interrup-
ted.

Other signals

Name Type Information

force_complete input Can be used to interrupt the SetForce instruction before the pro-
grammed force time is elapsed for a servo gun.
reweld_proc input Can be used to answer a weld error dialog on the FlexPendant with
an input signal. The same as tapping Reweld.
skip_proc input Can be used to answer an error dialog on the FlexPendant with an
input signal. The same as tapping Skip. Only in manual operating
mode.

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2.2.3 Spot I/O configuration for MultiMove / MultiProcess systems
Continued

Cross-connected signals

Resultant Activator(s) Information

doStartWater motor_on AND Water start signal, if any of the activators are
doEnableCurrent AND not set the water start signal will be reset.
doProcessFault (Inverted)
doWeldPower- motor_on AND Weld contactor signal, if any of the activators
Contact doEnableCurrent AND are not set the weld contactor signal will be
reset.
doProcessFault (Inverted)
diEquipmentOk diWaterFlow1Ok AND Equipment status signal, if any of the activat-
diWaterFlow2Ok AND ors are not set the equipment ok signal will
be reset.
diAirOk AND
diTempOk AND
diTimerReady
diWaterOk diWaterFlow1Ok AND Water status signal, if any of the activators
diWaterFlow2Ok are not set the water ok signal will be reset.

ext_override skip_proc AND Reset signal. Can be used to reset the oper-
reweld_proc ator error dialog on the FlexPendant when
an error occurs.
See Other signals on page 49.

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 2 Configuration
2.3.1 782-1 Bosch DeviceNet AC and 782-7 Bosch DeviceNet MFDC

2.3 Spot Weld timer configuration options

2.3.1 782-1 Bosch DeviceNet AC and 782-7 Bosch DeviceNet MFDC

Introduction
If either of the additional spot weld timer options 782-1 Bosch DeviceNet AC or
782-7 Bosch DeviceNet MFDC are selected when building a spot welding system,
the system will be prepared with signals for one spot welding equipment.

Default configuration
The default configuration is for one spot welding equipment. A set of customized
user modules are also installed if this option is selected.

Note

Some of the signals are only used in a Spot Pneumatic configuration.

Note

This option requires the option DeviceNet, see Application manual - DeviceNet
Master/Slave.

Predefined I/O devices

There are three pre-defined I/O devices configured by default:
• One DeviceNet device, named SW_BOARD, with signals for gun equipment,
media panel etc. This device is configured on DeviceNet address 10 by
default.
• One DeviceNet device, named BOSCH_TIMER, with signals for the weld
timer. This device is configured on DeviceNet address 21 by default.
• One simulated device, named SW_SIM_BOARD with some internal or
normally not connected signals.

Weld timer signals

Name Type Information

diWeldComplete input Weld complete signal from the weld timer.
diWeldFault input Fault signal from the weld timer. If this signal is activated
during the weld process the weld error handling in Spot
is started without waiting for weld time out.
diTimerReady input The timer is ready to weld.
doTimerOn output 24V safety signal cross connected to motors on, used to
turn off the timer logic in motor off state.
doStartWeld output Start signal to the weld timer.
doEnableCurrent output Signal used for the weld simulation function (simtype =
2). See Simulation modes on page 72.

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Continued

Name Type Information

doResetFault output Reset signal. Can be used to reset the welding controller
after a weld error. The signal is pulsed with a user defined
pulse length before manual or automatic rewelding.
goWeldProgram output group Selected weld program number in weld timer, see spot-
data - Spot weld data on page 140. Default size is 8 bits,
0 - 255, 256 different programs. It is possible to use up
to 20 bits for this timer.
doNewProgram output This signal is used as handshaking to let the timer know
a new program has been selected by the robot.

Note

This signal must be set after a new program number is

set in goWeldProgram in order for the timer to set the
corresponding inputs giGunForce, giPlateThickness, and
giPlateTolerance.

diProgSelectValid input This signal is used as handshaking to let spot know that
a valid program has been read by the timer and to contin-
ue the execution.

Note

For this timer type the valid program selection is not im-
plemented, but the signal is used by spot. If this signal is
not set, a program valid timeout will occur during execu-
tion.
Valid program = 1, Not valid = 0

diProgComplete input Signal used to let the robot know that a new program has
been selected. Will be set just after the doNewProgram
has been set.

Note

This signal will be set by the timer when a new program

selection has been done, and it is cross-connected to the
diProgSelectValid signal used to check if a valid weld
program is selected.

giGunForce input group Gun force from weld timer if tip_force in spotdata is
-1.
giPlateThickness input group Plate thickness from weld timer if plate_thickness in
spotdata is -1.
giPlateTolerance input group Plate tolerance from weld timer if plate_tolerance in
spotdata is -1.
giTimerStatus input group Weld timer status code.

Gun and media signals

Name Type Information

diGunOpen input Signal indicating that a pneumatic gun is opened.
diHighLiftOpen input Signal indicating that a pneumatic gun has reached the
highlift position.

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2.3.1 782-1 Bosch DeviceNet AC and 782-7 Bosch DeviceNet MFDC
Continued

Name Type Information

diPressureOk input Signal indicating that the right gun pressure is reached for
a pneumatic gun.
diTrafoTempOk input Signal indicating that the temperature is too high.
diWaterFlow1Ok input Signal that can be used to indicate problems with the water
supply in pipe 1.
diWaterFlow2Ok input Signal that can be used to indicate problems with the water
supply in pipe 2.
diAirOk input Signal indicating low air pressure in the equalize cylinder.
diWeldContact input Signal indicating the state of the weld contactor.
(0 = deactivated)
diEquipmentOk input Signal indicating the total gun status. A number of input
signals from the gun is cross connected to this signal.
doEqualize output Gun equalizing signal if mechanical equalizing system are
used.
doCloseGun output Gun close signal for a a pneumatic gun.
doOpenHighLift output Signal used to open a pneumatic gun to the highlift position.
doCloseHighLift output Signal used to close a pneumatic gun from the highlift pos-
ition.
doStartWater output Signal used to activate the water cooling system.
This signal is set depending on status of several cross-
connected signals.
See Cross-connected signals on page 49.
doWeldPowerContact output Signal used to pull the weld contactor.
This signal is set depending on status of several cross-
connected signals
See Cross-connected signals on page 49.

Process status signals

Name Type Information

doProcessRun output Is set at motion start and is reset when the weld process is ready
and motion is released.
doProcessFault output Is set when an error situation occurs and the process is interrup-
ted.

Other signals

Name Type Information

force_complete input Can be used to interrupt the SetForce instruction before the pro-
grammed force time is elapsed for a servo gun.
reweld_proc input Can be used to answer a weld error dialog on the FlexPendant with
an input signal. The same as tapping Reweld.
skip_proc input Can be used to answer an error dialog on the FlexPendant with an
input signal. The same as tapping Skip. Only in manual operating
mode.

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2 Configuration
2.3.1 782-1 Bosch DeviceNet AC and 782-7 Bosch DeviceNet MFDC
Continued

Cross-connected signals

Resultant Activator(s) Information

doStartWater motor_on AND Water start signal, if any of the activators are
doEnableCurrent AND not set the water start signal will be reset.
doProcessFault (Inverted)
doWeldPower- motor_on AND Weld contactor signal, if any of the activators
Contact doEnableCurrent AND are not set the weld contactor signal will be
reset.
doProcessFault (Inverted)
diEquipmentOk diWaterFlow1Ok AND Equipment status signal, if any of the activat-
diWaterFlow2Ok AND ors are not set the equipment ok signal will
be reset.
diAirOk AND
diTempOk AND
diTimerReady
diWaterOk diWaterFlow1Ok AND Water status signal, if any of the activators
diWaterFlow2Ok are not set the water ok signal will be reset.

ext_override skip_proc AND Reset signal. Can be used to reset the oper-
reweld_proc ator error dialog on the FlexPendant when
an error occur.
See Other signals on page 49.
diProgSelectValid diProgComplete Valid program selection signal, signal used
to check if a valid weld program is selected
in the timer.

Limitations
This configuration is only availible for single robot Spot systems, not in MultiProcess
systems with more than one Spot robot.

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 2 Configuration
2.3.2 782-11 Bosch PROFINET MFDC

2.3.2 782-11 Bosch PROFINET MFDC

Introduction
If the additional spot weld timer option 782-11 Bosch PROFINET MFDC is selected
when building a spot welding system, the system will be prepared with signals for
one spot welding equipment.

Default configuration
The default configuration is for one spot welding equipment. A set of customized
user modules are also installed if this option is selected.

Note

Some of the signals are only used in a Spot Pneumatic configuration.

Note

This option requires the option PROFINET Master and Slave, see Application
manual - PROFINET Controller/Device.

Predefined PROFINET bus and I/O devices

The pre-installed PROFINET I/O bus Profinet1 will be configured on address
192.168.5.1 by default if this option is selected, and the necessary network
configuration file IPPNIO.xml is copied to the home directory of the system.

Tip

The current KW-Software PROFINET Configurator project is available in the Spot

option utility directory in the RobotWare installation. This can be use if there is
a need to add new units or modify the configuration, see:
...\RobotPackages\RobotWare_RPK_<version>\utility\Spot\BoschPnet\KWPnetProj.
Navigate to the RobotWare installation folder from the RobotStudio Add-Ins tab,
by right-clicking on the installed RobotWare version in the Add-Ins browser and
selecting Open Package Folder.
For more information about PROFINET configuration, see Application
manual - PROFINET Controller/Device.
There are two predefined PROFINET I/O devices and one virtual device configured
by default:
• One PROFINET device, named sw_board, with signals for gun equipment,
media panel etc. This device is configured on address 192.168.5.5 by default.
• One PROFINET device, named bosch_timer, with signals for the weld timer.
This device is configured on address 192.168.5.7 by default.
• One simulated device, named sw_sim_board with some internal or normally
not connected signals.

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2 Configuration
2.3.2 782-11 Bosch PROFINET MFDC
Continued

Weld timer signals

Name Type Information

diWeldComplete input Weld complete signal from the weld timer.
diWeldFault input Fault signal from the weld timer. If this signal is activated
during the weld process the weld error handling inside
Spot is started without waiting for weld time out.
diTimerReady input The timer is ready to weld.
doTimerOn output 24V safety signal cross connected to motors on, used to
turn off the timer logic in motor off state.
doStartWeld output Start signal to the weld timer.
doEnableCurrent output Signal used for the weld simulation function (simtype =
2). See Simulation modes on page 72.
doResetFault output Reset signal. Can be used to reset the welding controller
after a weld error. The signal is pulsed with a user defined
pulse length before manual or automatic rewelding.
goWeldProgram output group Selected weld program number in weld timer, see spot-
data - Spot weld data on page 140. Default size is 8 bits,
0 - 255, 256 different programs. It is possible to use up
to 20 bits for this timer
doNewProgram output This signal can be used as handshaking to let the timer
know a new program has been selected.

Note

This timer requires this signal to be set after a new pro-

gram number is set in goWeldProgram in order for the
timer to set the corresponding inputs giGunForce, giPlat-
eThickness, and giPlateTolerance.

diProgSelectValid input This signal can be used as handshaking to let spot know
that a valid program has been read by the timer.

Note

This timer has the possibility to check if a valid weld pro-

gram selection has been done.
Valid program = 1, Not valid = 0
This signal is used by spot. If not set, a program valid
timeout will occur during execution.

giGunForce input group Gun force from weld timer if tip_force in spotdata is
-1.
giPlateThickness input group Plate thickness from weld timer if plate_thickness in
spotdata is -1.

giTimerStatus input group Weld timer status code.

Gun and media signals

Name Type Information

diGunOpen input Signal indicating that a pneumatic gun is opened.
diHighLiftOpen input Signal indicating that a pneumatic gun has reached the
highlift position.

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2.3.2 782-11 Bosch PROFINET MFDC
Continued

Name Type Information

diPressureOk input Signal indicating that the right gun pressure is reached for
a pneumatic gun.
diTrafoTempOk input Signal indicating that the temperature is too high.
diWaterFlow1Ok input Signal that can be used to indicate problems with the water
supply in pipe 1.
diWaterFlow2Ok input Signal that can be used to indicate problems with the water
supply in pipe 2.
diAirOk input Signal indicating low air pressure in the equalize cylinder.
diWeldContact input Signal indicating the state of the weld contactor.
(0 = deactivated)
diEquipmentOk input Signal indicating the total gun status. A number of input
signals from the gun is cross connected to this signal.
doEqualize output Gun equalizing signal if mechanical equalizing system are
used.
doCloseGun output Gun close signal for a pneumatic gun.
doOpenHighLift output Signal used to open a pneumatic gun to the highlift position.
doCloseHighLift output Signal used to close a pneumatic gun from the highlift pos-
ition.
doStartWater output Signal used to activate the water cooling system.
This signal is set depending on status of several cross-
connected signals.
See Cross-connected signals on page 49.
doWeldPowerContact output Signal used to pull the weld contactor.
This signal is set depending on status of several cross-
connected signals
See Cross-connected signals on page 49.

Process status signals

Name Type Information

doProcessRun output Is set at motion start and is reset when the weld process is ready
and motion is released.
doProcessFault output Is set when an error situation occurs and the process is interrup-
ted.

Other signals

Name Type Information

force_complete input Can be used to interrupt the SetForce instruction before the pro-
grammed force time is elapsed for a servo gun.
reweld_proc input Can be used to answer a weld error dialog on the FlexPendant with
an input signal. The same as tapping Reweld.
skip_proc input Can be used to answer an error dialog on the FlexPendant with an
input signal. The same as tapping Skip. Only in manual operating
mode.

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2.3.2 782-11 Bosch PROFINET MFDC
Continued

Cross-connected signals

Resultant Activator(s) Information

doStartWater motor_on AND Water start signal, if any of the activators are
doEnableCurrent AND not set the water start signal will be reset.
doProcessFault (Inverted)
doWeldPower- motor_on AND Weld contactor signal, if any of the activators
Contact doEnableCurrent AND are not set the weld contactor signal will be
reset.
doProcessFault (Inverted)
diEquipmentOk diWaterFlow1Ok AND Equipment status signal, if any of the activat-
diWaterFlow2Ok AND ors are not set the equipment ok signal will
be reset.
diAirOk AND
diTempOk AND
diTimerReady
diWaterOk diWaterFlow1Ok AND Water status signal, if any of the activators
diWaterFlow2Ok are not set the water ok signal will be reset.

ext_override skip_proc AND Reset signal. Can be used to reset the oper-
reweld_proc ator error dialog on the FlexPendant when
an error occur.
See Other signals on page 49.

Limitations
This configuration is only availible for single robot Spot systems, not in MultiProcess
systems with more than one Spot robot.

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 3 Programming

3 Programming
Introduction to programming
This chapter describes the basic functions and steps to take when creating, testing,
and running spot weld programs with the Spot options.
It is assumed that a servo gun is installed and tuned at this stage. If not, see Servo
gun motion control on page 195, and Application manual - Servo Gun Setup.

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3 Programming
3.1 Quick start for servo gun

3.1 Quick start for servo gun

Install servo gun parameters

If the system is cold started, the servo gun parameters are probably not loaded.
See Install servo gun parameters on page 202

Set the servo gun name

After the gun parameters are installed and the system is restarted, the gundata
needs to be updated with the servo gun name (mechanical unit name) so the spot
instructions will work correctly. See Set the servo gun name on page 203.

Servo gun force calibration

To protect the gun from to high forces there is a RAPID service routine to calibrate
the motor torque vs tip force characteristics, ManualForceCalib. See Servo gun
force calibration on page 203.

Servo gun init calibration

Before running any spot instructions, the gun must be synchronized by a fine
calibration. Apart from other kinds of additional axes, this action also requires
running a RAPID service routine,
ManualServiceCalib to initialize or synchronize the gun position. See Servo
gun init calibration on page 205.

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 3 Programming
3.2 Spot weld instructions and data

3.2 Spot weld instructions and data

Defining spot welding data

Before starting to program the instructions, define the spot welding data to be
used. This data is divided into two types:
• spotdata; describes the spot welding process specific data for a specific
spot. See spotdata - Spot weld data on page 140.
• gundata; describes spot welding gun specific data, weld counters, tip wear
data etc. All gun equipment used are defined in the gundata array
curr_gundata in SWUSER. See gundata - Equipment specific weld data
on page 135.

Spot weld instructions for sequential welding

SpotL and SpotJ are the basic spot welding instructions in the Spot options. The
instructions includes a movement to the weld position and performing the desired
weld process. They contains basically the same type of information as a positioning
instruction, but also arguments that serve as data for the spot welding process.
These instructions are used for welding with one gun or welding with several guns
in sequence.
For further details, see section SpotL/SpotJ - The basic spot welding instructions
on page 95.

Data for the spotweld process (spotdata)

Gun number (num) Switch inhibiting gun pre-closing

SpotL p1, vmax, gun1, spot1 \Inpos, tool \Wobj:=frame1;

L = Linear Argument as in the

J = Joint MoveL instruction

en1200000250

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3.2 Spot weld instructions and data
Continued

Programming example for one servo gun

In this example a single servo gun (gun1) is used, held by the robot. Four spots
are to be welded with two different spotdata used, spot10 and spot20. The data
is created in advance. The gun parameters are set in the first gundata in the
curr_gundata array located in the SWUSER module.
The robtargets p2 and p3 will be welded with weld program number 10 and the tip
force 2000N. Thickness is set to 1.6mm and the supervision tolerance is set to
0.5mm. If the tolerance is exeeded the execution will be stopped with an operator
dialog. The next two robtargets p4, p5 will be welded with weld program number
20 and the selected tip force is set to 3000N, the plate thickness 3mm, will not be
supervised since the tolerance is set to 0.

MoveL

SpotL
MoveJ p6

p1 p2
p3 p5

p4
Direction of movement

xx1200000245

spot10 curr_gundata{1}
prog_num = 10 gun_name = "SGUN_1"
tip_force = 2000 weld_counter = 112
plate_thickness = 1.6 max_nof_welds = 1000
plate_tolerance = 0.5 curr_tip_wear = 5.2
max_tip_wear = 8
spot20
prog_num = 20
tip_force = 3000
plate_thickness = 3
plate_tolerance = 0

RAPID code sequence:

MoveJ p1, v600, z50, toolGun1;
SpotL p2, vmax, gun1, spot10, toolGun1;
SpotL p3, vmax, gun1, spot10, toolGun1;
SpotL p4, vmax, gun1, spot20, toolGun1;
SpotL p5, vmax, gun1, spot20, toolGun1;
MoveL p6, v600, z50, toolGun1;

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 3 Programming
3.2 Spot weld instructions and data
Continued

Programming example for one pneumatic gun

Same example as above but with parameters for a pneumatic gun.
The robtargets p2 and p3 will be welded with weld program number 10 and the tip
force output group is set to 2. The next two robtargets p4, p5 will be welded with
weld program number 20 and the selected tip force output group is set to 3 It is
more common to control the the tip force from the weld timer, and in those cases
the tip force parameter can be ignored or removed. See How to change the Spot
data types on page 255.

MoveL

SpotL
MoveJ p6

p1 p2
p3 p5

p4
Direction of movement

xx1200000245

spot10 curr_gundata{}
prog_num = 10 gun_name = "PNEU_G1"
tip_force = 2 weld_counter = 112
spot20 max_nof_welds = 1000
prog_num = 20
tip_force = 3

RAPID code sequence:

MoveJ p1, v600, z50, toolGun1;
SpotL p2, vmax, gun1, spot10, toolGun1;
SpotL p3, vmax, gun1, spot10, toolGun1;
SpotL p4, vmax, gun1, spot20, toolGun1;
SpotL p5, vmax, gun1, spot20, toolGun1;
MoveL p6, v600, z50, toolGun1;

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3 Programming
3.2 Spot weld instructions and data
Continued

Spot weld instructions for simultaneous welding with multiple guns

SpotML and SpotMJ has to be used if welding with several guns at the same time
is desired. It is possible to use four guns simultaneously. The instruction includes
a movement to the weld position and performing the desired weld processes. It
contains basically the same type of information as a positioning instruction but
also arguments that serve as data for the different spot welding processes.
See SpotML/SpotMJ - Spot welding with multiple guns on page 100.

Data for the spotweld processes (spotdata)

Switch inhibiting gun pre-closing

SpotML p1, vmax, \G1:=spot1 \G2:=spot2 \Inpos, tool \Wobj:=frame1;

Arguments as in the
L = Linear
MoveL instruction
J = Joint

en1200000251

Programming example for two servo guns

In this example two different stationary guns are used, mounted close to each
other. The robot is holding the work piece. Seven spots are to be welded with two
different spotdata used, spot10 and spot20. Current gun parameters has been
set up in the first and second gundata in the curr_gundata array in SWUSER.
The robtarget p2 will be welded with gun1(SGUN_1) with weld program number
10 and the tip force 2000N. Thickness is set to 1.6mm and the supervision tolerance
is set to 0.5mm. If the tolerance is exeeded the execution will be stopped with an
operator dialog.
The next robtargets p3 and p4 will also be welded with gun 1 but also at the same
time with gun 2(SGUN_2) with weld program number 20 and the selected tip force

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 3 Programming
3.2 Spot weld instructions and data
Continued

is set to 3000N. No thickness supervion. The robtarget p5 will be welded with just
gun 2 also with weld program 20.

MoveL

SpotML
MoveJ p6

p1 p2
p3 p5
p4

Direction of movement

xx1200000241

spot10 curr_gundata{1}
prog_num = 10 gun_name = "SGUN_1"
tip_force = 2000 weld_counter = 112
plate_thickness = 1.6 max_nof_welds = 1000
plate_tolerance = 0.5 curr_tip_wear = 5.2
max_tip_wear = 8
spot20 curr_gundata{2}
prog_num = 20 gun_name = "SGUN_2"
tip_force = 3000 weld_counter = 345
plate_thickness = 3 max_nof_welds = 1000
plate_tolerance = 0 curr_tip_wear = 3.4
max_tip_wear = 11

RAPID code sequence:

MoveJ p1, v600, z50, toolGrip1\Wobj:= frame1;
SpotML p2, vmax\G1:=spot10,toolGrip1\Wobj:= frame1;
SpotML p3, vmax\G1:=spot20\G2:=spot20,toolGrip1\Wobj:= frame1;
SpotML p4, vmax\G1:=spot20\G2:=spot20,toolGrip1\Wobj:= frame1;
SpotML p5, vmax\G2:=spot20,toolGrip1\Wobj:= frame1;
MoveL p6, v600, z50, toolGrip1\Wobj:= frame1;

Programming example for two pneumatic guns

Same example as above but with parameters for pneumatic guns.
The robtarget p2 will be welded with gun1(PNEU_G1) with weld program number
10 and the tip force output group is set to 2.
The next robtargets p3 and p4 will also be welded with gun 1 but also at the same
time with gun 2(PNEU_G2) with weld program number 20 and the selected tip force
output group is set to 3. The robtarget p5 will be welded with only gun 2 also with
weld program 20 and the tip force output group is set to 3. It is more common to
control the the tip force from the weld timer, and in those cases the tip force

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3 Programming
3.2 Spot weld instructions and data
Continued

parameter can be ignore or removed. See How to change the Spot data types on
page 255.

MoveL

SpotML
MoveJ p6

p1 p2
p3 p5
p4

Direction of movement

xx1200000241

spot10 curr_gundata{1}
prog_num = 10 gun_name = "PNEU_G1"
tip_force = 2 weld_counter = 112
max_nof_welds = 1000
spot20 curr_gundata{2}
prog_num = 20 gun_name = "PNEU_G2"
tip_force = 3 weld_counter = 215
max_nof_welds = 1000

RAPID code sequence:

MoveJ p1, v600, z50, toolGrip1\Wobj:= frame1;
SpotML p2, vmax\G1:=spot10,toolGrip1\Wobj:= frame1;
SpotML p3, vmax\G1:=spot10\G2:=spot20, toolGrip1\Wobj:= frame1;
SpotML p4, vmax\G1:=spot20\G2:=spot20, toolGrip1\Wobj:= frame1;
SpotML p5, vmax\G2:=spot20, toolGrip1\Wobj:= frame1;
MoveL p6, v600, z50, toolGrip1\Wobj:= frame1;

Programming spot welding instructions

1 Jog the robot to the desired destination position and jog also the gun axis
to desired preclose tip position (Only for servo guns).
2 In the Program Editor, tap Add instruction, and then select SpotWeld from
the list of instructions.
3 Select the instruction SpotL or SpotJ.
The instruction will be added directly to the program. The arguments are set
in relation to the last programmed spot welding instruction.
4 Change the optional arguments if needed.
5 Jog the robot to another position and add more spot weld instructions the
same way.

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 3 Programming
3.2 Spot weld instructions and data
Continued

en1200000246

Edit current used spotdata

1 Select current spotdata in the instruction.
2 Tap Debug, and then tap View Value.
3 Change the value.
4 Tap OK.
§

en1200000243

Changing to another spotdata

1 Select current spotdata in the instruction.
2 Tap Edit, and then tap Change Selected.
3 Select a spotdata from the list of available spotdata.
4 Tap OK.

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3 Programming
3.3 Testing spot weld instructions in simulated mode

3.3 Testing spot weld instructions in simulated mode

Simulation modes
To prevent the spot welding process executing during programming and testing,
it is possible to run the program in different simulation modes. For more information
about simulation modes see Simulation modes on page 80.

Tip

The fastest way to change the simulation mode is to use the FlexPendant
Interface, see Simulation Main View on page 217.

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 3 Programming
3.4 Gun control

3.4 Gun control

Preclosing of gun
The spot welding instructions have a built-in preclosing of the weld guns, that is
when approaching the position the guns will start to close in advance to save time.
For more information about gun control, see Gun closing and pre closing time on
page 77.

Mechanical gun equalizing

The spot welding instructions have a function for equalizing with mechanical
equalizing systems in the gun, to minimize the impact on the plates during the
welding. See Gun equalizing on page 76.

Software equalizing
The spot welding instructions SpotL and SpotJ also has functions that make it
possible to use spot welding guns without mechanical equalizing systems. These
functions are available if the configuration Spot Servo Equalizing is selected. For
more information see Software Equalizing on page 169.

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3 Programming
3.5 Manual actions

3.5 Manual actions

Service routines
Some useful service routines are predefined to be used for manual actions during
programming and test.
• From the Spot GUI application, select RobotWare Spot and Manual Actions.
• From the Program Editor, tap Debug, and then tap Call Service Routine

en1200000242

Tip

It is also possible to access and run the service routines from the FlexPendant
interface, see Manual Actions on page 226

Available service routines

The following service routines are available in the Spot Options:
Service routine Description
ManualGunSearch This routine will search the system for available servo guns and add
their names to gun name in current gundata.
ManualGunControl This routine will close or open the gun according to data in
curr_forcedata. The gun equalize signal is also activated/deac-
tivated.
ManGunPosition This routine will open or close the pneumatic gun to the large stroke
or work stroke position.
ManualSpot This routine will perform a weld in current position according to data
in curr_spotdata.
ManualSetForce This routine will perform a SetForce action according to data in
curr_forcedata. The gun equalize signal is also activated/deac-
tivated.

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 3 Programming
3.5 Manual actions
Continued

Service routine Description

ManualCalib This routine will perform a calibration of the servo gun, 1 Tool
Change, 2 Tip Change or 3 Tip Wear calibration.
• Option 1. Tool Change calibration, used after changing tool
if using more than one gun.
• Option 2: Tip Change calibration, used after worn tips has
been replaced with new tips.
• Option 3: Tip Wear calibration, used after the tip has been
dressed.
See Tip management on page 200.
ManualForceCalib This routine will perform a force calibration of the servo gun. 2 - 10
forces and positions can be stored. See Servo gun force calibration
on page 203.
From this routine is also possible to store two reference forces can
be used to compensate for gravitational influences of gun force
during welding. This function can be used if a servo gun loses force
when the movable gun arm moves against gravity.
For more information, see Servo gun force gravity compensation
on page 204 and The type Spot Gun Equipment on page 31.
ManualServiceCalib This routine will perform a gun init calibration of the servo gun, find
the zero position.
• Option 1: Will synchronize the servo gun without jogging after
the revolution counter has been updated.
The servo gun will close slowly until it reaches the contact
position.
• Option 2: Will synchronize the servo gun without jogging after
the gun has been fine calibrated.
The servo gun will move fast to a predefined pre-position.
and then continue to close slowly until it reaches the contact
position.
See Servo gun init calibration on page 205.
ManualCheckMeas- This routine can be used to verify if a robot position or gun orienta-
Pos tion is suitable for a tip wear measurement with MeasureWearL.
When this routine is run in the selected position, status information
will be presented on the FlexPendant whether the position is suitable
or not. The recommended touch up axis should be 4 to 6 and the
touch up value should be in range between 0.25 and 1.
This instruction is only available if the Spot Servo Equalizing option
is installed.

Note

For some special configurations the MeasureWearL measuring

method is less suitable, for example very large guns and/or when
an acceptable touch up position is not possible to reach for some
reason. Then the ReCalcTcp method should be used instead.

If several guns are used then a dialog will appear asking for the gun number of the
gun to be handled.

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3.6 Process sequence and error handling

Process sequence
This section describes the internal process sequence when a SpotL/J or a
SpotML/MJ instruction is executed:
1 Data definition user routines are executed. (eg. DefineSpotData)
2 The weld program number is set. (eg. goWeldProgram)
3 The new program selection signal is set, if configured.
4 The robot and gun starts to move towards the programmed position.
5 The process will check and wait for the program valid signal from the weld
controller, if configured.
6 The new program selection signal is reset, if configured (doNewProgram).
7 If valid program selection (diProgSelectValid), the process will read the weld
controller groups if configured, (eg. giGunForce).
8 The new program selection signal is reset, if configured (doNewProgram).
9 User routine UpdateSpotData is executed.
10 User routine SwInitUserIO is executed.
11 User routine SwPrepare is executed.
12 User routine SwCloseGun is executed (pneumatic guns).
13 The gun will start to close before the position is reached (unless argument
\InPos is used), according to the predefined gun pre closing time.
14 The equalizing signal is set according to the predefined pre equalizing time.
(eg. doEqualize).
15 User routine SwPreWeld is executed when the weld position is reached.
(Preweld supervision.)
16 The plate thickness is checked. (Servo guns only). The requested gun force
is established if OK.
17 The start signal to the weld controller is set. (eg. doStartWeld).
18 The weld controller performs the weld, and can change the gun force during
the weld sequence if configured (eg. new value on giGunForce).
19 When the weld complete signal from the weld controller is received, (eg.
diWeldComplete) the start signal will be reset and the gun will start to open
and the equalizing signal will be reset.
20 User routine SwOpenGun is executed (pneumatic guns).
21 User routine SwPostWeld is executed.
22 The instruction is ready.

Gun equalizing
When approaching the position a signal is activated to be used for the gun
equalizing. The signal is deactivated after the weld process before the next robot
motion is released.

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The gun pre equalizing time, Gun pre equalizing time, is defined for each
used gun in Spot Gun Equipment process data. See The type Spot Gun
Equipment on page 31.

Note

The gun pre equalizing time in Spot Gun Equipment process data, Gun pre
equalizing time, is not used when SoftWare equalizing is used. For more
information see Software Equalizing on page 169.

Gun closing and pre closing time

The spot welding instructions have a built-in preclosing of the weld guns, that is
when approaching the position the guns will start to close in advance to save time.
The gun closure is activated at a defined time before the weld position. The gun
pre closing time, Gun pre closing time, can be defined for each used gun in
the Spot Gun Equipment process data. See The type Spot Gun Equipment on
page 31.
For servo guns the movement to the weld position starts with a synchronous phase
which means that the servo gun axis is moved synchronized with the robot
movement. The gun closing speed is automatically adapted so the contact position
is reached at the same time as the robot reaches the programmed weld position.
For more information about servo gun motion control, see Servo gun motion control
on page 195.

Note

The data Gun pre closing time is not used if Software Equalizing is active,
see Software Equalizing on page 169.

Note

The pre closing can be disabled by using the \InPos argument in the instruction.

Note

If the pre closing time is set to high it can lead to a longer cycle time if close
positions are programmed, because the gun movement will synchronize with
the robot.

Note

If the optional data \SMEQ is used in the SpotL/J instruction the robot will be set
into a soft state during the gun closing, for more information see SoftMove
Equalizing on page 185.

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Note

If using gun open position less than 10mm for servo guns, there may be problems
with sporadic "internal servo tool" errors. The reason for this is probably a too
hard tuned or a very fast gun.

Welding
When the welding position is reached the gun starts to build up the gun force and
the user hook SwPreWeld is executed, see Process hooks on page 160.
The plate thickness is checked (Servo guns only). The weld start signal is set as
soon as SwPreWeld is ready and the requested gun force is reached. After ordering
weld, the system waits for weld complete from the weld equipment. If configured
it is also possible to change the gun force before the weld complete is set. See
How to use spot data programmed in the weld timer on page 258.
For pneumatic guns the start signal is set as soon as the robot has reached the
weld position and a number of supervisions have been acknowledged. The start
signal is high during the entire welding period. It is reset either after weld complete
or after a predefined timeout time elapsed.

Gun opening
The gun starts to open to the programmed position after the weld process is
finished. At the same time the user hook SwOpenGun is executed. When the gun
is opened enough and SwOpenGun is ready then the movement is released and
the robot movement is started.
The gun is also opened to the programmed position after a weld error or in other
error situations.
For pneumatic guns the gun opens to a small or large stroke after the welding has
finished, depending on the parameter \OpenHLift. The opening is supervised in
such a way that the gun open signal is expected.

Note

The gun opening gap must be large enough that the tips are free from the plates
when welding.
So therefore, the software will compensate for the release distance that is used,
and the plate thickness, as the opening position is the same as the tips closed
with plates + release distance.
Example:
If release_dist is 10mm, the moving tip will open to 10mm even if you modify the
position with the gun closed on the plate surface.
A simple recommendation is to have approximately the same distance from the
plate to the movable electrode as the release_dist that has been configured.
For more information about the SoftWare Equalizing functionality, see Software
Equalizing on page 169.

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Program stop and restart

Stop during the motion and restart
The robot stops on the path. If the gun closure already is started the gun will open
to the programmed position.
On restart, the robot continues towards the programmed position, closes the gun
again and the sequence in SpotL/J carries on as normal.

Stop during welding and restart

The welding is finished, validation is done after the stop and the gun opens.
On restart, the robot continues with next instruction.

Quick stop and restart

Quick stop during the motion and restart
The robot stops immediately probably deviated from the path. If the gun closure
already is started the gun will open to the programmed or gun open position.
On restart, the robot first moves back to the path, then continues towards the
programmed position, closes the gun again and the sequence in SpotL/J and
SpotML/MJ carries on as normal.

Quick stop during welding and restart

The weld process is interrupted. The gun is still closed but the gun force will be
reduced. (Servo guns only).
A pneumatic gun will open in this situation.
On restart, the weld error handling is executed with possibilities to reweld the last
spot.

Power failure handling

At system restart after power failure:
• All spot welding output signals are set to the old status, except the weld start
signal.
At program restart after power failure:
• The robot returns to the path and the program execution which was
interrupted is continued.
• If a power failure occurred when a weld process was active, the current spot
is automatically rewelded.

Instruction by instruction execution

Forward
The instruction is executed in two steps (Recommended setting, Step Mode = Step
Over):
1 The robot will move to the weld position, an operator dialog will be shown
with instructions on how to continue. After this step it is possible to modify
the position if needed. It is possible to weld or skip the current position and
move to next instruction.

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2 If the step forward button is pressed again, current instruction will be skipped.
If start button is pressed the current instruction will be welded.

Note

To perform a weld in this position, the start button must be pressed. Program
execution will stop after the current instruction is ready. To restart the program
normally, the start button must be pressed again.

Backward
The motion is performed backwards to the programmed position with gun control,
but the gun is not closed in the weld position and no weld process is activated.
(Servo guns only).
For pneumatic guns the gun is set to work or highlift stroke depending on position
of the \OpenHLift switch. The motion is performed backwards.
The gun is set to work or highlift stroke depending on the position of the
\CloseHLift switch.

Simulation modes
All active simulation modes are defined in curr_simdata in SWUSER. See simdata
- Simulation data on page 146.

Weld simulation in the robot controller

Activated by setting sim_type = 1 in curr_simdata in SWUSER, simulated welding.
This will inhibit the weld start signal to the timer. The simulated weld time used is
the time sim_time in curr_simdata. In this simulation mode the start signal is never
sent to the welding timer.
No preweld supervision is performed, water air etc.

Note

Program valid check and reading of timer input groups will still be done in this
mode, tip force, plate thickness etc.

Weld simulation in the timer

Activated by setting sim_type = 2 in curr_simdata in SWUSER, dry welding.
This will set the enable current signal low to the timer at the next weld, the weld
program in the timer will be executed normally, but without current. The timer will
perform a "dry weld".
No preweld supervision is performed, water air etc.

Testing without closing the guns

When simulation is active it is also possible to run without closing the gun.
Ativated by setting inhib_close to TRUE in curr_simdata. This mode can only be
used when sim_type is set to 1 or 2.
This inhibits the gun closing and opening.

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Testing without plates

When simulation is active it is also possible to run without testing plate thickness
(servo guns only).
Activated by setting no_plates to TRUE in curr_simdata. This mode can only be
used when sim_type is set to 1 or 2. (Servo guns only).
This inhibits the plate thickness supervision.

Weld position Touch Up mode

If Spot Servo Equalizing is installed it is possible to set sim_type = 3 to activate
the weld position Touch Up function. See Software Equalizing on page 169
Activated by setting sim_type = 3 in curr_simdata.

Disable all simulations

All simulations are disabled if sim_type = 0 in curr_simdata.

Error handling
The following error situations can occur:
• Instruction parameter supervision
• Supervision of valid program selection (If configured)
• Supervision in the beginning of the movement
• Gun closure supervision
• Detection of missing or improper plates (Servo guns only)
• Supervision before weld start
• Weld error
• Supervision after welding
• Gun opening supervision

Instruction parameter supervision

The error occurs when SpotL/J or a SpotML/MJ is called with faulty parameters.
• The signal process_fault for the current equipment is set. The program
stops.
• An error message is displayed in a dialog box.
• The error message is logged
The parameter must be changed. When the program is restarted the current
instruction is restarted from the beginning.

Supervision of valid program selection

Supervision of valid program selection is done if it is configured (Not default).

Note

For more information, see Spot Weld timer configuration options on page 55

If an error occurs then:

• The signal process_fault for the current equipment is set. The program
stops.

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• An error message is displayed in a dialog box with retry possibilities.

• The error message is logged.

Supervision in the beginning of the movement

The default supervision checks are executed if configured, and the SwPrepare
routine is run. See Process hooks on page 160.
If an error occurs then:
• The signal process_fault for the current equipment is set. The program
stops.
• An error message is displayed in a dialog box with retry possibilities.
• The error message is logged.
See The type Spot Media Equipment on page 37

Gun closure supervision

The default gun closing sequence are executed if configured, and the SwCloseGun
routine is run. See Process hooks on page 160.
For a pneumatic gun an error occurs if the gun_open signal is not set within a
certain time.
• The signal process_fault the current equipment is set. The program stops.
• An error message is displayed in a dialog box with retry possibilities.
• The error message is logged
See The type Spot Gun Equipment on page 31

Detection of missing or improper plates (Servo guns only)

An error will be detected by the process kernel if the plate thickness differ more
than the allowed limit, defined by the tolerance, from the programmed thickness.
There are three types of errors:
• Negative gun position, one of the tips are missing on the gun, or a tip_wear
calibration is needed.
• Missing plates, the plate thickness is smaller than the thickness defined in
spotdata.
• Improper geometry, the plate thickness exceeds the tolerance defined in
spotdata.
The gun opens.
• The signal process_fault for the current equipment is set. The program
stops.
• An error message is displayed in a dialog box with retry possibilities.
• The error message is logged.

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xx1200000217

Ignore Close the gun again but without thickness detection and continue the execution.
Retry Start the interrupted process from the beginning.

If the error is of the type improper geometry there is a possibility to do a retry with
a higher force on the gun and complete the current weld, that is. when the plates
are not properly fixed together.

xx1200000216

Note

The accuracy of the thickness supervision is highly dependent of good gun tuning
and correct mechanical data, e.g. Transmission Gear Ratio.

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Supervision before the weld is started

The default preweld supervisions are executed if configured, and the SwPreWeld
routine is run. See Process hooks on page 160.
If an error occurs then:
• The signal process_fault for the current equipment is set. The program
stops.
• An error message is displayed in a dialog box with retry possibilities.
• The error message is logged
See The type Spot Weld Equipment on page 27

Weld error
A weld error occurs either if the weld_fault signal is set during the weld process
or if the weld complete signal from the weld timer has not been set in a certain
time, Weld timeout in the process configuration. See The type Spot Weld
Equipment on page 27.
SpotL/J and SpotML/MJ can be configured to automatically reweld a certain
number of times before the error is displayed and the execution stops, waiting for
a manual action.
• The gun opens.
• The signal process_error for current gun is set. The program stops.
• An error message is displayed in a dialog box with retry possibilities.
• The error message and the current robtarget name is logged.

xx1200000215

Skip (only avail- • The reset_fault signal is pulsed.

able in manual • The corresponding process error signal is reset.
mode) • The current robtarget name will be stored in the log. The program
execution is resumed but omitting the faulty weld.

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Reweld • The reset_fault signal is pulsed.

• The corresponding process error signal is reset.
• The gun closes.
• The start signal is set after a short time delay and the program
execution is resumed.

Note

If the optional signal Reset fault with reweld [DO] is configured,

the start weld signal will be set to 1 during the reweld sequence. This
will enable the KSR mode in a Bosch weld timer when performing a re-
weld in adaptive weld mode. See The type Spot Weld Equipment on
page 27

Skip and Reweld error recovery can also be activated by using the digital inputs
skip_proc and reweld_proc, see Other signals on page 49.

Note

If the spot system is built with an additional Bosch weld timer option there will
be more information in the operator dialog about the reason for the error, for
example, hardware fault in the weld timer etc.

Tip

The setup parameter Number of automatic rewelds in Spot Error

Handling can be set to the number of welds required. See The type Spot Error
Handling on page 25

Supervision after welding

The default gun opening sequence are executed if configured, and the SwOpenGun
routine is run. See Process hooks on page 160.
For a pneumatic gun an error occurs if the gun_open signal is not set within a
certain time.
• The signal process_fault for current gun is set.The program stops.
• An error message is displayed in a dialog box with retry possibilities.
• The error message is logged
See The type Spot Gun Equipment on page 31

Gun opening supervision (Servo guns only)

Any errors during gun opening will be detected by internal motion software. An
error results in an error message on the FlexPendant and a program stop.

User defined error handling

All error situations described above can also be handled in a predefined user
routine SwErrorRecover as an option to the built in error handling if needed. See
The type Spot Error Handling on page 25.
If the "user defined" error handling is activated, a dedicated routine
SwErrorRecover in SWUSER will be executed if any of the error cases described

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in section Error handling on page 81 occur, except for parameter errors.

SwErrorRecover is always executed from the robot task.
The input parameters to the SwErrorRecover routine carry information about the
error reason and the chosen error text.
This routine allows customizing of the error handling response, that is. the
FlexPendant layout and how to resume. For more information. See
SwErrorRecover in SWUSER on page 158.

Example
Default example if weld error occurs.

xx1200000214

Software Equalizing
When the software equalizing functions are activated the execution of the SpotL/J
instructions is influenced in different ways:
• The movement to the programmed position will be different.
• The gun preclose function is handled automatically.
• The \Inpos switch will not affect the program execution.

Note

The software equalizing functions are not implemented for the SpotML/MJ
instructions.
For more information, see Software Equalizing on page 169.

Multiple gun forces during welding

During the welding phase when a SpotL/J or a SpotML/MJ instruction is executed
there is a possiblity to use multiple gun forces if needed.
The servo gun force can be controlled from the welding controller via group inputs.

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Internally in the Spot software an input group will monitored during the weld, and
if the value on the input group changes, the gun force will change immediately to
a lower or higher force.
For more information, see How to use spot data programmed in the weld timer on
page 258 and Servo gun force calibration on page 203.

Note

Note that the force calibration procedure is very important if multiple forces has
to be used. The gun position at each force will be stored in the motion parameters
when running this routine. For more information see Servo gun force calibration
on page 203.

Customizing
The Spot package gives the user plenty of scope for customizing the Spot
functionality, see Customizing RobotWare-Spot on page 247.
However the main subject of the SpotL/J and SpotML/MJ instructions description
is the default setup.

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3.7 Weld process timing

3.7 Weld process timing

Weld process timing for pneumatic guns

The following graphic shows the weld process timing for a pneumatic gun and
where in the sequence the user hooks will be executed and affect the internal
behavior.
If welding is done with several guns at the same time then each process is handled
in separate tasks independent of each other.

en1200000238

Weld process timing for servo guns

The following figure shows the weld process timing for a servo gun and where in
the sequence the user hooks will be executed and affect the internal behavior.
If welding is done with several guns at the same time then each process is handled
in separate tasks independent of each other.
The system parameter Post_sync_time (Post-synchronization Time) in the topic
Motion, type SG Process, defines the predicted release time of the next robot
movement after a weld. Can be used to shorten the cycle time, the robot will start
to move before the gun is completely opened. Default value is 0.

Note

The value of this parameter (Post-synchronization Time) can affect the cycle
time of the program negatively if for example two welding points are programmed
at the same position. To minimize this risk the value can be increased. See
Application manual - Additional axes and stand alone controller.

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en1200000239

Weld process timing for software equalizing with servo guns

The following graphic shows the weld process timing for a servo gun when software
equalizing is activated, and where in the sequence the user hooks will be executed
and affect the internal behavior.
If welding is done with several guns at the same times then each process is handled
in separate tasks independent of each other.
The system parameter Post_sync_time (Post-synchronization Time) in the topic
Motion, type SG Process, defines the predicted release time of the next robot
movement after a weld. Can be used to shorten the cycle time, the robot will start
to move before the gun is completely opened. Default value is 0.

Note

If Soft Equalizing is activated the Spot Gun Equipment process data parameters
Gun pre closing time and Gun pre equalizing time are not used. The
preclosing of the gun is in this case handled automatically, see Software
Equalizing on page 169.

Note

The value of this parameter (Post-synchronization Time) can affect the cycle
time of the program negatively if for example two welding points are programmed
at the same position. To minimize this risk the value can be increased. See
Application manual - Additional axes and stand alone controller.

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en1200000237

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3.8.1 Jogging the robot after unintentional servo gun disconnection

3.8 Miscellaneous information

3.8.1 Jogging the robot after unintentional servo gun disconnection

Servo gun disconnection

If the motor cables are unintentional disconnected when the servo gun is activated,
the servo gun must be deactivated in order to jog the robot to a service position.
Deactivation is done in the Jogging window by selecting axis and tapping
Deactivate. After service or repair the revolution counter must be updated since
the position has been lost.
For more information, see Recover from accidental servo gun disconnection on
page 208.

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3.8.2 Tip dressing for servo guns

3.8.2 Tip dressing for servo guns

Tip dressing for servo guns

The gundata contains counters and tip wear information for each used gun. The
counters will be automatically incremented for each spot and the tip wear
information is updated after each gun calibration. This information can be used to
decide when to do next tip dressing or tip exchange.
For more information see gundata - Equipment specific weld data on page 135 and
Tip management on page 200

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3.8.3 Pneumatic spot welding gun and gripper

3.8.3 Pneumatic spot welding gun and gripper

Pneumatic spot welding gun and gripper

When the robot has a pneumatic spot welding gun and a gripper, with or without
a tool changer, it takes some special arrangements to control the clamps on the
gripper. The reason is that the air pressure valve on the Media Panel is controlled
by the weld timer, which uses the valve to obtain different gun forces. The weld
timer is in control of the air pressure valve, even when the robot is holding the
gripper.

Preparing control of the clamps

Use this procedure to prepare control of the clamps on the gripper:
1 In the weld timer, create weld programs for the desired pressures for gripper
control.

Note

The weld current MUST be deactivated in the programs.

2 In the RAPID code, create the necessary control routines, and include SetGO
instructions that sets the group output to the program number to the
corresponding program in the weld timer.

Note

The gX_new_prog signal must be on at all times for the air pressure valve
to follow immediately a new program number.

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3.9 Supervision task SW_SUP

3.9 Supervision task SW_SUP

Description
In spot options, there is a separate semistatic monitoring task that runs in the
background, SW_SUP. This task is selected by default when building a spot system
in Installation Manager and can be deselected if a supervision task is not needed,
e.g. if the supervision is handled by external equipment.
The SW_SUP task is handling the built in water supervision. There are some different
configuration possibilities regarding the behaviour of the water supervision, see
The type Spot Media Equipment on page 37.
In the SWUSER module there is a routine that is called from SW_SUP task,
SupervisionInit, here it is possible to add custom functionality / monitoring to
be run independently of program execution in motion task. No default functionality,
Supervision task hook on page 163.

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 4 RAPID references
4.1.1 SpotL/SpotJ - The basic spot welding instructions

4 RAPID references
4.1 Instructions

4.1.1 SpotL/SpotJ - The basic spot welding instructions

Descriptions
SpotL and SpotJ are used in spot welding when welding with one gun or several
guns in sequence. The instructions are used to control the complete welding
sequences, that is, the motion, gun closure/opening, and the welding process.
SpotL moves the TCP linearly to the weld position and then activates the weld
process. SpotJ moves the TCP non-linearly to the weld position before the weld
process is activated.
This instruction can only be used in the Main task or, if in a MultiMove system, in
Motion tasks.

Example
SpotL p100, vmax, gun1, spot10, tool1;
This is the only instruction needed to implement a complete welding operation with
one gun equipment.
• The TCP for tool1 is moved on a linear path to the position p100 with the
speed given in vmax.
• The weld position is always a stop position since the welding is always
performed while the robot is standing still.
• The gun is closed in advance when the robot is moved I .
• The weld process is started and supervised until finished and the gun is
reopened.
• The parameter spot10 is a data of type spotdata containing spot weld specific
parameters for the spot in p100, for example desired weld timer program
number and gun pressure.
• The parameter gun1 is a num corresponding to the used gun equipment. All
gun equipment used are defined in the gundata array curr_gundata located
in SWUSER.SYS module, see SWUSER on page 158.
I May differ depending on configuration.

Arguments
SpotL ToPoint Speed GunNo [\GunD] Spot [\InPos] [\OpenHLift] [\CloseHLift]
[\QuickRelease] [\SMEQ] Tool [\WObj] [\TLoad]
SpotJ ToPoint Speed GunNo [\GunD] Spot [\InPos] [\OpenHLift] [\CloseHLift]
[\QuickRelease] [\SMEQ] Tool [\WObj] [\TLoad]

ToPoint
Data type: robtarget
The destination point of the robot and additional axes. It is defined as a named
position or stored directly in the instruction (marked with an * in the instruction).

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4.1.1 SpotL/SpotJ - The basic spot welding instructions
Continued

Speed
Data type: speeddata
The speed data that applies to movements. Speed data defines the velocity for the
tool center point, the tool reorientation and additional axes.

GunNo
Data type: num
Used gun equipment number. Corresponding to the element number in the gundata
array curr_gundata located in the SWUSER.SYS module, see SWUSER on page 158.

[\GunD]
Data type: gundata
Used gun equipment data for the process, see gundata - Equipment specific weld
data on page 135.
Can be used if external gundata is required. If used the external gundata will be
temporary stored in the curr_gundata array during the process.

Spot
Data type: spotdata
Spot specific data for the weld process, weld program number, gun force etc, see
spotdata - Spot weld data on page 140

[\InPos]
Data type: switch
The optional argument \InPos inhibits the preclosing of the gun. The gun is closed
first when the robot has reached the end position. This argument will increase the
execution time but is useful in narrow situations.This switch will not affect the
execution when software equalizing is active.

[\OpenHLift]
Data type: switch
The optional argument \OpenHLift will set the gun to its large gap after the weld.
If the argument is omitted the gun opens to its small gap (work stroke). If the
instruction is executed backwards the gun opens to the large position before the
motion. (Only valid for pneumatic guns).

[\CloseHLift]
Data type: switch
The optional argument \CloseHLift will set the gun to its small gap (work stroke)
before closing the gun. If the instruction is executed backwards the gun opens to
the large position after the motion. (Only valid for pneumatic guns).

[\QuickRelease]
Data type: switch
The optional argument \QuickRelease will skip the release movement after the
weld if software equalizing is activated. Can be used to save cycle time.

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4.1.1 SpotL/SpotJ - The basic spot welding instructions
Continued

[\SMEQ]
Data type: smeqdata (SoftMove Equalizing data)
If the optional data \SMEQ is used the robot will be set into a soft state in the tool
z direction during the approach movement to the position.
This method can be used as a complement to the standard software equalizing
method if the tolerances of the parts to be welded are less exact.
For more information see SoftMove Equalizing on page 185

Note

The SoftMove functionality is only avalible if the options Spot Servo Equalizing
(635-6) and SoftMove (885-1) are installed together.

Tool
Data type: tooldata
The tool in use when the robot moves. The tool center point is the point moved to
the specified destination position, and should be the position for the electrode tips
when the gun is closed.

[\WObj]
Data type: wobjdata
The work object (coordinate system) to which the robot position in the instruction
is related.
This argument can be omitted, and if it is, the position is related to the world
coordinate system. If, on the other hand, a stationary TCP or coordinated additional
axes are used, this argument must be specified in order to perform a linear
movement relative to the work object.

[\TLoad]
Data type: loaddata
The \TLoad argument describes the total load used in the movement. The total
load is the tool load together with the payload that the tool is carrying. If the \TLoad
argument is used, then the loaddata in the current tooldata is not considered.
If the \TLoad argument is set to load0, then the \TLoad argument is not considered
and the loaddata in the current tooldata is used instead. For a complete description
of the \TLoad argument, see MoveL.

Communication
SpotL/J instructions communicates with the surrounding weld equipment using
digital signals.
The default I/O setup is located on local I/O devices unless a specific SpotPack
option is selected.
For a complete description of the I/O configuration, see Spot I/O configuration on
page 42 or Spot Weld timer configuration options on page 55.

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4.1.1 SpotL/SpotJ - The basic spot welding instructions
Continued

Program execution
For a complete description of the program execution sequence and error handling
in the SpotL/J instruction, see Process sequence and error handling on page 76.

Limitations

Note

It is not possible use independent gun mode when Software Equalizing is active.
This will cause an error message. For more information, see IndGunMove -
Activates independent mode for a servo gun on page 130.

Note

It is only possible to run this instruction in semi coordinated mode.

Note

The \QuickRelease function is suitable to use if weld positions are located

close to each other, not when there is a large distance between weld positions.

Syntax
SpotL or SpotJ
[ ToPoint ':=' ] < expression (IN) of robtarget > ','
[ Speed ':=' ] < expression (IN) of speeddata > ','
[ GunNo ':='] < expression (IN) of num >
[ '\' GunD ':='] < persistent(PERS) of gundata > ] ','
[ Spot ':='] < persistent (PERS) of spotdata >
[ '\' InPos ]
[ '\' OpenHLift ]
[ '\' CloseHLift ]
[ '\' QuickRelease ]
[ '\' SMEQ ':='] < persistent(PERS) of smeqdata > ] ','
[ Tool ':=' ] < persistent (PERS) of tooldata > ]
[ '\' WObj ':=' ] < persistent (PERS) of wobjdata > ]
[ '\' TLoad ':=' ] < persistent (PERS) of loaddata > ] ';'

Related information

Described in:
Definition of velocity, speeddata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of zone data, zonedata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of tool, tooldata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of work objects, wobjdata Technical reference manual - RAPID Instruc-
tions, Functions and Data types

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4.1.1 SpotL/SpotJ - The basic spot welding instructions
Continued

Described in:
MoveL Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of load data, loaddata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of spot data, spotdata spotdata - Spot weld data on page 140
Definition of gun data, gundata gundata - Equipment specific weld data on
page 135
SpotML/MJ SpotML/SpotMJ - Spot welding with multiple
guns on page 100
Overview Spot options Introduction to RobotWare Spot on page 15
Customizing possibilities Customizing RobotWare-Spot on page 247
I/O configuration Spot I/O configuration on page 42
Servo gun introduction Servo gun motion control on page 195
Servo gun motion parameters Application manual - Additional axes and
stand alone controller
Motion in general Technical reference manual - RAPID overview
Software Equalizing Software Equalizing on page 169
SoftMove Equalizing SoftMove Equalizing on page 185

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4 RAPID references
4.1.2 SpotML/SpotMJ - Spot welding with multiple guns

4.1.2 SpotML/SpotMJ - Spot welding with multiple guns

Description
SpotML and SpotMJ can be used in spot welding if welding with several guns at
the same time is desired. For servo guns it is possible to use two guns
simultaneously and for pneumatic guns it is possible to use four guns at the same
time. The instructions are used to control the complete welding sequences that is.
the motion, gun closure/opening and the welding processes.
• SpotML moves the TCP linearly to the weld position and then activates the
gun equipments.
• SpotMJ moves the TCP non-linearly to the weld position before the gun
equipment are activated.
These instructions can only be used in the Main task or, if in a MultiMove system,
in Motion tasks.

Example
SpotML p100, vmax \G1:=spot10 \G2:=spot20, tool1;
This is the only instruction needed to implement a complete welding operation with
two gun equipment.
• The TCP for tool1 is moved on a linear path to the position p100 with the
speed given in vmax. The weld position is always a stop position since the
welding is always performed while the robot is standing still. The guns are
closed in advance when the robot is moved. The weld processes are started
and supervised until finished and the guns are reopened.
• The optional arguments G1 and G2 will activate gun equipment 1 and gun
equipment 2. The parameter spot10 is a spotdata containing weld parameters
for the welding with gun equipment 1, for example desired weld timer program
number and gun pressure. The parameter spot20 contains weld parameters
for the welding with gun equipment 2.
All gun equipment used are defined in the gundata array curr_gundata in
SWUSER.SYS module, see SWUSER on page 158.

Arguments
SpotML ToPoint Speed [\G1] [\G2] [\G3] [\G4] [\Gun1] [\Gun2] [\Gun3] [\Gun4]
[\InPos] [\OpenHLift] [\CloseHLift] Tool [\WObj] [\TLoad]
SpotMJ ToPoint Speed [\G1] [\G2] [\G3] [\G4] [\Gun1] [\Gun2] [\Gun3] [\Gun4]
[\InPos] [\OpenHLift] [\CloseHLift] Tool [\WObj] [\TLoad]

ToPoint
Data type: robtarget
The destination point of the robot and additional axes. It is defined as a named
position or stored directly in the instruction (marked with an * in the instruction).
This name will be stored in the log if a error occurs during the welding.

Speed
Data type: speeddata

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4.1.2 SpotML/SpotMJ - Spot welding with multiple guns
Continued

The speed data that applies to movements. Speed data defines the velocity for the
tool center point, the tool reorientation and additional axes.

[G1] - [G4]
Data type: spotdata for gun equipment 1 - 4
Spot data with the spot specific data associated with the weld with gun equipment
1 - 4, see spotdata - Spot weld data on page 140 and gundata - Equipment specific
weld data on page 135.

[\Gun1] - [\Gun4]
Data type: gundata
Used gun equipment data for the process, see gundata - Equipment specific weld
data on page 135.
Can be used if external gundata is required. If used the external gundata will be
temporary stored in the curr_gundata array during the process.

[\InPos]
Data type: switch
The optional argument \InPos inhibits the preclosing of the guns. The guns are
closed first when the robot has reached the end position. This argument will
increase the execution time but is useful in narrow situations.

[\OpenHLift]
Data type: switch
The optional argument \OpenHLift will set the guns to its large gap after the weld.
If the argument is omitted the guns opens to its small gap (work stroke). If the
instruction is executed backwards the guns opens to the large position before the
motion. (Only valid for pneumatic guns).

[\CloseHLift]
Data type: switch
The optional argument \CloseHLift will set the guns to its small gap (work stroke)
before closing the guns. If the instruction is executed backwards the guns opens
to the large position after the motion. (Only valid for pneumatic guns).

Tool
Data type: tooldata
The tool in use when the robot moves. The tool center point is the point moved to
the specified destination position, and should be the position for the electrode tips
when the gun is closed.

[\WObj]
Data type: wobjdata
The work object (coordinate system) to which the robot position in the instruction
is related.
This argument can be omitted, and if it is, the position is related to the world
coordinate system. If, on the other hand, a stationary TCP or coordinated additional

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4.1.2 SpotML/SpotMJ - Spot welding with multiple guns
Continued

axes are used, this argument must be specified in order to perform a linear
movement relative to the work object.

[\TLoad]
Data type: loaddata
The \TLoad argument describes the total load used in the movement. The total
load is the tool load together with the payload that the tool is carrying. If the \TLoad
argument is used, then the loaddata in the current tooldata is not considered.
If the \TLoad argument is set to load0, then the \TLoad argument is not considered
and the loaddata in the current tooldata is used instead. For a complete description
of the \TLoad argument, see MoveL.

Communication
SpotML/MJ instructions communicates with the weld equipment using digital
signals. The default I/O setup is located on local I/O devices.
For a complete description of the I/O configuration, see Spot I/O configuration on
page 42

Program execution
For a complete description of the program execution sequence and error handling
in the SpotML/MJ instruction, see Process sequence and error handling on page 76.

Limitations
This instruction will not be installed if a Weld Timer Configuration option is selected
when building a spot system in RobotStudio. In this case only a minimal installation
of spot will be done with predefined signals for one weld equipment only.

Note

It is not possible to use Software Equalizing mode for this instruction,

SpotML/SpotMJ.
For more information, see Software Equalizing on page 169.

Note

It is only possible to run this instruction in semi coordinated mode.

Syntax
SpotML or SpotMJ
[ ToPoint ':=' ] < expression (IN) of robtarget > ','
[ Speed ':=' ] < expression (IN) of speeddata > ','
[ '\' G1 ':=' < persistent (PERS) of spotdata > ]
[ '\' G2 ':=' < persistent (PERS) of spotdata > ]
[ '\' G3 ':=' < persistent (PERS) of spotdata > ]
[ '\' G4 ':=' < persistent (PERS) of spotdata > ]
[ '\' Gun1 ':=' < persistent (PERS) of gundata > ]
[ '\' Gun2 ':=' < persistent (PERS) of gundata > ]
[ '\' Gun3 ':=' < persistent (PERS) of gundata > ]

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4.1.2 SpotML/SpotMJ - Spot welding with multiple guns
Continued

[ '\' Gun4 ':=' < persistent (PERS) of gundata > ]

[ '\' InPos ]
[ '\' OpenHLift ]
[ '\' CloseHLift ]','
[ Tool ':=' ] < persistent (PERS) of tooldata > ]
[ '\' WObj ':=' < persistent (PERS) of wobjdata > ]
[ '\' TLoad':=' ] < persistent (PERS) of loaddata > ] ';'

Related information

Described in:
Definition of velocity, speeddata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of zone data, zonedata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of tool, tooldata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of work objects, wobjdata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
MoveL Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of load data, loaddata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of spot data, spotdata spotdata - Spot weld data on page 140
Definition of gun data, gundata gundata - Equipment specific weld data on
page 135
SpotL/J SpotL/SpotJ - The basic spot welding instruc-
tions on page 95
Overview Spot options Introduction to RobotWare Spot on page 15
Customizing possibilities Customizing RobotWare-Spot on page 247
I/O configuration Spot I/O configuration on page 42
Servo gun introduction Servo gun motion control on page 195
Servo gun motion parameters Application manual - Additional axes and
stand alone controller
Motion in general Technical reference manual - RAPID overview

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4 RAPID references
4.1.3 SetForce - Close and Open a gun with desired force and time

4.1.3 SetForce - Close and Open a gun with desired force and time

Description
SetForce is used in spot welding to close the gun and apply a predefined force
during a desired time without activating a weld process. The gun will open again
after the elapsed time or when a digital input signal is set. This instruction can for
example be used for tip dressing.

Example
SetForce gun1, force10;
Forcedata force10 contains the parameters for the SetForce action, for example
desired tip force and force time.
The parameter gun1 is a num corresponding to the used gun equipment. All gun
equipment used are defined in the gundata array curr_gundata located in
SWUSER.SYS module. See SWUSER on page 158.

Arguments
SetForce GunNo [\GunD] Force [\RetThickness] [\PrePos] [\CloseSpeed]
[\OpenHLift] [\CloseHLift]

GunNo
Data type: num
Used gun number. Corresponding to the element number in the gundata array
curr_gundata in the SWUSER.SYS module. See SWUSER on page 158.

[\GunD]
Data type: gundata
Optional parameter. Used gun equipment data for the process, see gundata -
Equipment specific weld data on page 135.
Can be used if external gundata is required. If used the external gundata will be
temporary stored in the curr_gundata array during the process.

Force
Data type: forcedata
The forcedata with the force parameters. See forcedata - Spot gun force data on
page 143.

[\RetThickness]
(returned thickness)
Data type: num
Optional parameter. The achieved thickness [mm] (servo guns only).

[\IndPos]
(independent pre-position)
Data type: num
Optional parameter. The desired independent pre-position when the specified gun
speed should be used [mm]. (servo guns only).
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4.1.3 SetForce - Close and Open a gun with desired force and time
Continued

[\GunSpeed]
(gun speed)
Data type: num
Optional parameter. The desired gun speed that shall be used from the specified
independent pre-position [%]. (servo guns only). This parameter can be used to
get a better performance when e.g tip dressing by reducing the gun speed.
If an independent pre-position is not used the gun speed will be reduced from the
actual start position.

[\OpenHLift]
Data type: switch
The optional argument \OpenHLift will set the gun to its large gap after the
instuction. If the argument is omitted the gun opens to its small gap (work stroke).
If the instruction is executed backwards the gun opens to the large position before
the motion. (Only valid for pneumatic guns).

[\CloseHLift]
Data type: switch
The optional argument \CloseHLift will set the gun to its small gap (work stroke)
before closing the gun. If the instruction is executed backwards the gun opens to
the large position. (Only valid for pneumatic guns).

Program execution
Internal sequence when a SetForce instruction is executed:
1 The gun is closed to the specified thickness in the used forcedata. If
pre-position is used \IndPos, gun will be set to independent mode internally,
and the closing speed will be reduced from the independent position
according to the specified value in \GunSpeed.
2 The plate thickness is checked (servo guns only).
3 The requested gun force is established.
4 Wait until the desired force time elapsed or the force complete signal is
activated.
5 If configured, the second gun force in curr_forcedata is established, see
forcedata - Spot gun force data on page 143.
6 If configured, wait until the second force time has elapsed or the force
complete signal is activated.
7 The gun is opened to the previous position. If an independent pre-position
is used, the opening speed will be reduced to the independent position
according to the specified value in \GunSpeed and the independent mode
will be reset.
The force complete signal for each used gun is predefined in the I/O configuration.
For a complete description of the I/O configuration, see Spot I/O configuration on
page 42.

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4.1.3 SetForce - Close and Open a gun with desired force and time
Continued

Error handling
Instruction parameter supervision
The error occurs when SetForce is called with faulty parameters. The program
stops.
The parameter must be changed. When the program is restarted the current
instruction is restarted from the beginning.

Detection of missing or improper plates (Only for servo guns)

An error will be detected by the process kernel if the plate thickness differ more
than the allowed limit defined by the tolerance from the programmed thickness.
There are three different types of errors:
• Negative gun position, one of the tips are missing on the gun, or a tip_wear
calibration is needed.
• Missing plates, the plate thickness is smaller than the thickness defined in
forcedata.
• Improper geometry, the plate thickness exceeds the tolerance defined in
forcedata.
1 The gun opens.
2 The process error signal for the current gun equipment is set. The program
stops.
3 An error message is displayed in a dialog box with retry possibilities.
4 The error message is logged.

xx1200000217

Ignore Close the gun again but without thickness detection and continue the execution.
Retry Retry the SetForce instruction.
Skip If the error is of the type improper geometry there is a possibility to do a retry with
a higher force on the gun and complete the current weld, that is. when the plates
are not properly fixed together.
Only available in manual mode.

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4.1.3 SetForce - Close and Open a gun with desired force and time
Continued

xx1200000216

Note

The accuracy of the thickness supervision is highly dependent of good gun tuning
and correct mechanical data, e.g. Transmission Gear Ratio.

Limitations
If the \IndPos argument is used the gun will be set to an independent position. If
the instruction is aborted and the program pointer is moved, or an error occur while
the independent mode is active, the independent mode will be cleared depending
on if the system is in motors on state or not. If motors off state independent mode
will be cleared at the next start or restart.
Independent mode will cleared in the following situations:
Stop / QStop / Start / ReStart or program pointer moved:
• If motors on state: Independent mode will be cleared.
• If motors off state: Independent mode will not be cleared.
For more information about independent gun mode, see IndGunMove - Activates
independent mode for a servo gun on page 130 and IndGunMoveReset - Resets
servo gun from independent mode on page 132.

Syntax
SetForce
[ GunNo ':='] < expression (IN) of num >
[ '\' GunD ':='] < persistent(PERS) of gundata > ] ','
[ Force ':='] < persistent (PERS) of forcedata >
[ '\' RetThickness ':=' < variable or persistent(INOUT) of num
> ]
[ '\' IndPos ':=' < expression (IN) of num > ]
[ '\' GunSpeed ':=' < expression (IN) of num > ]
[ '\' OpenHLift ]
[ '\' CloseHLift ] ';'

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4.1.4 CalibL/CalibJ - Calibrate a servo gun during robot movement

4.1.4 CalibL/CalibJ - Calibrate a servo gun during robot movement

Description
CalibL/J is used in spot welding to calibrate the distance between the gun tips
for servo guns. This is necessary after tip change or tool change and it is
recommended after welding of a number of spots or performing a tip dress. Calibrate
will also update the tip wear data in the used gundata. The calibration is done
during a robot movement to a programmed position.
NB: The gun performs two non-synchronized close/open movements during the
calibration.
If the option Spot Servo Equalizing is installed there are additional error
handling included for lost tips when a TipChg calibration is done and supervision
of the tip wear when a Tip-Wear calibration is done.

Example
CalibL p400, v500, gun1\ TipWear, fine, tool1;
• The gun gun1 is calibrated for TipWear during the linear movement to p400.
• The parameter gun1 is a num corresponding to the used gun equipment. All
gun equipment used are defined in the gundata array curr_gundata in
SWUSER. See SWUSER on page 158.
• The data curr_tip_wear in curr_gundata will be automatically updated.
For more information about tip management, see Tip management on page 200.

Arguments
CalibL ToPoint Speed GunNo [\GunD] [\TipChg] | [\ToolChg] | [\TipWear]
[\RetTipWear] [\RetPosAdj] [\PrePos] [\TWeld], Zone Tool [\WObj] [\TLoad]
CalibJ ToPoint Speed GunNo [\GunD] [\TipChg] | [\ToolChg] | [\TipWear]
[\RetTipWear] [\RetPosAdj] [\PrePos] [\TWeld], Zone Tool [\WObj] [\TLoad]

ToPoint
Data type: robtarget
The destination point of the robot and additional axes. It is defined as a named
position or stored directly in the instruction (marked with an * in the instruction).
A movement of the gun tip position can not be programmed. This will cause an
error message.

Speed
Data type: speeddata
The speed data that applies to movements. Speed data defines the velocity for the
tool center point, the tool reorientation and additional axes.

GunNo
Data type: num
Used gun equipment number. Corresponding to the element number in the gundata
array curr_gundata located in the SWUSER.SYS module. See SWUSER on page 158.

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4.1.4 CalibL/CalibJ - Calibrate a servo gun during robot movement
Continued

[\GunD]
Data type: gundata
Used gun equipment data for the process, see gundata - Equipment specific weld
data on page 135.
Can be used if external gundata is required. If used the external gundata will be
temporary stored in the curr_gundata array during the process.

[\TipChg]
(tip change calibration)
Data type: switch
Calibration type. This calibration type is used after tip change.
The gun will close and open two times. The first close movement will be slow to
find the unknown contact position. The total tip wear is reset to zero.
If the option Spot Servo Equalizing is selected the difference since last
calibration will be supervised. If the difference since the last calibration exceeds
the supervision value in the Tip change supervision value an error will be
raised. See The type Spot Gun Equipment on page 31.
For more information about tip management, see Tip management on page 200,
Tip wear compensation on page 180, MeasureWearL - Measure current electrode
wear and recalculate the TCP on page 118 or the ReCalcTCP - Calculate current
electrode wear and recalculate the TCP on page 126.

[\ToolChg]
(tool change calibration)
Data type: switch
Calibration type. This calibration type is used after tool change.
The gun will close and open two times. The first close movement will be slow to
find the unknown contact position. The total tip wear will remain unchanged.

[\TipWear]
(tip wear calibration)
Data type: switch
Calibration type. This calibration type is used to update the tip wear and adjust the
contact position after tip dress or after welding a number of spots.
The gun will close and open fast two times. The total tip wear is updated.
If the option Spot Servo Equalizing is selected the difference since last
calibration will be supervised. If the difference since the last calibration exceeds
the supervision value in the Tip wear supervision value an error will be
raised. See The type Spot Gun Equipment on page 31.
For more information about tip management, see Tip management on page 200,
Tip wear compensation on page 180, MeasureWearL - Measure current electrode
wear and recalculate the TCP on page 118 or the ReCalcTCP - Calculate current
electrode wear and recalculate the TCP on page 126.

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4.1.4 CalibL/CalibJ - Calibrate a servo gun during robot movement
Continued

[\RetTipWear]
Data type: num
The achieved tip wear [mm].

[\RetPosAdj]
Data type: num
The positional adjustment since the last calibration [mm].

[\PrePos]
(pre position)
Data type: num
The position to move with high speed to before search for contact position with
slower speed is started [mm].

[\TWeld]
(test weld)
Data type: spotdata
If selected, a weld with the specified parameters will be performed after the
calibration and during the robot movement.
A weld can be done after tip dressing to check the tips, and to save cycle time the
test weld argument can be used instead of adding an extra SpotL instruction after
the calibration.

Zone
Data type: zonedata
Zone data for the movement. Zone data describes the size of the generated corner
path.

Tool
Data type: tooldata
The tool in use when the robot moves. The tool center point is the point moved to
the specified destination position, and should be the position for the electrode tips
when the gun is closed.

[\WObj]
Data type: wobjdata
The work object (coordinate system) to which the robot position in the instruction
is related.
This argument can be omitted, and if it is, the position is related to the world
coordinate system. If, on the other hand, a stationary TCP or coordinated additional
axes are used, this argument must be specified in order to perform a linear
movement relative to the work object.

[\TLoad]
Data type: loaddata

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4.1.4 CalibL/CalibJ - Calibrate a servo gun during robot movement
Continued

The \TLoad argument describes the total load used in the movement. The total
load is the tool load together with the payload that the tool is carrying. If the \TLoad
argument is used, then the loaddata in the current tooldata is not considered.
If the \TLoad argument is set to load0, then the \TLoad argument is not considered
and the loaddata in the current tooldata is used instead. For a complete description
of the \TLoad argument, see MoveL.

Program execution
Internal sequence when a CalibL/J instruction is executed:
• The robot starts the movement to the destination position.
• The gun will close and open two times during the robot movement. Different
tip speeds depending on selected calibration type.
• If the \TWeld is selected a test weld with the specified data will be done.
• The gun is opened to the previous position.
• For certain calibration types: curr_tip_wear in the array curr_gundata
in SWUSER is updated and saved.

Positional adjustment
The optional argument RetPosAdj can be used to detect if for example the tips
are lost after a tip change. The parameter will hold the value of the positional
adjustment since the last calibration. The value can be negative or positive.
If the option Spot Servo Equalizing is selected this value will be used to
calculate the difference since last calibration and supervise the tips when calibrating.

Using a pre position

In order to speed up the calibration, it is possible to define a pre position.When
the calibration starts, the gun arm will be run fast to the pre position, stop and then
continue slowly forward in order to detect the tip contact position. A pre position
will be ignored if it is larger than the current gun position (in order not to slow down
the calibration).

Instruction by instruction execution

Forward As during continuous execution.

Backward The motion is performed backwards to the programmed position, but no
calibration is activated. NB, the tip distance in this case is the pro-
grammed value in the instruction.
Positional adjust- The optional argument RetPosAdj can be used to detect if for example
ment the tips are lost after a tip change. The parameter will hold the value of
the positional adjustment since the last calibration. The value can be
negative or positive.
If the option Spot Servo Equalizing is selected this value will be used to
calculate the difference since last calibration and supervise the tips when
calibrating.
Using a pre posi- In order to speed up the calibration, it is possible to define a pre position.
tion When the calibration starts, the gun arm will be run fast to the pre posi-
tion, stop and then continue slowly forward in order to detect the tip
contact position. A pre position will be ignored if it is larger than the
current gun position (in order not to slow down the calibration).

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4.1.4 CalibL/CalibJ - Calibrate a servo gun during robot movement
Continued

Error handling
Instruction parameter supervision
The error occurs when CalibL/J is called with faulty parameters or if no calibration
type switch is programmed. The program stops with error text.
The parameter must be changed. When the program is restarted the current
instruction is restarted from the beginning.

Tip change supervision

If the calculated difference to the last calibration of the gun exceeds the supervision
value defined in the configuration data Tip change supervision value an
error will be raised and the program execution will be stopped. This error can occur
for example after tip change and when CalibL/J ... \TipChg is called with
wrong (too large or too small tips) tips. The program stops with error message.
See The type Spot Gun Equipment on page 31.
This error handling only exists for the Spot Servo Equalizing option. See
Additional components for Spot Servo Equalizing on page 136.
For more information about tip management, see Tip management on page 200.

Tip wear supervision

If the calculated difference to the last calibration of the gun exceeds the supervision
value defined in the configuration data Tip wear supervision value an error
will be raised and the program execution will be stopped. This error can occur for
example after tip dressing when CalibL/J .. \TipWear is called with badly
dressed tips. The program stops with error message. See The type Spot Gun
Equipment on page 31.
This error handling only exists for the Spot Servo Equalizing option. See
Additional components for Spot Servo Equalizing on page 136.
For more information about tip management, see Tip management on page 200.

Test weld error

If a weld error occur during the robot movement it will be handled in the same way
as a normal weld error, see Weld error on page 84
It is also possible to handle a weld error in the user defined error handling if needed,
see User defined error handling on page 85.

Limitations

Note

It is only possible to run this instruction from a motion task.

Note

It is only possible to run this instruction in semi coordinated mode.

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4.1.4 CalibL/CalibJ - Calibrate a servo gun during robot movement
Continued

Syntax
CalibL or CalibJ
[ ToPoint ':=' ] < expression (IN) of robtarget > ','
[ Speed ':=' ] < expression (IN) of speeddata > ','
[ GunNo ':='] < expression (IN) of num >
[ '\' GunD ':='] < persistent(PERS) of gundata > ]
[ \TipChg] | [\ToolChg] | [\TipWear]
[ '\' RetTipWear ':=' < variable or persistent(INOUT) of num >
]
[ '\' RetPosAdj ':=' < variable or persistent(INOUT) of num > ]
[ '\' PrePos ':=' < variable or persistent(IN) of num > ]
[ '\' TWeld ':=' < persistent(IN) of spotdata > ] ','
[ Zone ':=' ] < expression (IN) of zoneddata > ] ','
[ Tool ':=' ] < persistent (PERS) of tooldata > ]
[ '\' WObj ':=' < persistent (PERS) of wobjdata > ]
[ '\' TLoad':=' ] < persistent (PERS) of loaddata > ] ';'

Related information

Described in:
Definition of velocity, speeddata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of zone data, zonedata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of tool, tooldata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of work objects, wobjdata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
MoveL Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of load data, loaddata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Overview Spot options Introduction to RobotWare Spot on page 15
Servo gun introduction Servo gun motion control on page 195
Calibration without movement Servo gun motion control on page 195
Software Equalizing Software Equalizing on page 169
Setup data for Software Equalizing The type Spot SoftWare Equalizing on
page 39

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4 RAPID references
4.1.5 Calibrate - Calibrate a servo gun

4.1.5 Calibrate - Calibrate a servo gun

Description
Calibrate is used in spot welding to calibrate the distance between the gun tips
for servo guns. This is necessary after tip change or tool change and it is
recommended after welding of a number of spots or performing a tip dress.
Calibrate will also update the tip wear data in the used gundata. NB The gun
performs two non-synchronized close/open movements during the calibration. The
open distance after the calibration is finish will be the same as before the calibration
started.
If the option Spot Servo Equalizing is installed there are additional error
handling included for lost tips when a TipChg calibration is done and supervision
of the tip wear when a Tip-Wear calibration is done.

Example
Calibrate gun1\ TipChange;
• The gun gun1 is calibrated after TipChange.
• The parameter gun1 is a num corresponding to the used gun equipment. All
gun equipment used are defined in the gundata array curr_gundata in
SWUSER.
• The data curr_tip_wear in curr_gundata will be automatically set to
zero.
For more information about tip management, see Tip management on page 200.

Arguments
Calibrate GunNo [\GunD] [\TipChg] | [\ToolChg] | [\TipWear] [\RetTipWear] |
[\RetPosAdj] | [\PrePos]

GunNo
Data type: num
Used gun equipment number. Corresponding to the element number in the gundata
array curr_gundata located in the SWUSER.SYS module . See SWUSER on
page 158.

[\GunD]
Data type: gundata
Used gun equipment data for the process, see gundata - Equipment specific weld
data on page 135.
Can be used if external gundata is required. If used the external gundata will be
temporary stored in the curr_gundata array during the process.

[\TipChg]
Data type: switch
Calibration type. This calibration type is used after tip change.
The gun will close and open two times. The first close movement will be slow to
find the unknown contact position. The total tip wear is reset to zero.

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4.1.5 Calibrate - Calibrate a servo gun
Continued

If the option Spot Servo Equalizing is selected the difference since last
calibration will be supervised. If the difference since the last calibration exceeds
the supervision value in the Tip change supervision value an error will be
raised. See The type Spot Gun Equipment on page 31.
For more information about tip management, see Tip management on page 200,
Tip wear compensation on page 180, MeasureWearL - Measure current electrode
wear and recalculate the TCP on page 118 or the ReCalcTCP - Calculate current
electrode wear and recalculate the TCP on page 126.

[\ToolChg]
Data type: switch
Calibration type. This calibration type is used after tool change.
The gun will close and open two times. The first close movement will be slow to
find the unknown contact position. The total tip wear will remain unchanged.

[\TipWear]
Data type: switch
Calibration type. This calibration type is used to update the tip wear and adjust the
contact position after tip dress or after welding a number of spots.
The gun will close and open fast two times. The total tip wear is updated.
If the option Spot Servo Equalizing is selected the difference since last
calibration will be supervised. If the difference since the last calibration exceeds
the supervision value in the Tip wear supervision value an error will be
raised. See The type Spot Gun Equipment on page 31.
For more information about tip management, see Tip management on page 200,
Tip wear compensation on page 180, MeasureWearL - Measure current electrode
wear and recalculate the TCP on page 118 or the ReCalcTCP - Calculate current
electrode wear and recalculate the TCP on page 126.

[\RetTipWear]
Data type: num
The achieved tip wear [mm].

[\RetPosAdj]
Data type: num
The positional adjustment since the last calibration [mm].

[\PrePos]
Data type: num
The position to move with high speed to before search for contact position with
slower speed is started [mm].

Program execution
Internal sequence when a Calibrate instruction is executed:
• The gun will close and open two times during the robot movement. Different
tip speeds depending on selected calibration type.

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4.1.5 Calibrate - Calibrate a servo gun
Continued

• The gun is opened to the previous position.

• For certain calibration types: curr_tip_wear in the array curr_gundata
in SWUSER is updated and saved.

Positional adjustment
The optional argument RetPosAdj can be used to detect if for example the tips
are lost after a tip change. The parameter will hold the value of the positional
adjustment since the last calibration. The value can be negative or positive.
If the option Spot Servo Equalizing is selected this value will be used to
calculate the difference since last calibration and supervise the tips when calibrating.

Using a pre position

In order to speed up the calibration, it is possible to define a pre position.When
the calibration starts, the gun arm will be run fast to the pre position, stop and then
continue slowly forward in order to detect the tip contact position. A pre position
will be ignored if it is larger than the current gun position (in order not to slow down
the calibration).

Error handling
Instruction parameter supervision
The error occurs when Calibrate is called with faulty parameters or if no
calibration type switch is programmed. The program stops with error text.
The parameter must be changed. When the program is restarted the current
instruction is restarted from the beginning.

Tip change supervision

If the calculated difference to the last calibration of the gun exceeds the supervision
value defined in the configuration data Tip change supervision value an
error will be raised and the program execution will be stopped. This error can occur
for example after tip change and when Calibrate ... \TipChg is called with
wrong (too large or too small) tips. The program stops with error message. See
The type Spot Gun Equipment on page 31.
This error handling only exists for the Spot Servo Equalizing option.
For more information about tip management, see Tip management on page 200.

Tip wear supervision

If the calculated difference to the last calibration of the gun exceeds the supervision
value defined in the configuration data Tip wear supervision value an error
will be raised and the program execution will be stopped. This error can occur for
example after tip dressing when Calibrate ... \Tip- Wear is called with badly dressed
tips. The program stops with error message. See The type Spot Gun Equipment
on page 31.
This error handling only exists for the Spot Servo Equalizing option.
For more information about tip management, see Tip management on page 200.

Continues on next page

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4.1.5 Calibrate - Calibrate a servo gun
Continued

Syntax
Calibrate
[ GunNo ':='] < expression (IN) of num >
[ '\' GunD ':='] < persistent(PERS) of gundata > ]
[ \TipChg]
| [\ToolChg]
| [\TipWear]
[ '\' RetTipWear ':=' < variable or persistent(INOUT) of num >
]
[ '\' RetPosAdj ':=' < variable or persistent(INOUT) of num > ]
[ '\' PrePos ':=' < variable or persistent(IN) of num > ] ';'

Related information

Described in:
Overview Spot Servo Introduction to RobotWare Spot on page 15
Servo gun introduction Servo gun motion control on page 195
Calibration with movement Servo gun motion control on page 195
Software Equalizing Software Equalizing on page 169
Setup data for Software Equalizing The type Spot SoftWare Equalizing on
page 39

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4 RAPID references
4.1.6 MeasureWearL - Measure current electrode wear and recalculate the TCP

4.1.6 MeasureWearL - Measure current electrode wear and recalculate the TCP

Description
MeasureWearL is used in spot welding to measure current electrode wear for the
tip on the fixed electrode. This can be done with or without external measurement
equipment, and without manual interaction. The TCP is automatically recalculated
after the measurement. The instruction also updates tip wear data in the used
gundata.
When the gun is held by the robot the gun performs a search movement during
the measurement. The gun is moving in the z-direction, in the tool coordinate
system, until the fixed electrode touches a fixed reference plate or a sensor of
some sort, e.g. BullsEye.
This instruction can be used also for stationary guns. In this case the robot moves
the gripper and the work object until a reference position on the gripper is touching
the tip on the fixed electrode.
This instruction is only available if the Spot Servo Equalizing configuration
is installed.

Example
In this example the gun is held by the robot. The principles are the same also when
stationary guns are used.

xx1200000206

Measurement preparation
The measurement instruction is executed with a reference tip with an accurate
TCP (tooldata in this example: ref_tool1). This reference measurement has to
be done before the tip wear measuring is performed the first time. Also each time
when the TCP for this gun is changed for some reason or if the reference plate or
sensor is dislocated for some reason.
Running the instruction Calibrate\TipChg after the MeasureWearL will also
reset the total wear of the tips curr_tip_wear in curr_gundata and check the
difference since the last calibration.
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4.1.6 MeasureWearL - Measure current electrode wear and recalculate the TCP
Continued

Program example for reference measurement:

MoveJ p1,v1000,z50,ref_tool1;
MeasureWearL p2,v1000,gun1\Reference,ref_tool1;
tool1 := ref_tool1;
! tool1 is then used during the production
MoveL p1,v1000,z50,tool1;
Calibrate gun1\TipChg;
When the MeasureWearL instruction with the optional argument \Reference is
executed, first a linear movement to a position about 10 mm outside p2 is done.
Then the gun is moved in the z direction in the tool coordinate system until the
fixed tip touches the reference plate. During this reference measurement the
reference plate is touched twice. When the measurement is ready some reference
data is stored, tw_ref_tool and tw_ref_dist in SWUSER.
The parameter gun1 is a num corresponding to the used gun equipment. All gun
equipment used are defined in the gundata array curr_gundata in SWUSER.

Tip

To verify if the selected measuring position or gun orientation is good enough a

service routine is available; ManualCheckMeasPos. Run this routine is run in
the selected position and status information will be presented on the FlexPendant
whether the position is suitable or not. See Manual actions on page 74

Measurement after tip wear

When it is time to compensate for current tip wear, probably after each tip dressing,
the following instruction sequence should be executed:
Program example for tipwear measurement:
MoveJ p1,v1000,z50,tool1;
MeasureWearL p2,v1000,gun1\TipWear,tool1;
MoveL p1,v1000,z50,tool1;
Calibrate gun1\TipWear;
When the instruction with the optional argument TipWear is executed, a search
movement to the reference plate or sensor is performed and the tip wear of the
fixed electrode is measured. The TCP in the used tooldata tool1 is then recalculated
and the data curr_wear_fix in curr_gundata is automatically updated.
Running the instruction Calibrate\TipWear after the MeasureWearL will also
update the total wear of the tips curr_tip_wear in curr_gundata and check
the difference since the last calibration.

Measurement after tip change (with or without tip dressing)

In the first measurement after tip change a similar sequence can be used as after
tip wear. In this case the optional argument \TipChange has to be used.
Program example for tip change measurement:
MoveJ p1,v1000,z50,tool1;
MeasureWearL p2,v1000,gun1\TipChange,tool1;
MoveL p1,v1000,z5,tool1;
Calibrate gun1\TipChg;

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4.1.6 MeasureWearL - Measure current electrode wear and recalculate the TCP
Continued

When the instruction with the optional argument TipChange is executed, similar
movements as above are performed and the tip wear of the fixed electrode is
measured. The TCP in the used tooldata tool1 is then recalculated and the data
curr_wear_fix in curr_gundata is automatically updated. This is the same
functionality as after tip wear above. Only some extra error handling is done
internally.
Running the instruction Calibrate\TipChg after the MeasureWearL will also
reset the total wear of the tips curr_tip_wear in curr_gundata and check the
difference since the last calibration. See SWUSER on page 158

Note

It is important that p2 is the same position in all cases above. If this position is
modified a new reference or reference changed measurement has to be done.

Measurement after reference plate/sensor changed

This mode can be used when the TCP for this gun is changed for some reason or
if the reference plate or sensor is dislocated for some reason.
Program example for reference changed measurement:
MoveJ p1,v1000,z50,ref_tool1;
MeasureWearL p2,v1000,gun1\RefChange,ref_tool1;
MoveL p1,v1000,z50,tool1;
When the MeasureWearL instruction with the optional argument \RefChange is
executed, first a linear movement to a position about 10 mm outside p2 is done.
Then the gun is moved in the z direction in the tool coordinate system until the
fixed tip touches the reference plate. During this reference measurement the
reference plate is touched twice. When the measurement is ready some reference
data is stored, tw_ref_dist in the SWUSER.SYS module.
The parameter gun1 is a num corresponding to the used gun equipment. All gun
equipment used are defined in the gundata array curr_gundata in the
SWUSER.SYS module. See SWUSER on page 158.

Tip

To verify if the selected measuring position or gun orientation is good enough a

service routine is available; ManualCheckMeasPos. Run this routine is run in
the selected position and status information will be presented on the FlexPendant
whether the position is suitable or not. See Manual actions on page 74

Arguments
MeasureWearL ToPoint Speed GunNo [\GunD] [\Reference] | [\TipWear] |
[\TipChange] | [\RefChange] [\SSearch], Tool [\WObj] [\TLoad]

ToPoint
Data type: robtarget

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4.1.6 MeasureWearL - Measure current electrode wear and recalculate the TCP
Continued

The destination point for the robot and additional axes. This position should be a
point close to the reference position, see figure in the example above. If this position
is modified a new reference measurement has to be done.

Speed
Data type: speeddata
The speed data that applies to movements. Speed data defines the velocity for the
tool center point, the tool reorientation and additional axes.

GunNo
Data type: num
Used gun equipment number. Corresponding to the element number in the gundata
array curr_gundata located in the SWUSER.SYS module. See SWUSER on page 158.

[\GunD]
Data type: gundata
Used gun equipment data for the process, see gundata - Equipment specific weld
data on page 135.
Can be used if external gundata is required. If used the external gundata will be
temporary stored in the curr_gundata array during the process.

[\Reference]
(reference measurement)
Data type: switch
Measurement type. This calibration type is used for the reference measurement
with a reference tip with a well known TCP.
This measurement has to be done before the tip wear measuring is done the first
time and each time when the TCP for this gun (with the reference tip mounted) is
changed. It has also to be done if the reference plate (or reference position when
a stationary gun is used) is dislocated of any reason.
If the reference plate is moved the switch \RefChange can be used instead.
Fore more information abot tip management, see Tip wear compensation on
page 180.

[\TipWear]
(tip wear measurement)
Data type: switch
Measurement type. This measurement type is used when it is time to compensate
for current tip wear, probably after each tip dressing. The data curr_wear_fix
in curr_gundata will be automatically updated and the TCP in the used tooldata
is recalculated.
For more information about tip management, see Tip management on page 200 and
Tip wear compensation on page 180.

[\TipChange]
(tip change measurement)
Data type: switch

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4.1.6 MeasureWearL - Measure current electrode wear and recalculate the TCP
Continued

Measurement type. This measurement type is used in the first measurement after
tip change. The data curr_wear_fix in curr_gundata will be automatically
updated and the TCP in the used tooldata is recalculated.
For more information about tip management, see Tip management on page 200 and
Tip wear compensation on page 180.

[\RefChange]
(reference changed measurement)
Data type: switch
Measurement type. This calibration type is used if the reference plate (or reference
position when a stationary gun is used) is dislocated of any reason.
The reference tool tw_ref_tool in SWUSER module will not be updated if this
calibration type is used.

[\SSearch]
(signal/sensor search)
Data type: switch
Measurement method. If this switch is used, the search will be done against a
sensor signal instead of a fixed reference surface.
The required I/O signal that should be used is defined in the process configuration,
see The type Spot Gun Equipment on page 31.

Tool
Data type: tooldata
The tool in use when the robot moves. The tool center point (TCP) is the point
moved to the specified destination position, and should for a spot weld gun be the
position on the tip of the fixed electrode.

Note

The TCP is automatically recalculated and changed when the optional argument
\TipWear or \TipChange is used.

[\WObj]
Data type: wobjdata
The work object (coordinate system) to which the robot position in the instruction
is related.
This argument can be omitted, and if it is, the position is related to the world
coordinate system. If, on the other hand, a stationary gun is used, this argument
must be specified in order to perform a linear movement relative to the work object.

[\TLoad]
Data type: loaddata
The \TLoad argument describes the total load used in the movement. The total
load is the tool load together with the payload that the tool is carrying. If the \TLoad
argument is used, then the loaddata in the current tooldata is not considered.

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4.1.6 MeasureWearL - Measure current electrode wear and recalculate the TCP
Continued

If the \TLoad argument is set to load0, then the \TLoad argument is not considered
and the loaddata in the current tooldata is used instead. For a complete description
of the TLoad argument, see MoveL.

Program execution
Internal sequence when a MeasureWearL instruction is executed:
1 The robot starts the movement to the destination position.
2 When the destination position is reached the search movements to the
reference position or sensor is started.
3 If using the reference position search method the fixed tip will touch the
reference position with a predefined pressure, this force can be modified by
changing the setup data MeasureWearL TouchUp force in the process
configuration. See The type Spot SoftWare Equalizing on page 39.
4 If the optional argument \Reference is used: Some reference data is stored
in the user module swuser.sys, tw_ref_tool and tw_ref_dist.
5 If the optional argument \TipWear or \TipChange is used: The TCP in the
used tooldata is recalculated and the data curr_wear_fix in curr_gundata
is updated.

Instruction by instruction execution

Forward As during continuous execution.

Backward The motion is performed backwards to the destination position, but no meas-
urement is activated.

Error handling
Following error situations are handled:
• If the search distance after tip wear measurement or measurement after tip
change differs a lot from expected (for example missed tip). It is possible to
change the tip change and tip wear supervision limit values, see The type
Spot Gun Equipment on page 31.
• If the search sequence is interrupted by for example a Stop or Emergency
Stop then the search sequence is automatically restarted from the beginning
at program restart.

Limitations
About how to place the fixed reference plate:
The reference plate can be mounted in an optional position in the work range, but
it is necessary to orient the tool in the measuring position in that way that an

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4.1.6 MeasureWearL - Measure current electrode wear and recalculate the TCP
Continued

additional torque is generated on at least one of the robot motors when the robot
is touching the reference position, preferably axis 4 to 6.

Note

When using the reference plate search method there are occasions when the
MeasureWearL is less suitable, for example very large guns and/or when an
acceptable touchup position is not possible to reach for some reason (poor
position). Then the ReCalcTCP method should be used instead.

Note

When using the sensor search method (\SSearch) a fast I/O response is critical
for a good performance. A slow or inconsistent I/O response can give poor
accuracy.

Note

It is only possible to run this instruction in semi coordinated mode.

Syntax
MeasureWearL
[ ToPoint ':=' ] < expression (IN) of robtarget > ','
[ Speed ':=' ] < expression (IN) of speeddata > ','
[ GunNo ':=' ] < expression (IN) of num >
[ '\' GunD ':='] < persistent(PERS) of gundata > ]
[ \Reference] | [\TipWear] | [\TipChange] | [\RefChange]
[ '\' SSearch ] ','
[ Tool ':=' ] < persistent (PERS) of tooldata > ]
[ '\' WObj ':=' < persistent (PERS) of wobjdata > ]
[ '\' TLoad':=' ] < persistent (PERS) of loaddata > ] ';'

Related information

Described in:
Definition of velocity, speeddata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of tool, tooldata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of work objects, wobjdata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
MoveL Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Definition of load data, loaddata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
Overview Spot options Introduction to RobotWare Spot on page 15
System module SWUSER SWUSER on page 158
Definition of gundata gundata - Equipment specific weld data on
page 135

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4.1.6 MeasureWearL - Measure current electrode wear and recalculate the TCP
Continued

Described in:
Software Equalizing The type Spot SoftWare Equalizing on
page 39

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4 RAPID references
4.1.7 ReCalcTCP - Calculate current electrode wear and recalculate the TCP

4.1.7 ReCalcTCP - Calculate current electrode wear and recalculate the TCP

Description
ReCalcTCP is used in spot welding to calculate current electrode wear for the tip
on the fixed electrode and then recalculate the used TCP to compensate for current
tip wear. The calculation is based on stored information about the total tip wear
and about the expected tip wear ratio, the wear of the fixed tip related to the total
tip wear. The instruction also updates tip wear data in the used gundata.
This instruction can be used also for stationary guns.
This instruction is only available if the Spot Servo Equalizing option is installed.

Example
In this example the gun can be hold by the robot or stationary. The principles are
the same also when stationary guns are used.

Preparation
First the expected relation between the tip wear of the fixed tip and the total tip
wear must be established, the data Tip wear ratio, fixed vs total wear
in the process configuration must be set to a relevant value. For example 50, the
wear of the fixed tip is 50% of the total wear. See The type Spot Gun Equipment
on page 31.
This instruction has to be executed with the \Reference switch activated before
it is used for tip wear compensation the first time. This also has to be done when
the TCP for this gun, with new tips mounted, is changed for some reason. The TCP
in the tooldata parameter, ref_tool1 in this example, has to be valid for gun1
with new tips with the same size mounted.
ReCalcTCP gun1\Reference,ref_tool1;
tool1 := ref_tool1;
! tool1 is then used during the production.
When the ReCalcTCP instruction with the optional argument \Reference is
executed some reference data (the tooldata ref_tool1) is stored internally in
the user module swuser.sys. See Data on page 159.
The parameter gun1 is a num corresponding to the used gun equipment. All gun
equipment used are defined in the gundata array curr_gundata located in the
SWUSER module.

Compensation after tip wear

When it is time to compensate for tip wear, after each tip dressing, the ReCalcTCP
instruction should be executed with the \TipWear switch activated. This has to
be done after the gun calibration, since the total tip wear is updated during the
calibration and used when executing ReCalcTCP.
Calibrate gun1\TipWear;(CalibL/J can also be used)
ReCalcTCP gun1\TipWear,tool1;
When the ReCalcTCP instruction with the optional argument \TipWear is executed,
the TCP in the used tooldata (tool1 in this example) is recalculated and the data
curr_wear_fix in curr_gundata is automatically updated. The data

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4.1.7 ReCalcTCP - Calculate current electrode wear and recalculate the TCP
Continued

curr_tip_wear and in gundata and the Tip wear ratio, fixed vs total
wear in the process configuration is used for the calculations. See The type Spot
Gun Equipment on page 31.

Reset the TCP after tip change

After the tips has been replaced with new ones, the instruction has to be executed,
with the \TipChange switch activated.
Calibrate gun1\TipChange;
ReCalcTCP gun1\TipChange,tool1;
When the ReCalcTCP instruction with the optional argument \TipChange is
executed, the TCP in the used tooldata, tool1, is set to the value used for new tips
and the data curr_wear_fix in curr_gundata is cleared.

Arguments
ReCalcTCP GunNo [\GunD] [\Reference] | [\TipWear] | [\TipChange] Tool

GunNo
Data type: num
Used gun equipment number. Corresponding to the element number in the gundata
array curr_gundata located in the SWUSER.SYS module. See SWUSER on page 158.

[\GunD]
Data type: gundata
Used gun equipment data for the process, see gundata - Equipment specific weld
data on page 135.
Can be used if external gundata is required. If used the external gundata will be
temporary stored in the curr_gundata array during the process.

[\Reference]
Data type: switch
This switch is used for preparation of the calculations.This preparation has to be
done before the tip wear compensation is done the first time and also each time
the TCP for this gun (with new tips mounted) is changed.
The TCP in tooldata has to be valid for a gun with new tips mounted.
Fore more information abot tip managemant, see Tip wear compensation on
page 180.

[\TipWear]
Data type: switch
This switch is used when it is time to compensate for current tip wear, probably
after the gun calibration after each tip dressing. The data curr_wear_fix in
curr_gundata will be automatically updated and the TCP in the used tooldata is
recalculated. See Additional components for Spot Servo Equalizing on page 136.
For more information about tip management, see Tip management on page 200 and
Tip wear compensation on page 180.

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4.1.7 ReCalcTCP - Calculate current electrode wear and recalculate the TCP
Continued

[\TipChange]
Data type: switch
This switch is used when the instruction is executed after tip change. The data
curr_wear_fix in curr_gundata is cleared and the TCP in the used tooldata
is set to the value valid for new tips. See Additional components for Spot Servo
Equalizing on page 136.
For more information about tip management, see Tip management on page 200 and
Tip wear compensation on page 180.

Tool
Data type: tooldata
Tooldata for the used gun. The tool center point (TCP) should for a spot weld gun
be the tip position for the fixed electrode tip.

Note

The TCP in current tooldata is automatically recalculated and changed when

the optional argument \TipWear or \TipChange is used.

Program execution
Internal sequence when a ReCalcTCP instruction is executed:
• If the optional argument \Reference is used: Some reference data is stored
internally.
• If the optional argument \TipWear is used: The TCP in the used tooldata is
recalculated and the data curr_wear_fix in curr_gundata is updated.
• If the optional argument \TipChange is used: The TCP in the used tooldata
is set to a value valid for new tips and the data curr_wear_fix in
curr_gundata is cleared.

Error handling
Following error situations are handled:
• If the calculated tip wear differ a lot from expected (for example missed tip
or wrong sized tip). It is possible to change the tip wear supervision limit
value if needed, see The type Spot Gun Equipment on page 31.

Syntax
ReCalcTCP
[ GunNo ':='] < expression (IN) of num >
[ '\' GunD ':='] < persistent(PERS) of gundata > ]
[ \Reference] | [\TipWear] | [\TipChange]
[ Tool ':=' (PERS) of tooldata > ';'

Related information

Described in:
Definition of gun data, gundata gundata - Equipment specific weld data on
page 135

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4.1.7 ReCalcTCP - Calculate current electrode wear and recalculate the TCP
Continued

Described in:
Overview Spot options Introduction to RobotWare Spot on page 15
System module SWUSER SWUSER on page 158
Software Equalizing The type Spot SoftWare Equalizing on
page 39

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4 RAPID references
4.1.8 IndGunMove - Activates independent mode for a servo gun

4.1.8 IndGunMove - Activates independent mode for a servo gun

Description
IndGunMove (Independent Gun Movement) is used to set the gun in independent
mode and thereafter move the gun to a specified independent position. The gun
will stay in independent mode until the instruction IndGunMoveReset is executed.
During independent mode, the control of the servo gun is separated from the robot.
The gun can be closed, opened, calibrated or moved to a new independent position,
but it will not follow coordinated robot movements.
It is also possible to set the gun in independent mode from a background task
while the robot in the main task can continue with for example move instructions.
For more information of how to set the gun in independent mode, see Technical
reference manual - RAPID Instructions, Functions and Data types.

Example
PROC tipdress()
! Note that the gun will move to current robtarget position, if
already in independent mode.
IndGunMoveReset gun1;
.......
.......
.......
IndGunMove gun1, 30;
......
SetForce gun1, force10;
......
IndGunMoveReset gun1;
ENDPROC
Independent mode is activated and the gun is moved to an independent position
(30 mm). During independent mode the instruction SetForce is executed, without
interfering with robot motion. The instruction IndGunMoveReset will take the gun
out of independent mode and move the gun to current robtarget position.

xx1200000207

The position p1 depends on the position of the gun given in the robtarget just
performed by the robot.

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4.1.8 IndGunMove - Activates independent mode for a servo gun
Continued

Arguments
IndGunMove GunNo [\GunD] GunPos

GunNo
Data type: num
Used gun equipment number. Corresponding to the element number in the gundata
array curr_gundata located in the SWUSER.SYS module. See SWUSER on page 158

[\GunD]
Data type: gundata
Used gun equipment data for the process, see gundata - Equipment specific weld
data on page 135.
Can be used if external gundata is required. If used the external gundata will be
temporary stored in the curr_gundata array during the process.

GunPos
Data type: num
The position (stroke) of the servo gun in mm.

Program execution
The instruction activates independent mode and moves the gun from the
coordinated position to a specified independent position. During the independent
mode the gun may be closed, opened, calibrated or moved to a new independent
position without interfering with robot motion.
Program restart during independent mode will always start with a regain movement
to the current independent position.
The gun will recover independent mode after a system restart. Moving the program
pointer will NOT reset independent mode. When the program is started, no regain
movement will occur but the gun will return to independent mode after the first gun
closing or calibration.

Limitations
It is not possible to use this instruction is used in combination with spot instructions
when Spot Servo Equalizing is activated.

Syntax
IndGunMove
[ GunNo ':=' <expression (IN) of num> ]
[ '\' GunD ':='] < persistent(PERS) of gundata > ] ','
[ GunPos ':=' <expression (IN) of num> ] ';'

Related information

Described in:
SetForce SetForce - Close and Open a gun with de-
sired force and time on page 104
STIndGun Technical reference manual - RAPID Instruc-
tions, Functions and Data types

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4 RAPID references
4.1.9 IndGunMoveReset - Resets servo gun from independent mode

4.1.9 IndGunMoveReset - Resets servo gun from independent mode

Description
IndGunMoveReset (Independent Gun Movement Reset) is used to reset the gun
from independent mode and thereafter move the gun to current robtarget position.

Example
IndGunMoveReset gun1;

Arguments
IndGunMoveReset GunNo [\GunD]

GunNo
Data type: num
Used gun equipment number. Corresponding to the element number in the gundata
array curr_gundata located in the SWUSER.SYS module. The gun was previously
set independent with the instruction IndGunMove.

[\GunD]
Data type: gundata
Used gun equipment data for the process, see gundata - Equipment specific weld
data on page 135.
Can be used if external gundata is required. If used the external gundata will be
temporary stored in the curr_gundata array during the process.

Program execution
The instruction will reset the gun from independent mode and move the gun to
current robtarget position. During this movement the coordinated speed of the gun
must be zero, otherwise an error will occur. The coordinated speed will be zero if
the robot is standing still or if the current robot movement includes a "zero
movement" of the gun.

Syntax
IndGunMove
[ GunNo ':=' <expression (IN) of num> ]
[ '\' GunD ':='] < persistent(PERS) of gundata > ] ';'

Related information

Described in:
Definition of gundata gundata - Equipment specific weld data on
page 135

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 4 RAPID references
4.1.10 OpenHighLift/CloseHighLift - Control the position of a pneumatic gun

4.1.10 OpenHighLift/CloseHighLift - Control the position of a pneumatic gun

Description
OpenHighLift is used in spot welding to open a pneumatic gun to the highlift
position (large gap).
CloseHighLift is used in spot welding to close a pneumatic gun to the work
stroke position (small gap).

Example
OpenHighLift, gun1;
• The gun gun1 is opened to the highlift position.
CloseHighLift, gun1;
• The gun gun1 is closed to the work stroke position.
The parameter gun1 is a num corresponding to the used gun equipment. All gun
equipment used are defined in the gundata array curr_gundata in SWUSER.

Arguments
OpenHighLift GunNo [\GunD]
CloseHighLift GunNo [\GunD]

GunNo
Data type: num
Used gun equipment number. Corresponding to the element number in the gundata
array curr_gundata in SWUSER.

[\GunD]
Data type: gundata
Used gun equipment data for the process, see gundata - Equipment specific weld
data on page 135.
Can be used if external gundata is required. If used the external gundata will be
temporary stored in the curr_gundata array during the process.

Program execution
Internal sequence when a OpenHighLift instruction is executed:
• The inhibit_close is simulated.
• The user routine SwInitUserIO is executed.
• The user routine SwOpenGun is executed and the gun is opened to the highlift
position.
Internal sequence when a CloseHighLift instruction is executed:
• The inhibit_close is simulated.
• The user routine SwInitUserIO is executed.
• The user routine SwCloseGun is executed and the gun is closed to the work
stroke position.

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4.1.10 OpenHighLift/CloseHighLift - Control the position of a pneumatic gun
Continued

Instruction by instruction execution

Forward As during continuous execution.

Backward As during continuous execution.

Error handling
No error handling.

Syntax
OpenHighLift or CloseHighLift
[ GunNo ':='] < expression (IN) of num >
[ '\' GunD ':='] < persistent(PERS) of gundata > ] ';'

Related information

Described in:
Overview Spot Servo Introduction to RobotWare Spot on page 15

134 Application manual - Spot options

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 4 RAPID references
4.2.1 gundata - Equipment specific weld data

4.2 Data types

4.2.1 gundata - Equipment specific weld data

Description
Gundata is used to define spot weld equipment specific data, to control the gun
in an optimal way in the weld process when the spot instructions are used. Each
gundata defines one gun equipment.

Note

The gundata structure and order of parameters differs between different spot
options.
Gundata has the following default structure when servo guns are used:
• Gun name
• Weld counter and a max value.
• Current tip wear and a max value.
• Specific parameters for the Software Equalizing functions. (Only if Spot Servo
Equalizing is installed.)
Gundata has the following default structure when pneumatic guns are used:
• Gun name
• Weld counter and a max value.

Components
gun_name
(gun name)
Data type: string
The name of the mechanical unit used for the servo gun. This name must be
identical with the name of the mechanical unit defined in the motion servo gun
parameters.
Normally the gun name will be updated automatically at startup. A service routine
is available to search the system for servo guns and update the gun name,
ManualGunSearch, see Manual actions on page 74.

weld_counter
(weld counter)
Data type: num
Counter for the number of welds done with this gun. The counter is automatically
incremented after process is ready. Use of this data is optional. Zero set shall be
handled by the user program.

max_nof_welds
(max number of welds)
Data type: num

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4.2.1 gundata - Equipment specific weld data
Continued

Max number of performed welds. Use of this data is optional.

curr_tip_wear
(current tip wear)
Data type: num
Current tip wear [mm]. This data is automatically updated after each gun calibration.
Use of this data is optional. (Servo guns only).

max_tip_wear
(max tip wear)
Data type: num
Max allowed tip wear before tip exchange [mm]. Use of this data is optional. (Servo
guns only).

Additional components for Spot Servo Equalizing

curr_wear_fix
(current tip wear for the fixed tip)
Data type: num
Current tip wear for the fixed gun electrode tip [mm]. This data is automatically
updated when MeasureWearL or ReCalcTCP is used.

wear_moveable
(current tip wear for the moveable tip)
Data type: num
Current tip wear for the moveable gun electrode tip [mm]. This data is automatically
updated when CalibL/J and Calibrate is used.

release_dist
(release distance)
Data type: num
The release distance [mm] when the robot is moving between weld positions during
normal program execution and during Weld position Touch Up.

deflection_dist_z
(deflection distance in z-direction)
Data type: num
TCP deviation [mm] in z-direction caused of gun arm deflection when the gun is
closed with the force specified in deflection_force. This data is used for the
deflection compensation movement of the robot. Default value 0 mm.

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4.2.1 gundata - Equipment specific weld data
Continued

Only positive values are allowed, the Opposite z-direction parameter

determines the direction for the deflection compensation. See The type Spot Gun
Equipment on page 31.

Note

This parameter can also be configured via system parameters, see System
Parameters, Topic Motion and Type SG Process, Technical reference
manual - System parameters.
In this case this parameter has to be removed, see How to change the Spot data
types on page 255.

deflection_dist_x
(deflection distance in x-direction)
Data type: num
TCP deviation [mm] in x-direction caused of gun arm deflection when the gun is
closed with the force specified in deflection_force. This data is used for the
deflection compensation of the robot. Default value 0mm.
This value can be both positive and negative depending on which direction the
deflection compensation shall be performed.
Example: If the gun bends outwards 2mm (positive x), this value should be set to
2mm.

Note

This parameter can also be configured via system parameters, see System
Parameters, Topic Motion and Type SG Process, Technical reference
manual - System parameters.
In this case this parameter has to be removed, see How to change the Spot data
types on page 255.

deflection_force
(deflection force)
Data type: num
Applied force [N] corresponding to the TCP deviation deflection_dist_
parameters caused of gun arm deflection. This data is used for the deflection
compensation.

Note

This parameter can also be configured via system parameters, see System
Parameters, Topic Motion and Type SG Process, Technical reference
manual - System parameters.
In this case this parameter has to be removed, see How to change the Spot data
types on page 255.

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4.2.1 gundata - Equipment specific weld data
Continued

deflection_time
(deflection time)
Data type: num
The time for the gun to build up the gun force [s]. This data is used for the deflection
compensation. If no data information exists, use the default value (0.1 s).

Note

This parameter can also be configured via system parameters, see System
Parameters, Topic Motion and Type SG Process, Technical reference
manual - System parameters.
In this case this parameter has to be removed, see How to change the Spot data
types on page 255.

Default structure
For servo guns if Spot Servo is installed:
<dataobject of gundata>
<gun_name of num>
<weld_counter of num>
<max_nof_welds of num>
<curr_tip_wear of num>
<max_tip_wear of num>
For servo guns if Spot Servo Equalizing is installed:
<dataobject of gundata>
<gun_name of num>
<weld_counter of num>
<max_nof_welds of num>
<curr_tip_wear of num>
<max_tip_wear of num>
<curr_wear_fix of num>
<wear_moveable of num>
<release_dist of num>
<deflection_dist_z of num>
<deflection_dist_x of num>
<deflection_force of num>
<deflection_time of num>
For pneumatic guns:
<dataobject of gundata>
<gun_name of num>
<weld_counter of num>
<max_nof_welds of num>

Predefined data
For servo guns if Spot Servo is installed:
PERS gundata curr_gundata{4} :=
[["SGUN_1", 0, 1000, 0, 10],
["NOT USED", 0, 1000, 0, 10],
["NOT USED", 0, 1000, 0, 10],

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4.2.1 gundata - Equipment specific weld data
Continued

["NOT USED", 0, 1000, 0, 10]];

For servo guns if Spot Servo Equalizing is installed:
PERS gundata curr_gundata{4} :=
[["SGUN_1",0,1000,0,10,0,0,5,0,0,5000,0.1],
["NOT USED",0,1000,0,10,0,0,5,0,0,5000,0.1],
["NOT USED",0,1000,0,10,0,0,5,0,0,5000,0.1],
["NOT USED",0,1000,0,10,0,0,5,0,0,5000,0.1]];
For pneumatic guns:
PERS gundata curr_gundata{4} :=
[["PGUN_1", 0, 1000],
["PGUN_2", 0, 1000],
["PGUN_3", 0, 1000],
["PGUN_4", 0, 1000]];
curr_gundata is an array with active gundata parameters for each used gun.
These parameters have to be changed by the user during the installation and
programming phase to be in agreement with the weld equipment in use. In the
default package, curr_gundata is defined in module SWUSER.
It is also possible to use external gundata in the spot instructions, Arguments on
page 95.

Note

The size of the gundata array may depend on the selected spot configuration,
for a single gun configuration the size of the array will be only one instance.

Customizing
The Spot package provides opportunities for the user to customize the functionality
to adapt to different types of spot weld equipment and user defined standards. For
this data type it is possible to delete components if they are not used. It is also
possible to give the components own user defined names.
However, the main subject of this description is the default setup.
See Customizing RobotWare-Spot on page 247.

Related information

Described in:
SpotL/SpotJ SpotL/SpotJ - The basic spot welding instruc-
tions on page 95
Overview Spot options Introduction to RobotWare Spot on page 15
Customizing possibilities Customizing RobotWare-Spot on page 247
Definition of spot data, spotdata Technical reference manual - RAPID Instruc-
tions, Functions and Data types
System module SWUSER SWUSER on page 158

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4 RAPID references
4.2.2 spotdata - Spot weld data

4.2.2 spotdata - Spot weld data

Description
Spotdata is used to define the parameters that control the weld equipment when
welding a certain spot.
Spotdata is used by the SpotL/J and SpotML/J instructions and contains data
which controls the welding of one spot.
Spotdata has the following default structure when servo guns are used:
• Program number for the program in the weld timer to be used.
• Desired gun tip force.
• Expected total plate thickness.
Only valid for servo guns.
• Allowed variation when checking the plate thickness.
Only valid for servo guns.

Tip

It is possible to use spot data parameters programmed in the weld timer

if needed instead of the spotdata parameters, see
How to use spot data programmed in the weld timer on page 258

Components
prog_no
(program number)
Data type: dnum
Defines the internal program in the weld timer to be used for the welding. This
data will set an output group signal when a spot instruction is run.
Permitted values: 0 - to the size of the I/O group for the equipment.
Absolute max is the size of dnum, 4294967295 - 32bit.

tip_force
(gun tip force)
Data type: num
Defines the desired gun tip force. [Default - Newton], unit type can be changed via
configuration, see The type Spot System on page 23
Permitted values: -1, to the defined max gun force, see The type Spot Gun
Equipment on page 31
-1 will disable this parameter, and external timer data will be used instead, see
How to use spot data programmed in the weld timer on page 258.
If pneumatic gun is used, this value controls a group output, see The type Spot
Gun Equipment on page 31

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4.2.2 spotdata - Spot weld data
Continued

plate_thickness
(plate thickness)
Data type: num
Defines the expected total plate thickness. [mm].
Permitted values: -1, to the defined max plate thickness, see The type Spot System
on page 23.
-1 will disable this parameter, and external timer data will be used instead, see
How to use spot data programmed in the weld timer on page 258.

Note

This parameter is only valid for servo guns.

plate_tolerance
(plate tolerance)
Data type: num
Defines the allowed variation when checking the plate thickness [mm]
If the value is 0 the thickness check is deactivated.
Permitted values: -1, to the defined max plate tolerance, see The type Spot System
on page 23.
-1 will disable this parameter, and external timer data will be used instead, see
How to use spot data programmed in the weld timer on page 258.

Note

This parameter is only valid for servo guns.

Predefined data
Servo guns:
PERS spotdata spot1 := [1, 1000, 0, 0];
Pneumatic guns:
PERS spotdata spot1 := [1, 1];
Defined in module SWUSRM.
Spot1 is used as default in the first programmed Spot instruction and has following
default data:
• The program number 1 in the weld controller shall be used.
• Desired gun tip force = 1000 N. (Gun pressure level 1 for pneumatic guns).
• Expected total plate thickness = 0 mm. (Servo guns).
• Allowed variation in the thickness = 0 (thickness check is deactivated) (Servo
guns).
Servo guns:
PERS spotdata
curr_spotdata{4} := [[0,0,0,0],[0,0,0,0],[0,0,0,0],[0,0,0,0 ]];

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4.2.2 spotdata - Spot weld data
Continued

Pneumatic guns:
PERS spotdata curr_spotdata{4} := [[0,0],[0,0],[0,0],[0,0]];
Defined in module SWUSER.
curr_spotdata is an array with active or latest used spotdata parameters for
each defined gun. This parameters are automatically updated by the kernel when
spot instructions are executed. This spotdata are used for reweld situations and
if welding is manually activated (see Manual actions on page 74)

Customizing
The Spot package provides opportunities for the user to customize the functionality
to adapt to different types of spot weld equipment and user defined standards. For
this data type it is possible to delete components if they are not used. It is also
possible to give the components own user defined names.
However, the main subject of this description is the default setup.
See How to change the Spot data types on page 255.

Default structure
For servo guns:
<dataobject of spotdata>
<prog_no of dnum>
<tip_force of num>
<plate_thickness of num>
<plate_tolerance of num>
For pneumatic guns:
<dataobject of spotdata>
<prog_no of dnum>
<tip_force of num>

Related information

Described in:
SpotL/J SpotL/SpotJ - The basic spot welding instruc-
tions on page 95
Overview Spot options Introduction to RobotWare Spot on page 15
Customizing possibilities Customizing RobotWare-Spot on page 247
Definition of gun data, gundata gundata - Equipment specific weld data on
page 135
System module SWUSER SWUSER on page 158

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4.2.3 forcedata - Spot gun force data

4.2.3 forcedata - Spot gun force data

Description
Forcedata is used to define the parameters for control of the spot weld gun when
it is closed without welding, e.g. when tip dressing.
Forcedata is used when a SetForce instruction is run, or from certain manual
actions.
It has the following default structure when servo guns are used:
• Desired gun tip force.
• Desired force time.
• Expected total plate thickness. (Only valid for servo guns.)
Allowed variation when checking the plate thickness. (Only valid for servo guns.)

Components
tip_force
(gun tip force)
Data type: num
Defines the desired gun tip force [Default - Newton], unit type can be changed via
configuration, see The type Spot System on page 23
If pneumatic gun is used, this value controls a group output, see The type Spot
Gun Equipment on page 31

force_time
(gun force time)
Data type: num
Defines the desired gun force time [s].

plate_thickness
Data type: num
Defines the expected total plate thickness [mm].

Note

This parameter is only valid for servo guns.

plate_tolerance
(plate tolerance)
Data type: num
Defines the allowed variation when checking the plate thickness [mm].
If the value is 0 the thickness check is deactivated.

Note

This parameter is only valid for servo guns.

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4.2.3 forcedata - Spot gun force data
Continued

\tip_force2
(optional second gun tip force)
Data type: num
Defines the second gun tip force [Default - N]. This data can be used when a second
gun force is required. See SwSetIntForceData - Set the internal forcedata on
page 153.

\force_time2
(optional second gun force time)
Data type: num
Defines the second gun force time [s]. This data can be used when a second force
time is required. See SwSetIntForceData - Set the internal forcedata on page 153

Predefined data
Servo guns:
PERS forcedata force1 := [1000, 1, 0, 0];
Pneumatic guns:
PERS forcedata force1 := [1, 1];
Defined in module SWUSRM.
force1 is used as default in the first programmed SetForce instruction and has
following default data:
• Desired gun tip force = 1000 N.
(Gun pressure 1 for pneumatic gun)
• Desired force time = 1 s.
• Expected total plate thickness = 0 mm.
(Servo gun)
• Allowed variation in the thickness = 0 (thickness check is deactivated)
(Servo gun)
Servo guns:
PERS forcedata curr_forcedata{2} := [[0,0,0,0],[0,0,0,0]];
Pneumatic guns:
PERS forcedata curr_forcedata{2} := [[0,0],[0,0]];
Defined in module SWUSER.
curr_forcedata is an array with active or latest used forcedata parameters for
each defined gun. This parameters are automatically updated by the kernel when
a SetForce instruction is executed. The parameters are used when gun closure
is manually activated, see Manual actions on page 74.

Customizing
The Spot package provides opportunities for the user to customize the functionality
to adapt to different types of spot weld equipment and user defined standards. For
this data type it is possible to delete components if they are not used. It is also
possible to give the components own user defined names.

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4.2.3 forcedata - Spot gun force data
Continued

However, the main subject of this description is the default setup. See Customizing
RobotWare-Spot on page 247.

Default structure
For servo guns:
<dataobject of forcedata>
<tip_force of num>
<force_time of num>
<plate_thickness of num>
<plate_tolerance of num>
For pneumatic guns:
<dataobject of forcedata>
<tip_force of num>
<force_time of num>

Related information

Described in:
SetForce SetForce - Close and Open a gun with de-
sired force and time on page 104
Overview Spot options Introduction to RobotWare Spot on page 15
Customizing possibilities Customizing RobotWare-Spot on page 247
Definition of spot data, spotdata spotdata - Spot weld data on page 140
System module SWUSER SWUSER on page 158

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4.2.4 simdata - Simulation data

4.2.4 simdata - Simulation data

Description
Simdata is used to define the parameters that control the different simulation
modes used when testing spot weld programs.
Simdata has the following default structure when servo guns are used:
• Desired simulation type.
• Desired simulation time.
• If testing is performed with/without gun closure.
• If testing is performed with/without plates. (Only valid for servo guns).

Components
sim_type
(simulation type)
Data type: num
Desired simulation type. Permitted values:
0 All simulations are deactivated. (Weld mode)
1 Simulation of the weld is performed in the robot controller. (No start signal
to weld controller). Program valid check is done and timer input groups are
checked if configured.
2 Simulation of the weld is performed in the weld controller with no current.
The signal enable_current is reset.
3 Weld position Touch Up mode. Only available if Spot Servo Equalizing is
installed.

sim_time
(simulation time)
Data type: num
Defines the desired simulation time [s] when simulation of the weld is performed
in the robot controller (sim_type = 1).

inhib_close
(inhib close)
Data type: bool
Testing without closing the guns. Only relevant if sim_type = 1 or 2.

no_plates
(no plates)
Data type: bool
Testing without plates. Only relevant if sim_type = 1 or 2. If this mode is set,
the robot and gun will move to the nominal positions. The plate thickness
supervision, SoftMove Equalizing will be disabled to be able to run a cycle without
parts. (Only valid for servo guns).

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4.2.4 simdata - Simulation data
Continued

Predefined data
Servo guns:
PERS simdata data curr_simdata := [0, 0.5, FALSE, FALSE];
Pneumatic guns:
PERS simdata data curr_simdata := [0, 0.5, FALSE];
Defined in module SWUSER.
curr_simdata is holding all active simulation data. This data influences all used
weld equipment when SpotL/J or SpotML/J instructions are executed. The user
has to change this data to activate a simulation mode. All simulations are
deactivated if sim_type = 0 (default).

Customizing
The Spot package provides opportunities for the user to customize the functionality
to adapt to different types of spot weld equipment and user defined standards. For
this data type it is possible to delete components if they are not used. It is also
possible to give the components own user defined names. However, the main
subject of this description is the default setup.
See Customizing RobotWare-Spot on page 247.

Default structure
For servo guns:
<dataobject of simdata>
<sim_type of num>
<sim_time of num>
<inhib_close of bool>
<no_plates of bool>
For pneumatic guns:
<dataobject of simdata>
<sim_type of num>
<sim_time of num>
<inhib_close of bool>

Related information

Described in:
SpotL SpotL/SpotJ - The basic spot welding instruc-
tions on page 95
SpotML SpotML/SpotMJ - Spot welding with multiple
guns on page 100
Overview Spot & Spot Servo Introduction to RobotWare Spot on page 15
Customizing possibilities Customizing RobotWare-Spot on page 247
System module SWUSER SWUSER on page 158

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4.2.5 smeqdata - SoftMove Equalizing data

4.2.5 smeqdata - SoftMove Equalizing data

Description
smeqdata is used to define the parameters used to control the SoftMove function
that can be used when welding a certain spot. This data has to be used by the
SpotL/J instructions if SoftMove equalizing is required.
smeqdata has the following structure:
• Desired smeq_type of the robot for the specific position.
• Desired force_offset friction compensation for the specific position.

Components
smeq_type
(SoftMove type of the robot)
Data type: smeqtype (alias num)
Defines what SoftMove type that shall be used in the specific position, there are 2
types possible, no gun deflection mode(0), standard mode(1).
0 - No gun deflection mode: During the final robot movement to the position and
closing of the gun the robot will be set into soft state using the specified
force_offset value during the complete weld cycle.
1 - Standard mode: During the final robot movement to the position and closing
of the gun the robot will be set into soft state using the specified force_offset
value, during the weld cycle the robot will be stiff and gun arm deflection will be
used.

force_offset
(friction compensation)
Data type: num
Defines the desired force in Newton, corresponding to the static friction of the robot
in the soft z direction and the force needed to achieve a small movement to the
plate. This value must be set for each position the first time the program is executed.
If the force value is too low it will be difficult for the robot to reach the position, and
if the force value is too high the robot may damage the plate. Possible values for
this parameter are in between 0.1 and 2000 N. The friction compensation needed
will be measured for each SpotL/J instruction if the initial value is zero, see Friction
compensation procedure on page 191.

Note

The force_offset should be seen as friction force and force applied to the
plates.
Example: 100N is identified in the friction compensation procedure.
To be sure that robot will move to the plate the force_offset can be set to
130N. If the friction is constant during the movement it will be 30N applied on
the plate.

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4.2.5 smeqdata - SoftMove Equalizing data
Continued

Example
Program example with and without SoftMove Equalizing functionality:
PERS smeqdata smeq10:=[1,150];
PERS smeqdata smeq11:=[1,170];

PROC main()
MoveJ P10, v1000, z50, tool1;
SpotL P20, vmax, gun1, spot11, tool1;
SpotL P30, vmax, gun1, spot12 \SMEQ:=smeq10, tool1;
SpotL P40, vmax, gun1, spot13 \SMEQ:=smeq11, tool1;
SpotL P50, vmax, gun1, spot14, tool1;
ENDPROC

Default structure
<dataobject of smeqdata>
<smeq_type of smeqtype>
<force_offset of num>

Related information

Described in:
SpotL/J SpotL/SpotJ - The basic spot welding instruc-
tions on page 95
SoftMove Equalizing SoftMove Equalizing on page 185
SoftMove Application manual - SoftMove

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4.3.1 SwGetCurrTargetName - Get the current robtarget name

4.3 Global instructions and functions

4.3.1 SwGetCurrTargetName - Get the current robtarget name

Description
SwGetCurrTargetName can be used in the user routines to retrieve the current
robtarget name for each spot instruction.

Example
A basic example of the function SwGetCurrTargetName used in the SwPrepare
hook is illustrated below.
PROC main()
SpotL p100, vmax, gun1, spot10, tool1;
ENDPROC
PROC SwPrepare(num GunNum, string ErrText)
VAR string tmp_str;
tmp_str := SwGetCurrTargetName();
TPWrite "Current robtarget name - "+tmp_str;
ENDPROC
1 The robot executes a SpotL instruction to the position p100.
2 In the SwPrepare user hook the function SwGetCurrTargetName is called.
3 The TPWrite instruction will write "p100" on the FlexPendant.

Return value
Data type: string
If a spot instruction has been executed prior to this, the robtarget name will be
returned, otherwise an empty string will be returned.

Syntax
SwGetCurrTargetName '(' ')'
A function with a return value of the data type string.

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4.3.2 SwGetCurrSpotName - Get the current spotdata name

4.3.2 SwGetCurrSpotName - Get the current spotdata name

Description
SwGetCurrSpotName can be used in the user routines to retrieve the current
spotdata name for each spot instruction.

Example
A basic example of the function SwGetCurrSpotName used in the SwPrepare
hook is illustrated below.
PROC main()
SpotL p100, vmax, gun1, spot10, tool1;
ENDPROC
PROC SwPrepare(num GunNum, string ErrText)
VAR string tmp_str;
tmp_str := SwGetCurrSpotName();
TPWrite "Current spotdata name - "+tmp_str;
ENDPROC
1 The robot executes a SpotL instruction to the position p100.
2 In the SwPrepare user hook the function SwGetCurrSpotName are called.
3 The TPWrite instruction will write "spot10" on the FlexPendant.

Return value
Data type: string
If a spot instruction has been executed prior to this, the spotdata name will be
returned, otherwise an empty string will be returned.

Syntax
SwGetCurrSpotName '(' ')'
A function with a return value of the data type string.

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4.3.3 SwSetIntSpotData - Set the internal spotdata

4.3.3 SwSetIntSpotData - Set the internal spotdata

Description
The SwSetIntSpotData routine is used to transfer user spotdata components
to internally used spotdata components.

Example
An example of the function SwSetIntSpotData used in the DefineSpotData
routine is illustrated below.
PROC DefineSpotData(spotdata Spot, num GunNum)
SwSetIntSpotData GunNum \ProgNo:=Spot.prog_no
\TipForce:=Spot.tip_force;
ENDPROC
1 The robot executes a SpotL instruction and calls the SwSetIntSpotData
routine.
2 The internally used spotdata parameters are updated and used during the
process.

Syntax
[ GunNum ':=' ] < expression (IN) of num >
[ '\' ProgNo ':=' ] < expression (IN) of dnum >
[ '\' TipForce ':='] < expression (IN) of num > ]
[ '\' PlateThickness ':='] < expression (IN) of num > ]
[ '\' PlateTolerance ':=' ] < expression (IN) of num > ]';'

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4.3.4 SwSetIntForceData - Set the internal forcedata

4.3.4 SwSetIntForceData - Set the internal forcedata

Description
The SwSetIntForceData routine is used to transfer user forcedata components
to internally used forcedata components.

Example
An example of the function SwSetIntForceData used in the DefineForceData
routine is illustrated below.
PROC DefineForceData(forcedata Force, num GunNum)
SwSetIntForceData GunNum \TipForce:=Force.tip_force
\ForceTime:=Force.force_time
\PlateThickness:=Force.plate_thickness
\PlateTolerance:=Force.plate_tolerance;
ENDPROC
Example of the function SwSetIntForceData routine with optional force data
parameters is illustrated below.
PROC DefineForceData(forcedata Force, num GunNum)
SwSetIntForceData GunNum \TipForce:=Force.tip_force
\ForceTime:=Force.force_time
\PlateThickness:=Force.plate_thickness
\PlateTolerance:=Force.plate_tolerance
\TipForce2:=Force.tip_force2
\ForceTime2:=Force.force_time2;
ENDPROC
1 The robot executes a SetForce instruction and calls the
SwSetIntForceData routine.
2 The internally used forcedata parameters are updated and used during
the process.

Syntax
[ GunNum ':=' ] < expression (IN) of num >
[ '\' TipForce ':='] < expression (IN) of num > ]
[ '\' ForceTime ':=' ] < expression (IN) of num > ]
[ '\' PlateThickness ':='] < expression (IN) of num > ]
[ '\' PlateTolerance ':=' ] < expression (IN) of num > ]
[ '\' TipForce2 ':='] < expression (IN) of num > ]
[ '\' ForceTime2 ':=' ] < expression (IN) of num > ]';'

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4.3.5 SwSetIntGunData - Set the internal gundata

4.3.5 SwSetIntGunData - Set the internal gundata

Description
The SwSetIntGunData routine is used to transfer user gundata components to
internally used gundata components.

Example
An example of the function SwSetIntGunData used in the DefineGunData routine
is illustrated below.
PROC DefineGunData()
SwSetIntGunData GunNum \GunName:=curr_gundata{GunNum}.gun_name
\TotalTipWear:=curr_gundata{GunNum}.curr_tip_wear;
ENDPROC
1 The robot executes a SpotL instruction and calls the SwSetIntGunData
routine.
2 The internally used gundata parameters are updated and used during the
process.

Syntax
[ GunNum ':=' ] < expression (IN) of num >
[ '\' GunName ':=' ] < expression (IN) of string >
[ '\' CurrWearFix ':='] < expression (IN) of num > ]
[ '\' CurrWearMov ':='] < expression (IN) of num > ]
[ '\' TotalTipWear ':=' ] < expression (IN) of num > ]
[ '\' MaxTipWear ':=' ] < expression (IN) of num > ]
[ '\' ReleaseDist ':=' ] < expression (IN) of num > ]
[ '\' DeflectionDistZ ':=' ] < expression (IN) of num > ]
[ '\' DeflectionDistX ':=' ] < expression (IN) of num > ]
[ '\' DeflectionForce ':=' ] < expression (IN) of num > ]
[ '\' DeflectionTime ':=' ] < expression (IN) of num > ] ';'

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4.3.6 SwSetIntSimData - Set the internal simdata

4.3.6 SwSetIntSimData - Set the internal simdata

Description
The SwSetIntSimData routine is used to transfer user simdata components to
internally used simdata components.

Example
An example of the function SwSetIntSimData used in the DefineSimData routine
is illustrated below.
PROC DefineSimData()
SwSetIntSimData \SimType:=curr_simdata.sim_type
\SimTime:=curr_simdata.sim_time
\InhibGunClose:=curr_simdata.inhib_close;
ENDPROC
1 The robot executes a SpotL instruction and calls the SwSetIntSimData
routine.
2 The internally used simdata parameters are updated and used during the
process.

Syntax
[ '\' SimType ':='] < expression (IN) of num > ]
[ '\' SimTime ':=' ] < expression (IN) of num >
[ '\' InhibGunClose ':='] < expression (IN) of bool > ]
[ '\' PlatesCheck ':=' ] < expression (IN) of bool > ]';'

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4.3.7 SwGetCalibData - Get the latest total tip wear and position adjustment

4.3.7 SwGetCalibData - Get the latest total tip wear and position adjustment

Description
SwGetCalibData can be used to retrieve the current total tip wear and positional
adjustment for the specified gun after a CalibL/J or Calibrate instruction has
been run.

Example
A basic example of the routine SwGetCalibData is illustrated below.
PROC MyProc()
VAR num curr_tip_wear;
VAR num curr_pos_adj;
CalibL p10, vmax, gun1\TipChg, z50, tool1;
SwGetCalibData \CurrTipWear:=curr_tip_wear
\CurrPosAdj:=curr_pos_adj;
ENDPROC
• The robot executes a CalibL instruction to the position p10.
• The instruction SwGetCalibData are called.
• The curr_tip_wear and curr_pos_adj variables are assigned with the
return values from the CalibL instruction.

Syntax
[ GunNum ':=' ] < expression (IN) of num > ]
[ '\' CurrTipWear ':='] < expression (INOUT) of num > ]
[ '\' CurrPosAdj ':=' ] < expression (INOUT) of num > ]';'

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4.3.8 SwGetFixTipData - Get the latest fixed tip wear and position adjustment

4.3.8 SwGetFixTipData - Get the latest fixed tip wear and position adjustment

Description
SwGetFixTipData can be used to retrieve the current fixed tip wear and positional
adjustment for the specified gun after a MeasureWearL or ReCalcTCP instruction
has been run..

Example
A basic example of the routine SwGetFixTipData is illustrated below.
PROC MyProc()
VAR num curr_tip_wear;
VAR num curr_pos_adj;
ReCalcTCP gun1\TipWear, tool1;
SwGetFixTipData \CurrTipWear:=curr_tip_wear
\CurrPosAdj:=curr_pos_adj;
ENDPROC
• The robot executes a ReCalTCP instruction.
• The instruction SwGetFixTipData is called.
• The curr_tip_wear and curr_pos_adj variables are assigned with the
return values from the ReCalTCP instruction.

Syntax
[ GunNum ':=' ] < expression (IN) of num > ]
[ '\' CurrTipWear ':='] < expression (INOUT) of num > ]
[ '\' CurrPosAdj ':=' ] < expression (INOUT) of num > ]';'

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4.4.1 SWUSER

4.4 System modules

4.4.1 SWUSER

Description
The SWUSER user module is configured to run in all tasks in the system, and
contains the spot data definitions, and routines that can be used to shape the
behavior of the process, e.g add additional supervisions in the process sequence
if needed.
In normal cases there is no need to change this module. he default functionality
should be good enough in most cases. But if the default data types has to be
modified and/or additional logic has to be added in the process sequence this
module needs to be changed.
It contains process routines (hooks) (for example SwPreWeld and SwPostWeld),
and it also contains a supervision task routine where custom
functionality/supervision can be added if needed.
The process routines has no default functionality, but can easily be changed to fit
different environment/equipment in case the default process behavior is not suitable,
for example, add supervision in the process sequence.

Note

Default content depends on the spot configuration.

Note

After changing any routines in SWUSER, the following steps must be taken
before there is an effect on the application:
• Save SWUSER. The old one is overwritten.
• Generate a Reset Rapid restart to affect all tasks.

Data definitions
The following global data records are predefined.
Record data Description Default value
forcedata Definition of force data num tip_force;
num force_time;
num plate_thickness;
num plate_tolerance;
simdata Definition of simulation data num sim_type;
num sim_time;
bool inhib_close;
bool no_plates;

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4.4.1 SWUSER
Continued

Record data Description Default value

spotdata Definition of process spot dnum prog_no;
data num tip_force;
num plate_thickness;
num plate_tolerance;
gundata Definition of process gun data string gun_name;
num weld_counter;
num max_nof_welds;
num curr_tip_wear;
num max_tip_wear;
num curr_wear_fix;
num curr_wear_mov;
num release_dist;
num deflection_dist_z;
num deflection_dist_x;
num deflection_force;
num deflection_time;

Note

Some of the parameters in gundata only concerns servo guns and Software
Equalizing and depends on the selected configuration.

Data
The names are predefined and used internally when Spot instructions are used.
They must therefore not be deleted or renamed.

Global data
The following global data are predefined:
Name Declaration Description
curr_gundata{4} PERS gundata Current gun specific data for gun equipment
1 to 4.
curr_spotdata{4} PERS spotdata Current or latest used spot data for gun
equipment 1 to 4. Is automatically updated
from the instruction before the first process
hook is called. This data is used when the
manual action ManualSpot is activated.
curr_forcedata{4} PERS forcedata Current or latest used forcedata for gun
equipment 1 to 4. Is automatically updated
when the SetForce instruction are run. Is
also used when manual actions are activated
(ManualGunControl and
(ManualSetForce.
curr_simdata PERS simdata Current parameters for simulation. These
parameters have influence on all used
equipment.
tw_ref_dist{4, 2} PERS num Distance to the reference surface for the ref-
erence fixed tip. See Tip measurement se-
quence on page 181.
(This only concerns Spot servo equalizing)

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4.4.1 SWUSER
Continued

Name Declaration Description

tw_ref_tool{4} PERS tooldata Reference tooldata for each gun, used in
software equalizing. See Tip measurement
sequence on page 181.
(This only concerns Spot servo equalizing)
reference_done{4} PERS bool Boolean used in routine ReCalcTCP to check
if a reference measurement has been done.
(This only concerns Spot servo equalizing)

Process hooks
The following predefined routines are installed with the application. They are called
from the kernel during the process. These routines has no default functionality but
can easily be modified to fit specific equipment's.
Parameters description for the process hooks:
• num GunNum: Gun equipment number.
• INOUT ErrText: Error message. If an error text is returned in this parameter
it will generate an error dialog with possibilities for the operator to decide
what to do. If ErrText = "Retry" is returned from some of the hooks then no
interaction with the operator will be performed. The process is restarted from
the beginning.

PROC SwInitUserIO(num GunNum)

This routine is the first called process hook, called in the beginning of the motion
towards the position.
There is no default functionality.

PROC SwPrepare(num GunNum, INOUT string ErrText)

This routine is called in the beginning of the motion part but after SwInitUserIO.
See The type Spot Media Equipment on page 37
No default functionality.

PROC SwCloseGun(num GunNum, INOUT string ErrText)

This routine is called a predefined time, pre closing time before the robot TCP
reaches the weld position. See The type Spot Gun Equipment on page 31
No default functionality.

Note

The presence of this routine depends on the selected spot configuration.

PROC SwPreWeld(num GunNum, INOUT string ErrText)

This routine is called in the weld position and is the last routine to be called before
the start signal to the timer is activated. See The type Spot Weld Equipment on
page 27
No default functionality.

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4.4.1 SWUSER
Continued

PROC SwOpenGun(num GunNum, INOUT string ErrText)

This routine is called just after receiving the weld complete signal from the timer,
before the open gun order is activated. See The type Spot Gun Equipment on
page 31
No default functionality.

Note

The presence of this routine depends on the selected spot configuration.

PROC SwPostWeld(num GunNum, INOUT string ErrText)

This routine is called when the process is ready, after the SwOpenGun is executed.
• If no simulations are active then the weld counter in curr_gundata is
updated.

PROC SwWeldFault(num GunNum, INOUT string ErrText)

This routine is called when the configured weld timeout time has elapsed without
receiving the weld complete signal frtom the timer, or when receiving the fault
signal from the weld timer during the weld sequence. The gun has been ordered
to open just before this hook is called. See The type Spot Weld Equipment on
page 27
No default functionality.

PROC SwErrorRecover(num GunNum, string ErrType, string ErrText, \num CurrThickness INOUT num
Status)
This routine will be called instead of the built-in error handling from the motion
task if the process configuration data User defined error handling is set to
Yes. When using this routine it is possible to customize the error dialogs on the
FlexPendant when an error has occurred. No means that standard built-in error
recovery is used. See Spot Error Handling dataThe type Spot Error Handling on
page 25.

Parameter Description
GunNum Current gun number

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4.4.1 SWUSER
Continued

Parameter Description
ErrType Type of error that occurred. Possible cases
are:
• SW_PREPARE_ERR: prepare error.
Error reported in the prepare sequence
or by the SwPrepare routine.
• SW_CLOSE_GUN_ERR: close gun
error. Error reported in the close gun
sequence or by the SwCloseGun
routine.
• SW_PRE_WELD_ERR: preweld super-
vision error. Error reported in the
preweld sequence or by the
SwPreWeld routine.
• SW_WELD_ERR: weld error timeout.
• SW_WELD_TEST_ERR: weld test error
timeout. Error if test weld error in the
CalibL or CalibJ instructions.
• SW_OPEN_GUN_ERR: open gun er-
ror. Error reported in the open gun
sequence or by the SwOpenGun
routine.
• SW_POST_WELD_ERR: postweld su-
pervision error. Error reported in the
post weld sequence or by the
SwPostWeld routine.
• SW_TIP_POS_ERR: tip position error.
Only for servo guns.
• SW_PROG_VALID_ERR: program
valid timeout.
• SW_WATER_SUP_ERR: water flow
timeout. Water flow error reported by
the SW_SUP task if the continuous wa-
ter supervision is activated. See The
type Spot Media Equipment on
page 37
• SW_MEAS_TIP_CHANGE_ERR: Tip
change supervision error in the
MeasureWearL instruction.
• SW_MEAS_TIP_WEAR_ERR: Tip wear
supervision error in the
MeasureWearL instruction.
• SW_RECAL_TIP_WEAR_ERR: Tip
wear supervision error in the
ReCalcTCP instruction.

Note

To retrieve the latest measured data when a

tip management error has occurred, the in-
structions SwGetFixTipData - Get the latest
fixed tip wear and position adjustment on
page 157 and SwGetCalibData - Get the latest
total tip wear and position adjustment on
page 156 can be used.

ErrText Text string that was returned by the function

that reported the error.

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4.4.1 SWUSER
Continued

The return values of this function defines how the Spot options shall resume after
this error. There are three possible return values:
Return value Description
SW_RETRY The weld process is started from the begin-
ning after weld error and after errors reported
by:
• SwPrepare
• SwCloseGun
• SwPreWeld
SW_SKIP The current spot weld process is abandoned
and cleaned up.
SW_IGNORE The current tip position error is ignored and
the weld is executed again without plate
thickness supervision. (Only for servo guns.)

Note

The number of available user hooks depends on the selected configuration.

Supervision task hook

The SupervisionInit routine is called from the main routine in the SW_SUP task at
power on.
• SupervisionInit()

PROC SupervisionInit()
There is no default functionality.

Related information

Described in:
Customizing possibilities Customizing RobotWare-Spot on page 247

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4.4.2 SWUSRM

4.4.2 SWUSRM

Description
The SWUSRM user module is configured to run in all motion tasks in the system,
and contains some default Spot related data. It also contains routines for data
transfer (for example DefineSpotData, used to copy user defined spotdata to
internally used spotdata.
In normal cases there is no need to change this module. The default functionality
should be good enough in most cases. But if the default data types are changed
there may be a need to modify this module also.

Note

Default functionality depends on the spot configuration.

Note

After changing any routines in SWUSRM, the following steps must be taken
before there is an affect on the application:
• Save SWUSRM. The old one is overwritten.
• Generate a Reset Rapid restart to affect all tasks

Note

If data is moved from this module the Spot MMI application might not work
properly!

Default data
The following default data are predefined.
Name Description Default value
gun1, 4 Gun number used in the spot 1 to 4
instruction, gun index number
in curr_gundata.
spot1 Default spotdata when pro- prog_no - 1
gramming the spot instruc- tip_force - 1000 N
tions on the FlexPendant.
plate_thickness 0 mm
plate_tolerance - 0 mm
Tip

It is possible to use spot data

parameters programmed in
the weld timer if needed in-
stead of the spotdata paramet-
ers, see How to use spot data
programmed in the weld timer
on page 258

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4.4.2 SWUSRM
Continued

Name Description Default value

force1 Default forcedata when pro- tip_force - 1000 N
gramming the SetForce in- force_time 1 s
struction on the FlexPendant
plate_thickness 0 mm
plate_tolerance - 0 mm

Process data routines

These routines can be used to perform actions inside the Spot routines. The
following process routines are installed with the application.

PROC DefineUsrData(num GunNum \INOUT gundata UserGunData)

This routine is called in the beginning of all Spot shell routines. Here user gundata
can be transferred into the Spot instruction, using this data instead of the default
curr_gundata.

Note

The optional \UserGunData parameter will be used if the optional \GunD argument
is used in the spot instructions. See SpotL/SpotJ - The basic spot welding
instructions on page 95
IF Present (UserGunData) THEN
curr_gundata{GunNum} := UserGunData;
ENDIF

PROC UpdateUsrData(num GunNum \INOUT gundata UserGunData)

This routine is called at the end of all Spot shell routines. Here gundata can be
transferred back to the user gundata.

Note

The optional \UserGunData parameter will be used if the optional \GunD argument
is used in the spot instructions. See SpotL/SpotJ - The basic spot welding
instructions on page 95
IF Present (UserGunData) THEN
UserGunData := curr_gundata{GunNum};
ENDIF

Data definition routines

The following predefined routines are used to transfer user defined data to internally
used data. They are used by the spot welding instructions and are called from the
kernel during the process. Some of them are also called during system events
such like poweron, program start, program stop etc.

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4.4.2 SWUSRM
Continued

These routines have a default functionality but can easily be changed. The routines
cannot be deleted since they are called from internal modules.

PROC DefineSpotData(spotdata Spot, num GunNum)

This routine is executed in the beginning of each Spot instruction. Transfer user
spotdata to internal spot data, that is spotdata in the SpotL instruction.
The weld program group output signal will be set just after leaving this routine.
See SwSetIntSpotData - Set the internal spotdata on page 152.

PROC DefineGunData()
This routine is executed in the beginning of all Spot shell routines, SwStart or
SwReStart. Transfer user gun data to internal gun data, that is curr_gundata.
See SwSetIntGunData - Set the internal gundata on page 154.

PROC DefineForceData(forcedata Force, num GunNum)

This routine is executed in the beginning of each SetForce instruction. Transfer
user forcedata to internal force data, that is forcedata in the SetForce
instruction. See SwSetIntForceData - Set the internal forcedata on page 153.

PROC DefineSimData()
This routine is executed in the beginning of all Spot shell routines. Transfer user
simdata to internal simdata, that is curr_simdata. See SwSetIntSimData - Set
the internal simdata on page 155.

PROC UpdateCalibData(num TotalTipWear, num WearMoveable, num GunNum \switch ToolChg | switch
TipChg | switch TipWear | switch FineCalib)
This routine updates the current tipwear parameters in curr_gundata. It is
executed at the end of each CalibL/J and Calibrate instruction.

PROC UpdateFixTipData(num CurrWearFixed, num DiffDistance, num GunNum \switch Reference |

switch TipChange | switch TipWear | switch RefChange)
This routine updates the current fixed tipwear parameters in curr_gundata It is
executed at the end of each MeasureWearL and ReCalcTcp instruction.

Note

This routine is only present if the SoftWare Equalizing option is selected.

PROC UpdateSpotData(z_int_spotdata Spot, num GunNum)

This routine updates the curr_spotdata with the latest used spotdata. It is
executed at the start of motion, that is when the robot starts to move.

Note

Default functionality depends on the spot configuration.

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Continued

Event routines
The following predefined event routines are installed with the application. These
routines have no default functionality but can easily be changed. If not needed
they can be removed.

PROC SwPowerOn()
This routine is called when the robot is restarted (warm started) or by power on.
There is no default functionality.

PROC SwStart()
This routine is called when execution is started from the beginning of the program.
There is no default functionality.

PROC SwReStart()
This routine is called when execution is started from the position where it was
stopped.
There is no default functionality.

PROC SwStop()
This routine is called when the program is stopped.
There is no default functionality.

PROC SwQStop()
This routine is called when the robot is quick stopped (E-stop).
There is no default functionality.

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4.4.3

4.4.3

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 5 Software Equalizing
5.1 Introduction to Software Equalizing

5 Software Equalizing
5.1 Introduction to Software Equalizing

Introduction
This chapter describes the Software Equalizing functions. These functions makes
it possible to use spot welding guns without mechanical equalizing systems. The
functions are available if the option Spot Servo Equalizing is installed.

Available functions
The Software Equalizing functions are a number of functions intended to handle
these issues for the user. However, it is not always necessary to use all functions.
It depends on desired accuracy, sheet stiffness, gun properties as type, size and
stiffness and so on.
The following Equalizing functions are available:
• Weld position Touch Up.
• Release of the fixed gun arm.
• Gun arm Deflection Compensation.
• Tip Wear Measurement and Compensation.
• SoftMove Equalizing
It is possible to use guns with mechanical equalizing and guns using Software
Equalizing in the same user program. The equalizing type is determined in the
process data Use SoftWare equalizing located in Spot Gun Equipment.
For more information, see gundata - Equipment specific weld data on page 135.

Recommendations
When guns without mechanical equalizing systems are used it is very important
to have good accuracy when the TCP is defined and when the weld positions are
taught.
It is also important to handle the tip wear and recalculate the TCP regularly and
also to release the fixed gun arm from the sheet when the gun is moved between
weld positions. For most guns it is also necessary to handle the gun arm deflection
during the weld.

Note

When using Software equalizing it is important to have good control of the part
tolerances and the tip wear of the electrodes. This functionality can only tolerate
variations up to approximately 1-2 mm.

Note

When using SoftMove equalizing functionality the tolerances can be a bit bigger
than with Software equalizing only, up to 4-5 mm.

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5.1 Introduction to Software Equalizing
Continued

Limitations
• The functions Gun Arm Release and Deflection Compensation are only
availible when SpotL/SpotJ instructions are used, not for the SpotML/SpotMJ
instructions.
• The gun pre closing time is not used when software equalizing is active. In
this case the pre closing is handled automatically during the movement from
the release distance to the weld position.
• For some special configurations an acceptable touch up position can be hard
to reach with the MeasureWearL instruction. If that is the case, ReCalcTcp
instruction can be used as an alternative method.
• It is not possible to run SpotL/SpotJ instructions with software equalizing
active if independent mode is activated.
• It is only possible to run spot instructions in semi coordinated mode.
• When using only gun arm deflection compensation it is important to have
good control of the tolerances of the parts, and the wear of the electrodes.
This functionality can only tolerate variations up to approximately 1-2 mm.
(If the tolerances of the parts are inferior, then the Soft Move Equalizing
method can be used at the locations where it is needed.)

Note

Software Equalizing does not work for the SpotML and SpotMJ instructions.

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 5 Software Equalizing
5.2 Some basic definitions

5.2 Some basic definitions

How to define the TCP

The TCP has to be defined, as normally, on the tip of the fixed gun arm.
It is important to define also the z-direction in the tool coordinate system since all
automatically search movements and compensations will be done in the z-direction.
See the graphics below.
Normally the z-direction should point out from the fixed tip, and the tip of the gun
should move towards the work piece when jogging the robot in the positive
z-direction.
To achieve the same behavior on a stationary tool the z-direction needs to be
reversed into the fixed tip, and in order to get the correct search and compensation
movements, the setup data Opposite z-direction has to be set to Yes in Spot
Gun Equipment process data, see The type Spot Gun Equipment on page 31.

en1200000236

The z-direction when different gun types are used:

en1200000235

Note

It is very important to define the z-direction correctly in the tool coordinate system
since all automatically search movements and compensations will be done in
the z-direction.

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5.2 Some basic definitions
Continued

How to setup the tool TCP

1 Define the TCP for the used gun with a new tip mounted. Use the 5 point
method.
See Operating manual - IRC5 with FlexPendant.
2 Store the result in a tooldata for example ref_tool1.
3 Save the tip (tool) as a reference tip (the physical tip).

How to program the weld positions

en1200000234

The weld position should be teached in the position where the fixed electrode is
touching the sheet during the weld process. See the graphic above.

Note

Before touching up the weld positions a MeasureWearL with the Reference

switch has to be done. See Tip measurement sequence on page 181.

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 5 Software Equalizing
5.3 Weld position Touch Up

5.3 Weld position Touch Up

Introduction
This is a support function used in manual mode to get a faster and easier way to
adjust the programmed weld positions. During the touch up it is possible to change
the fixed gun tip in the z-direction and it is also possible to change the position for
the movable gun arm.
Normally a touch up has to be done at least once in the beginning after manual or
offline programming of the weld positions.

en1200000232

How to use the weld position touch up function

1 Make sure that current TCP is relevant for the used tip, define the tool data
correctly.
2 Set the system in weld position touch up mode (simtype = 3 in
curr_simdata).
See simdata - Simulation data on page 146.
3 Start the program. The robot is running the program as normal, but all SpotL
and SpotJ instructions are executed as move instructions.
4 The robot stops in each programmed weld position and a user interaction is
started which gives possibilities to confirm and directly go to next spot or
adjust current position.
5 During adjustment the fixed gun tip is moved in small steps to the sheet or
to desired distance from the sheet.
It is also possible to adjust the position of the movable gun arm in a similar
way.
6 When both tips are in desired position it is possible to do a Modpos, with
confirmation, to definitely reprogram the position.
7 When the gun is moved between programmed weld positions the fixed gun
tip is automatically released from the sheet.
Desired distance to the sheet is a user defined data predefined for each used
gun, release_dist.

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5 Software Equalizing
5.3 Weld position Touch Up
Continued

This release movement can be skipped to save cycle time if the optional
switch \QuickRelease is selected in the SpotL or SpotJ instruction.
See gundata - Equipment specific weld data on page 135 and SpotL/SpotJ -
The basic spot welding instructions on page 95.
8 When all weld positions are checked, set simtype = 0 to disconnect the
Touch Up mode.
See gundata - Equipment specific weld data on page 135.

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 5 Software Equalizing
5.4 Releasing of the fixed gun arm and gun opening

5.4 Releasing of the fixed gun arm and gun opening

Description
This function is used to get an automatic release of the fixed gun arm from the
sheet, when the gun is moved between the weld positions during normal program
execution.

en1200000231

Releasing the fixed gun arm

During execution of SpotL/SpotJ instructions, the robot moves the gun to the
weld position, via a position a release distance from the sheet.
After the weld when the gun is opened, an extra movement is performed to release
the fixed gun arm from the sheet except if the QuickRelease functionality is
activated in the SpotL/SpotJ instruction.
If the \QuickRelease switch is selected in the SpotL/SpotJ instruction the release
distance movement after the weld will be skipped, this may save some cycle time
and can be used when the spots are located close together

Note

The \QuickRelease function is suitable when programming close weld positions,

not when there are large distances between the weld positions.
The release distance, release_dist, is a user defined data predefined for each
used gun. see gundata - Equipment specific weld data on page 135.

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5 Software Equalizing
5.4 Releasing of the fixed gun arm and gun opening
Continued

This function will be disabled if release_dist is set to zero or if softw_equ is

set to FALSE in current gundata.

Note

To get a good synchronization between the release movement and the gun
opening when software equalizing is used, the gun is always held in the closed
state 40 ms extra after weld complete. To save cycle time, the programmed cool
time after weld in the weld controller can be reduced this amount of time (2
periods).

Gun opening
The gun opening gap must be large enough that the tips are free from the plates
when welding.
So therefore, the software will compensate for the release distance that is used,
and the plate thickness, as the opening position is the same as the tips closed with
plates + release_dist.
Example:
If release_dist is 10mm, the moving tip will open to 10mm even if you modify the
position with the gun closed on the plate surface.
A simple recommendation is to have approximately the same distance from the
plate to the movable electrode as the release_dist that has been configured.
For more information about the release_dist parameter, see Additional components
for Spot Servo Equalizing on page 136.

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 5 Software Equalizing
5.5 Gun arm deflection compensation

5.5 Gun arm deflection compensation

Introduction
Most weld guns deflects more or less depending on the stiffness of the gun arms
when the gun is closed with force. In these cases there is a need to compensate
for the fixed gun arm bending with an extra robot movement to minimize the risk
of deformation on the sheets. The deflection compensation can be done in the tool
z and x-direction.
With this function the gun arm deflection is automatically compensated with an
extra robot movement when the gun is closed and the gun force is applied. See
graphic below.

xx1200000230

A Sheets
B Robot flange
C Gun arm deflection
D Robot compensation movement

The graphic shows gun arm deflection in both z and x-directions, and robot
compensation movement in the opposite directions. If the gun bends outwards
(positive x), the robot will move in the opposite direction.

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5 Software Equalizing
5.5 Gun arm deflection compensation
Continued

en1200000229

Data
Data for the correlation between the gun force and the arm deflection is user defined
data, predefined for each used gun: deflection_dist_z, deflection_dist_x,
deflection_force and deflection_time, see gundata - Equipment specific
weld data on page 135. This data is normally found in the data sheet for the used
gun.
Then, during program execution of SpotL/J instructions, there is an added robot
movement, activated at the same time as the gun force is established, to
compensate for the gun arm deflection, see graphics above.
The actual gun arm deflection is calculated from the force value (tip_force) in
current spotdata. Deflection calculation in SpotL/SpotJ instruction.
deflection := spotdata.tip_force * gundata.deflection_dist /
gundata.deflection_force;
A movement in the opposite direction is performed after the weld, when the gun
is opened. This movement is combined with the release movement.

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 5 Software Equalizing
5.5 Gun arm deflection compensation
Continued

This function is disabled if the deflection distance parameters are set to zero, or
if the Spot Gun Equipment, Use SoftWare equalizing setup data is not
activated.

How to setup the data for gun arm deflection

1 Find out how much gun arm deflection there is at a specific force when the
gun arms are closed, this data is normally found in the data sheet for the
used gun.

Tip

If this information is missing the gun arm deflection can be measured

manually by closing the gun at a specific force, for example 4000 N and
measure how much the gun arm deflects related to a fixed reference
position on the tip dresser stand for instance.

2 Enter the measured values in gundata, deflection_dist_z and

deflection_force, for example 5 mm at 4000 N.
See gundata - Equipment specific weld data on page 135.
3 Save the user module swuser.sys since the current gundata is located there.

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5 Software Equalizing
5.6 Tip wear compensation

5.6 Tip wear compensation

Introduction
When guns without mechanical equalizing systems are used, it is important to
handle the tip wear, especially the tip wear on the fixed tip, since this tip is
controlling the weld position. Therefore the tip wear has to be regularly compensated
during production. There are two methods available for the compensation.

Method 1
MeasureWearL, the tip wear for the fixed tip is measured and the tip wear is then
compensated in current used tooldata.

Method 2
ReCalcTcp, the tip wear of the fixed tip is calculated based on stored information
about the total tip wear and the expected relation between the tip wear of the fixed
tip and the total tip wear. The tip wear is then compensated in current used
tooldata. This method can be used as an alternative if method 1 is not suitable.

Method 1: Tip wear measurement and compensation with MeasureWearL

A RAPID instruction is available for tip wear measuring and TCP adjustment:
MeasureWearL. This instruction is used one time for a reference measurement
with new tips and then one time after each tip dressing and after the tips have been
exchanged.

en1200000228

A code sequence with the measuring instruction included has to be prepared in

the user program. The position in the MeasureWearL instruction has to be
programmed close to a fix reference plate, see figure above. Also see Measurement
preparation on page 118.
When the instruction is executed the robot first moves the gun to a start position
for the search movement about 10 mm from the reference plate. Then the gun is
moved until the fixed gun tip touches the reference plate. The tip wear of the fixed

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5.6 Tip wear compensation
Continued

gun tip is calculated. Currently used TCP value is automatically recalculated and
tip wear data for the fixed tip in gundata is automatically updated.

Note

This movement of 10mm has to take care of the wear of the tips that could be
for example 20mm, it means that the total gun opening should take care of the
10mm position, the plate thickness and the total wear of the tips.
When using this method the gun calibration instructions (Calibrate or CalibL/J)
has to be executed after MeasureWearL since the moveable tip wear will be
calculated based on the result of the measurement.
The reference plate can be mounted in an optional position in the work range,
preferably on the tip dresser stand. But it is necessary to orient the tool in the
measuring position in that way that an additional torque is generated on at least
one of the robot motors when the robot is touching the fixed plate, preferably axis
4 to 6.
It is possible to verify if the selected measuring position or gun orientation is good
enough by using a service routine; ManualCheckMeasPos. Just run the service
routine when the robot is in the selected position and you will get status information
on the display.

How to find a good measuring position

1 Jog the robot to the position where the fixed plate is mounted, for example
on the tip dresser stand.
2 Run the service routine ManCheckMeasPos to find out if the position is good
or not, if not jog/reorient the robot to a new position.
See Manual actions on page 74.
3 Create a program with a code sequence with the measuring instruction
included.
See MeasureWearL - Measure current electrode wear and recalculate the
TCP on page 118.

Tip measurement sequence

The reference measurement with MeasureWearL \Reference will calibrate the
position of the reference plate for the tip wear measurement with the robot. The
parameters of the tool used for the reference measurement (RefTool) and the
calibration values are stored in the persistent variables tw_ref_tool and
tw_ref_dist located in the user module swuser.sys. All following calls of
MeasureWearL (\TipWear, \TipChg) measures only the difference to the reference
position.
The tips (or the real TCP) and the tool (RefTool) used for the reference measurement
must be the same as used for teaching of the weld positions (robtargets).
The reference measurement needs to be done again when the reference plate has
been moved or the TCP has been changed (for example after a crash) or the

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5 Software Equalizing
5.6 Tip wear compensation
Continued

\RefChange switch can be used instead, see Measurement after reference

plate/sensor changed on page 120.
For the measurements the robot contacts the reference surface always with the
same force, MeasureWearL TouchUp force in the Spot Equalizing process
configuration. See The type Spot SoftWare Equalizing on page 39.
Since the calibration values are stored in swuser.sys the file should be saved after
the reference measurement.
Input values of CurrTipWear and RetPosAdj in UpdateCalibData and
UpdateFixTipData.

CurrTipWear RetPosAdj
Calib* ... \TipWear 0 Difference to the last calibration of the gun.
Normally last call with \TipWear. Total differ-
ence between the new and the old (worn)
tips.
Calib* ... \TipChg Total wear of both tips Difference to the last calibration of the gun.
Calib* ... \ToolChg Total wear of both tips Difference to the last calibration of the gun.
MeasureWearL .. 0 Difference between the actual and the tip
\TipChg used for the reference measurement.
MeasureWearL .. 0 Measured reference distance.
\Reference

See MeasureWearL - Measure current electrode wear and recalculate the TCP on
page 118.

Note

For some special configurations the MeasureWearL is less suitable, for example
very large guns and/or when an acceptable touch up position is not possible to
reach for some reason. Then the ReCalcTcp method should be used instead.

Tip wear measurement and compensation for stationary guns

Generally when stationary tools are used, the work object is held by the robot and
related to the wrist coordinate system and the TCP, still defined on the tool, is
related to the world coordinate system. This is the case also when stationary guns
are used. As before, the TCP has to be defined on the fixed tip and the z-direction
has to be defined, see figure below and How to define the TCP on page 171
The parameter robhold in current tooldata and wobjdata defines whether the
robot is holding the gun or not.

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For more information about how to define the stationary tool coordinate system,
see Operating manual - IRC5 with FlexPendant.

en1200000227

All Software Equalizing functions are working in a similar way as when the robot
is holding the gun. But the tip wear measurement has to be arranged a little different,
since it is not possible to use a fix reference plate in this case. To be able to use
the same principles for the measurement and the MeasureWearL instruction, it
has to be done as described in following items:

en1200000226

• Select or create a relatively stable position on the robot held gripper. It shall
be possible for the robot to move this point to the fixed gun tip. see an
example in the figure above.
• As in the normal case, code sequences with the measuring instructions
included have to be prepared in the user program to be used for the reference
measurement and for the tip wear measurement.
• We recommend programming the gun calibration instructions in the same
code sequences, directly after the tip wear measurement. See Calibrate -
Calibrate a servo gun on page 114 and CalibL/CalibJ - Calibrate a servo gun
during robot movement on page 108.

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• The position in the MeasureWearL instruction has to be programmed close

to the selected position on the gripper, see graphic above.
• When the instruction is executed the fixed gun tip is touched by the gripper.
The tip wear of the fixed gun tip is calculated. Currently used TCP value is
automatically recalculated and tip wear data in gundata is automatically
updated. For more information, see MeasureWearL - Measure current
electrode wear and recalculate the TCP on page 118.

Method 2: Tip wear calculation and compensation with ReCalcTcp

A RAPID instruction to be used for tip wear calculation and TCP adjustment with
this method is available: ReCalcTCP.
As the measurement instruction used in method 1, MeasureWearL this instruction
is used one time for a preparation and then one time after each tip dressing and
after the tips have been exchanged. But in this case the instruction is a logical
instruction without movements.
When the instruction is executed the tip wear of the fixed tip is calculated. The
calculations are based on stored information about the total tip wear and the
expected relation between the tip wear of the fixed tip and the total tip wear. The
tip wear is then compensated in current tooldata. Current used TCP value is
then automatically recalculated and tip wear data for the fixed tip in gundata is
automatically updated.
In this case the gun calibration instructions (Calibrate or CalibL/J) has to be
executed before ReCalcTCP is used since the total tip wear is used for the
calculations.
For more information, see ReCalcTCP - Calculate current electrode wear and
recalculate the TCP on page 126.
The advantages with the calculation method is that it is faster since no extra
measurement has to be done, and it is also easier to set up since no reference
position has to be arranged for. The disadvantage is that the compensation will
not be as accurate as with the measuring method in the cases when the tip wear
ratio value not is set to a value in agreement with the reality, or after tip change if
the new tips not have the same size every time.

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 5 Software Equalizing
5.7 SoftMove Equalizing

5.7 SoftMove Equalizing

Introduction
This section describes the SoftMove Equalizing method which can be used as a
complement to the standard software equalizing method if there is a need to
compensate for programming errors, for example if the plates are not located in
the nominal position.
When a spot instruction with SoftMove activated is run, the robot will move to the
programmed and nominal position, and set the robot into soft state using SoftMove
in the tool z-direction during the last part of the movement into the position.
This method can be used together with the standard software equalizing
functionality, that is, gun arm deflection compensation.

Prerequisites
SoftMove Equalizing is available for the SpotL and SpotJ instructions, and it is
only available if the RobotWare options Spot Servo Equalizing (635-6) and SoftMove
(885-1) are installed together.

Recommendations
When using SoftMove Equalizing it is important that the tool data (tooldata) is
defined correctly, especially the mass. Errors in the load definition will be interpreted
as external forces, which in turn can cause the robot to move. Hence, an incorrect
definition can cause unwanted robot movements.
Some general tips when using SoftMove Equalizing:
• Verify that the load definition of the tool is correct.
• Avoid singular robot orientations.
• The robot axis configuration will affect the softmove performance, there are
configurations where performance can be poor.
• A gun configuration that allows axis 5 movement gives better performance
in general (Avoid gun configurations when z-axis of the gun is in linearity
with axis 6 of the robot).
• The clamping distances cannot be too far apart, as there must be some
resistance for the robot to react on.

Note

When using SoftMove equalizing functionality the part tolerances can be higher
than with Software equalizing only, up to 4-5 mm.
For more information about SoftMove, see Application manual - SoftMove.

Limitations
The following limitations apply when using SoftMove Equalizing:
• The same limitations as for Software Equalizing also applies for SoftMove
equalizing.

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• Cannot be used to compensate for too large variations in the objects to be

welded, only up to a few mm.
• Not all positions or arm configurations are suitable for SoftMove Equalizing,
if poor performance (for example not reaching the position or pressing too
hard) is experienced, then try to reorient the robot axes or gun arm
configuration if possible. Friction force may vary too much so that the force
offset needed will be too high, this can deform the plate.
• SoftMove performance will in general depend on robot type, robot arm
configuration, gun configuration, and load data definition. Larger robot types
will have higher internal gear friction and inertia and that will affect the
sensitivity, and it will be harder to find a friction value good enough.
• This function should in general not affect the plates more than 50N to 100N
during the welding sequence, however there are positions in the work area
where it will be difficult to get good results, and the force applied on plates
can be higher.
• When tuning the friction compensation needed in a position, the robot can
move in a unexpected direction because of high friction in axis 2 and/or 3,
this may indicate a difficult or unsuitable position.
• Cycle times will be longer when using SoftMove Equalizing because of the
the lower TCP speed and gun speed into position, compared to using standard
SoftWare Equalizing.
• When tuning the friction compensation in a certain position the value is
usually good enough, but the acheived value may need to be manually tuned
to get better performance. If the measured value is higher than ~300 N there
may also be a need to manually modify the measured value.
• When SafeMove is used together with SoftMove there is a risk for servo lag
problems. The recommended action is to add a Contact Application Tolerance
(CAP) in the area where SoftMove is active.
When the function is active, that is, during the welding phase in the SpotL/J
instructions, the following functionality is not accessible:
• Collision Detection (option 613-1)

Note

For more information about SoftMove limitations, see Application

manual - SoftMove.

Note

For safety reasons the position supervision limits in x, y, and z directions has
been limited. These values can be changed in the motion parameter configuration
if needed, for example type Motion type CSS and Max pos error in z. Default
configuration is x = 10 mm, y = 10 mm, and z = 10 mm.

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Continued

Note

SoftMove Equalizing is only implemented for the SpotL and SpotJ instructions
and does not work for the SpotML and SpotMJ instructions.

Note

This function allows the tolerances of the parts to vary a bit more compared to
using only standard software equalizing, but it should be noted that the cycle
time will be longer than without, 200-700 ms per spot depending on the current
settings and the actual plate position.

WARNING

When using SoftMove Equalizing it is very important that the load definition of
the tool is defined correctly.

Function overview
SoftMove equalizing is activated by selecting an optional switch in the SpotL and
SpotJ instructions, see SpotL/SpotJ - The basic spot welding instructions on
page 95.
When a spot instruction with SoftMove activated is run, the robot will move to the
programmed and nominal position, but during the last part of the movement into
the position the robot will be set into soft state in the tool z-direction. When the
gun has closed, the soft mode will be deactivated if SoftMove type is set to 1, and
the deflection compensation will be activated as normal during the welding process
if configured. If SoftMove type is set to 0, SoftMove will be activated during the
compete weld cycle and no gun deflection compensation will be performed, see
smeqdata - SoftMove Equalizing data on page 148.
The SoftMove equalizing method can be more forgiving regarding programming
errors than only using the standard software equalizing method. For example, if
the plates are not located exactly in the nominal position but some millimeters
away, up to 4-5 mm.

Note

If the normal software equalizing is deactivated then the SoftMove equalizing

will also be deactivated, and it is considered that mechanical equalizing system
is being used.

Programming
An optional parameter must be activated in the spot instructions to be able to use
the SoftMove Equalizing functionality (\SMEQ). The parameter is an on/off switch
for the SoftMove functionality, that is, if the parameter is not used, then the normal
software equalizing functionality will be used for that position, see programming
example below.

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Continued

The optional parameter \SMEQ of type smeqdata has data components for
SoftMove, specific for each position. smeqdata has the following structure:
• Desired smeq_type (SoftMove type) used in the specific position.
• Measured force_offset (friction compensation and force applied on the
plates) for the specific position.
The parameter smeq_type defines what SoftMove type that shall be used in the
specific position. There are 2 types; no gun deflection mode (0) and standard mode
(1).
The parameter force_offset is needed to compensate for the robot's static
friction in a specific position and to achieve a small movement to the plates. The
value must be set for each position for the first time the program is executed, see
Friction compensation procedure on page 191.

Note

The force_offset should be seen as friction force and force applied to the
plates.
Example: 100N is identified in the friction compensation procedure.
To be sure that robot will move to the plate the force_offset can be set to
130N. If the friction is constant during the movement it will be 30N applied on
the plate.

Note

It may be possible to use the same force_offset value for several positions.

For more information about this data type, see smeqdata - SoftMove Equalizing
data on page 148.

Example
This program example uses SpotL instructions with and without SoftMove
Equalizing functionality. Instructions at targets P20 and P40 will be executed with
only software equalizing activated while instruction at P30 is executed with SoftMove
Equalizing because of tolerance issues in that position.
PERS smeqdata smeq1:=[1,150]
PROC main()
MoveJ P10, v1000, z50, tool1;
SpotL P20, vmax, gun1, spot11, tool1;
SpotL P30, vmax, gun1, spot12\SMEQ:=smeq1, tool1;
SpotL P40, vmax, gun1, spot14, tool1;
ENDPROC

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Continued

Execution
No gun deflection mode (SoftMove type 0)
When a spot instruction is executed with the \SMEQ data set, the robot will move
to the programmed and nominal position, at the same time as the gun starts to
close. During the movement and closing of the gun the robot will be set into soft
state with the specified force offset activated, according to the used data to
overcome the friction of the robot.
When the gun has closed the position is considered to be "found" and the weld
will be performed from that new position. After the weld process is completed the
gun will start to open and SoftMove will be deactivated, see figure below.

Note

This method is a bit quicker compared to the standard mode because no

synchronization with the gun closing is done before the process is started, but
it is only suitable for guns with no or very small arm deflection values.

en1200000225

1 Movement to the nominal position, via release release distance.

2 From the SoftMove offset distance SoftMove is activated with the specified
force_offset (friction compensation+force applied on the plate) while the
gun closes.
3 When the gun is closed the plate is considered to be "found" and the weld
will be done from that new position.
4 After weld the gun and robot will move to the release distance at the same
time as the gun opens and SoftMove is deactivated.

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Continued

Standard mode (SoftMove type 1)

When a spot instruction is executed with the \SMEQ data set, the robot will move
to the programmed and nominal position, at the same time as the gun starts to
close. During the movement and closing of the gun the robot will be set into soft
state with the specified force offset activated, according to the used data to
overcome the friction of the robot.
When the gun has closed the position is considered to be "found" and the soft
state will be deactivated and the normal gun arm deflection compensation will be
performed if configured. After the weld process is completed the gun will start to
open and the gun arm deflection will be deactivated, see figure below.

Note

This method is a bit slower compared to the no gun deflection mode because
the process waits for the gun closing before the process is started and performs
arm deflection compensation during the weld. This method is suitable for guns
with relatively big arm deflection values.

en1200000225

1 Movement to the nominal position, via release release distance.

2 From the SoftMove offset distance SoftMove is activated with the specified
force_offset (friction compensation+force applied on the plate) while the
gun closes.
3 When the gun is closed the plate is considered to be "found" and SoftMove
will be deactivated and the weld will be done from that new position.
4 After weld the gun and robot will move to the release distance at the same
time as the gun opens.

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Continued

Friction compensation procedure

When a spot instruction is executed with SoftMove Equalizing activated for the
first time there is a need to compensate for the robot's static friction in a specific
position and to achieve a small movement towards the plate. For this there is a
parameter that needs to be tuned to a certain value for each position that uses
SoftMove in the program, force_offset
By default the tuning will be done automatically for each position, it is possible to
configure manual tuning iff needed, see The type Spot SoftWare Equalizing on
page 39
When a spot instruction is run the force_offset parameter in the current
smeqdata will be checked, if the value is equal to zero the robot will move to the
release distance outside the robtarget specified in the instruction and stop, or
if configured, perform an auto tuning in that position. The operator can then tune
the force_offset value needed for the current position, see figures below.
If the force_offset parameter is greater than zero the spot instruction will be
executed normally with the current value to compensate for the friction. The
force_offset should be seen as friction force and force applied to the plates.
A typical force offset value for an IRB 6640 can be approximately 100-400 N
depending on arm configuration.

en1200000223

Stop Stops the program execution.

Tune The force offset will be tuned for the current position. The tuning will take a few
seconds and after that a dialog appears with the possibility to accept the measured
value or redo the tuning.

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5.7 SoftMove Equalizing
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en1200000222

Redo Returns to the previous screen with the possibility to tune the force offset needed
again.
OK Updates the current smeqdata with the measured value.

Note

The force_offset should be seen as friction force and force applied to the
plates.
Example: 100N is identified in the friction compensation procedure.
To be sure that robot will move to the plate the force_offset can be set to
130N. If the friction is constant during the movement it will be 30N applied on
the plate.

Note

The measured value of force_offset is an approximate value and it may be

necessary to have a higher or lower value than measured for the current position
since the friction value is measured while the robot is not moving.
The actual force needed to overcome the friction or overcome frictional force
and accomplish a movement of the robot may vary slightly depending on
cold/warm robot etc. And it may turn out that the value may seem a little too low
when running the robot in manual mode, but when running in automatic mode,
the value is right. If the robot does not reach the position in manual mode,
increase the value manually by 5-10N and run again.
For more information about SoftMove limitations, see Application
manual - SoftMove

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Continued

Note

When tuning the friction compensation in a certain position the value is usually
good enough, but the acheived value may need to be manually tuned to get
better performance. If the measured value is higher than ~300 N there may also
be a need to manually modify the measured value.

Note

It is recommended that the friction compensation procedure is done without

welding activated.

Related information

Described in
Manual actions Manual actions on page 74
Process configuration Spot process configuration on page 21
MeasureWearL MeasureWearL - Measure current electrode
wear and recalculate the TCP on page 118
ReCalcTcp ReCalcTCP - Calculate current electrode
wear and recalculate the TCP on page 126
Customizing Customizing RobotWare-Spot on page 247
SpotL/SpotJ SpotL/SpotJ - The basic spot welding instruc-
tions on page 95
SoftMove Equalizing data smeqdata - SoftMove Equalizing data on
page 148
SoftMove Application manual - SoftMove

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 6 Servo gun motion control
6.1 Servo gun introduction

6 Servo gun motion control

6.1 Servo gun introduction

Additional axes
The robot controller has functionality to control additional axes configured as servo
guns (other types of supported additional axes are track motion, positioners,
conveyors etc.). All servo guns are handled as separate mechanical units. This
means that before a servo gun may be moved, the mechanical unit to which it
belongs must be activated. Several servo guns may be active at the same time.

Hardware overview
Servo gun axes are controlled by the drive module. Internal drive units are mounted
inside a standard drive module (for example for an IRB 6700 with one servo gun
or for an IRB 6700 with two stationary servo guns).

Motion servo gun parameters

A set of motion servo gun parameter file should be installed in the controller for
each servo gun. The parameter files are optimized designed concerning system
behavior and motion/process performance.
It is possible to read and change most of the parameters from the RobotStudio
application after installation, as well as from the FlexPendant. With the Spot Servo
options some gun specific system parameters may be updated temporarily directly
in the robot program using the instruction STTune. This function will make tuning
of gun parameters easier.
Normally these parameters are supplied by the gun manufacturer.

References

Type of information See

CalibL, CalibJ, Calibrate, SpotL, SpotJ, RAPID references on page 95
SetForce, STTune, gundata, spotdata,
forcedata
General motion control and programming Operating manual - IRC5 with FlexPendant
ActUnit, DeactUnit, MoveL, MoveJ, Technical reference manual - RAPID Instruc-
robtarget, tooldata tions, Functions and Data types
How to tune a servo gun Application manual - Servo Gun Setup
Hardware: motors, resolvers, drives, servo Application manual - Additional axes and
gun parameters, tuning a servo gun stand alone controller

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6 Servo gun motion control
6.2 General motion control for servo guns

6.2 General motion control for servo guns

Introduction
The motion functionality described in this section is common for servo guns and
most other types of additional axes. The description is however adapted for servo
guns.

Activation and deactivation

A servo gun may be activated when the robot and all additional axes have come
to a standstill by using the ActUnit instruction. This means that the servo gun is
controlled and monitored by the robot controller.
A servo gun is normally automatically activated directly after loading its parameters
and starting up the system (activate at startup). It may be deactivated during
program execution later.
If several guns are sharing one tool changer there will be no automatic activation
at startup. When the connected gun is activated, it will not be possible to activate
another gun until the first one is deactivated (mutual exclusion).
Deactivation of the gun is only needed if the gun has to be disconnected, for service
or for a tool change. The deactivation will store the guns current position. This
position will be restored when the gun is activated next time. Deactivation is
performed with a DeactUnit instruction and this will also stop the control and
monitoring of the axis.

Jogging
The position of the gun arm can be jogged with the joystick (see Operating
manual - IRC5 with FlexPendant). The distance between the two tips is displayed
in the jogging window, expressed in mm. An out of range supervision will stop the
movement if the gun is reaching max stroke or min stroke. Min stroke is normally
zero or a small negative value (gun tips closed to contact with each other).

Synchronous movements of robot and servo gun

Normally, as for other additional axes a servo gun axis is moved synchronous with
the robot movements in such a way that both movements will be completed exactly
at the same time. However, it can also be moved independent of the robot
movements, for example when closing the gun tips with a force. But during normal
movements (for example MoveL, MoveJ, MoveC) in program execution, the tool
axis movement will be synchronized. The combined path of robot and servo gun(s)
will be repeatable and independent of programmed speed. The robot TCP path,
will be the same irrespective of the programmed movements of the servo gun's
movable arm.
A robtarget includes position data for additional axes which also will be set when
a ModPos is performed. Example:
• p10 is a robtarget RAPID data.
• p10.extax.eax_a is the position of the additional axis with logical axis 7.
• p10.extax.eax_b is the position of the additional axis with logical axis 8.

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6.2 General motion control for servo guns
Continued

• p10.extax.eax_f is the position of the additional axis with logical axis 12.
Logical axis is a system parameter defined for each axis (RobotStudio: Configuration
Editor, Motion, Joint). The robot itself uses logical axes 1-6 and additional axes
use 7-12. The user can change the logical axis number to fit the application. Only
axes with unique logical axis numbers may be activated at the same time.
For a servo gun, the position is defined as the opening distance of the tips in mm.
The value 9E+09 is defined for axes that are not activated.

Independent gun movement

The gun is in independent mode and can be moved to a specified independent
position. During independent mode, the control of the servo gun is separated from
the robot. The gun can be closed, opened, calibrated or moved to a new
independent position, but it will not follow coordinated robot movements.
The instruction IndGunMove is used to set the gun in independent mode and
thereafter move the gun to a specific independent position, see IndGunMove -
Activates independent mode for a servo gun on page 130. This mode can be reset
by executing the instruction IndGunMoveReset. See IndGunMoveReset - Resets
servo gun from independent mode on page 132.

Supervision during general motion control

An out of range supervision will stop the movement if the gun is reaching max
stroke or if it is closed to contact with the tips (reaching min stroke). Motion collision
detection may be activated for the robot. There is also a separate motion supervision
for each controlled axis, including the gun axis. This axis supervision will detect if
the gun arm collides or get stuck. A motion error will occur and the motion will be
stopped.

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6 Servo gun motion control
6.3 Asynchronous movements with force control

6.3 Asynchronous movements with force control

Introduction
The motion functionality described in this section is only valid for servo gun axes.

Opening and closing in general

The gun may be closed asynchronously (independent of current robot movement)
to a predefined plate thickness and tip force. The closing will immediately start to
run the gun arm to the expected contact position (thickness). The closing movement
will interrupt an on-going synchronous movement of the gun. When the tips reaches
the programmed plate thickness, the movement is stopped and there is an
immediate switch from position control mode to force control mode. In the force
control mode a motor torque will be applied to achieve the desired tip force.
The force remains constant until an opening is ordered unless support for multiple
forces are configured. See Multiple gun forces during welding on page 86.
Opening of the gun will reduce the tip force to zero and move the gun arm back to
the pre-close position, that is, the position of the axis specified in the robtarget.
The gun opening may also take place while the robot is moving. But it is not possible
if the robot movement includes a synchronized movement of the servo gun axis.
In that case a motion error, tool opening could not be synchronized with robot
movement, will occur.

Welding
A gun closing is done when performing a weld. The applied force may be taken
from the weld timer or from a RAPID data (spotdata). See spotdata - Spot weld
data on page 140.
During force build up, the thickness of the plates will be measured. The welding
is started when the force is reached but only if the measured plate thickness is
approved. When the weld is ready, the gun is immediately opened to the pre-close
to position.
In the Spot Servo options, the closing, opening, thickness measurement, weld start
and opening is integrated in the SpotL/J and SpotML/MJ instructions. See
SpotL/SpotJ - The basic spot welding instructions on page 95 and SpotML/SpotMJ
- Spot welding with multiple guns on page 100.

Squeezing without welding

A gun closing is also typically done when doing tip dressing or when changing
tips. The force will be held constant for a certain time, and then the gun is opened
up again.
In the Spot Servo options, the SetForce instruction will squeeze the gun with a
specified force, thickness and during a specified time. SetForce takes a
forcedata as argument where these values are defined. A thickness test is
integrated in the instruction. See SetForce - Close and Open a gun with desired
force and time on page 104.

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Continued

Supervision during asynchronous movements with force control

During the position control phase of the closing/opening, motion supervision is
active for the servo gun to detect if the arm collides or gets stuck. There is a
maximum motor torque defined in the motion parameters for the gun that never
will be exceeded in order to protect the gun from damage.
If the force is programmed out of range according to the guns force-torque table,
the output force will be limited to this maximum allowed motor torque and a motion
warning will be logged.
During the force control phase, the motion supervision will supervise the gun
position not to exceed a certain distance from the expected contact position. This
distance, Forced on Position Limit, is defined in the motion gun parameters
(topic Motion, type Supervision) and will typically depend on the flexibility of
the gun arm. This supervision will protect the gun if for instance one tip is lost.
During the force control phase there is an active speed limitation which will limit
the speed of the gun. The speed limit value is defined in the gun parameters (see
the tuning chapter in Application manual - Additional axes and stand alone
controller) or the Servo Gun Setup wizard ( see Application manual - Servo Gun
Setup).
The speed will be actively limited to increase further when the speed limit is reached.
The speed limitation will give a controlled behavior of the gun when it is ordered
to close to a position where the tips not are in contact, avoiding a hard impact when
tip contact is established.

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6.4 Tip management

6.4 Tip management

Introduction
The tip management functionality will find and calibrate the contact position of the
gun tips automatically. It will also update and monitor the total tip wear of the gun
tips. The total tip wear for each gun is stored in a RAPID data (see gundata -
Equipment specific weld data on page 135). The tips are calibrated with special
RAPID instructions. Typically, two gun closings will be performed during a
calibration. The calibration may be done when the robot is standing still, see
Calibrate - Calibrate a servo gun on page 114, or during a robot movement, see
CalibL/CalibJ - Calibrate a servo gun during robot movement on page 108.
Three different types of calibrations are supported: tip wear, tip change and tool
change. All three will calibrate the contact position of the tips. The total tip wear
will however be updated differently by these methods.

Note

If software equalizing is used there are other methods available for the tip wear
compensation. See Software Equalizing on page 169.

Tip wear calibration

To be used after a tip dressing. The gun contact position is calibrated and the total
tip wear of the gun is updated. The calibration movements are fast and the switch
to force control mode will take place at the zero position.

Note

This method must only be used to make small positional adjustments (< 3 mm)
caused by tip wear / tip dressing

Tip change calibration

To be used after mounting a new pair of tips. The gun contact position is calibrated
and the total tip wear of the gun is reset. The first calibration movement is slow in
order to find the unknown tip collision position and switch to force control. The
second calibration movement is fast. This calibration method will handle big
positional adjustments of the gun.
This calibration may be followed by a gun closing in order to squeeze the tips in
place (using the SetForce instruction). A new tip change calibration is then done
to update possible positional differences after the tip squeeze.

Tool change calibration

To be used after reconnecting and activating a servo gun. The gun contact position
is calibrated and the total tip wear of the gun remains unchanged. The first
calibration movement is slow in order to find the unknown tip collision position and
switch to force control. The second calibration movement is fast. This calibration
method will handle big positional adjustments of the gun.

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Continued

The method should always be used after reconnecting a gun since the activation
will restore the latest known position of the gun, and that position may be different
from the actual gun arm position; the gun arm may have been moved when
disconnected. This calibration method will handle big positional adjustments of
the gun.

Tip change requirement

The total tip wear of the gun (stored in RAPID gundata) may be supervised in
order to detect when a tip change is needed. See gundata - Equipment specific
weld data on page 135

Tool center point adjustment

Part of the total tip wear may be used to adjust / optimize the tool center point of
the robot tool (RAPID tooldata). The instructions MeasureWearL or RecalcTcp
should be used in combination with the CalibL/J or Calibrate instructions to
update the fixed tip of the gun (tool center point). For more information see Tip
wear compensation on page 180 and MeasureWearL - Measure current electrode
wear and recalculate the TCP on page 118 or the ReCalcTCP - Calculate current
electrode wear and recalculate the TCP on page 126.

Supervision during tip calibration

The same supervision will be active during calibration as during asynchronous
movements with force control.

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6.5 Installation and service

6.5 Installation and service

Install servo gun parameters

If the system is cold started, the servo gun parameters are most likely not loaded.
1 Load the gun parameters from the FlexPendant via the configuration editor,
tap File and then tap Add new parameters. If a complete moc.cfg file is
loaded, then select Delete existing parameters before loading instead.
2 Restart the system.
3 Activate the gun in order to control and monitor the axis if it is not activated
(normally the gun is setup activated at startup).
The servo gun parameters can also be loaded from RobotStudio, in the configuration
editor.

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Tip

If a backup is available, restore the backup instead, then the complete system
will be ready for production after restart.

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6.5 Installation and service
Continued

Set the servo gun name

After the gun parameters has been installed and the system has been restarted,
the gundata needs to be updated with the servo gun name (mechanical unit name).
For this a service routine is available to search for installed guns in the system,
instead of manually enter the gun name in gundata.
Action Note
1 Run the service routine ManualGunSearch Follow the instructions in the routine.
to find all configured servo guns in the sys-
tem, and add their names to the gundata
array (curr_gundata).
See gundata - Equipment specific weld data
on page 135.
2 Ready.

Servo gun force calibration

There is a RAPID service routine to calibrate the motor torque versus tip force
characteristics, ManualForceCalib. A separate sensor is needed to measure the
tip force. An optional number of force recordings (2-10) can be made where
measured tip force is inserted with corresponding motor torque.
A force calibration must be done in order to get a good force accuracy and also to
protect the servo gun from too high forces.
In the Program Editor, Tap Debug and then tap Call Service Routine. This routine
can also be run from the Spot FlexPendant interface.

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Action Note
1 Run the service routine ManualForceCalib, Change the max allowed force for the
select 'Setup'. gun, the of number of calibrations and the
sensor thickness to be used during the
calibration.
2 Then select 'Run'. This will perform the calib- Follow the instructions in the routine.
rations.

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Continued

Action Note
3 Ready.

Note

The first time this routine is run and if working from a servo gun template file, a
default force table with 2 forces based on the entered max force will be created.
Follow the instructions in the routine.

Note

For the force change functionality to work correctly, the gun positions are stored
in the SG_PROCESS table when performing a force calibration, squeeze_pos1
- 10. It is really important for the gun force accuracy and performance that this
procedure is done properly.
It is also very important that the gun forces used during production later on is in
the range of the force calibration table in order to get a acceptable accuracy of
the force. See Multiple gun forces during welding on page 86.

Note

If a gun service / repair has been made, the force calibration should be done
again to ensure the performance is the same as before.

Servo gun force gravity compensation

In the ManualForceCalib routine it is also possible to setup configuration data
that can be used for gun force gravity compensation. See The type Spot Gun
Equipment on page 31.
This function can be used if a servo gun loses force when the movable gun arm
moves against gravity when closing. Normally there should be no need to
compensate for loss of gun force, but for certain types of guns there may be a risk
that gravity can influence the gun force negatively depending on on the moveable
gun arm weight etc.
In those cases this functionality can be used to minimize the loss of gun force and
maintain a stable force during welding.
There are two methods that can be used to setup the needed compensation data.
• A manual method that requires a hand held force sensor.
• An automatic method that will move the gun (axis 5) between 0 to 90° and
0 to -90° and calculate/estimate the gun force in the "worst" angle and update
the compensation data.

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Continued

In the Program Editor, Tap Debug and then tap Call Service Routine. This routine
can also be run from the Spot FlexPendant interface.

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Action Note
1 Run the service routine ManualForceCalib, Change the force calibration setup data,
select 'Setup'. i.e. the sensor thickness and the max
force to be used during the setup.

2 Then select 'Gravity'. Follow the instructions in the routine.

3 Ready.

WARNING

If using the automatic method the robot will first move to sync position, and then
start move axis 5 in-between 0 and 90° and/or 0 to -90°. Make sure that the robot
can move freely without crashing into objects around it.

Note

The actual force will not be compensated with 100% accuracy, but the deviation
from ordered gun force will be less than without compensation.

Servo gun init calibration

After installing the gun parameters and restarting the system, the gun like any
other additional axis must be calibrated by performing a fine calibration or a
revolution counter update. Apart from other kinds of additional axes, it is also
required to run a RAPID service routine, ManualServiceCalib to find the contact
position or zero position of the gun.
There are two options in this routine that can be run depending on if the gun has
been fine calibrated or if the revolution counters has been updated. See Manual
actions on page 74.

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In the Program Editor, tap Debug and then tap Call Service Routine. This routine
can also be run from the Spot FlexPendant interface.

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Servo gun init calibration after fine calibration

Fine calibration must be performed when installing a new servo gun or if the servo
gun axis is in state Not Calibrated.
Use this procedure to fine calibrate.
Action Note
1 On the FlexPendant go to the Calibration
view, select the desired gun and then tap Note
Fine calibration.
There is no need to jog the axis to any partic- Make sure that new tips are used since
ular position. tip wear data will be cleared.

2 Run the service routine ManualServiceCalib If the gun is considered to be force calib-
option 2. rated, the gun will move fast to the selec-
Follow the instructions in the routine. ted pre-position and then close slowly
until tip contact is detected, since the zero
position is unknown. Otherwise a warning
dialog will be displayed with a question
whether the gun has been force calibrated
or not. Answering Yes will perform the
service calibration anyway, No will end
the routine.

Note

If the gun is not force calibrated and

properly tuned, follow the tuning proced-
ure described in Application manu-
al - Servo Gun Setup.

3 As a result, the gun position is updated to be Ready.

zero in the position of contact and the tip
wear value is reset.

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Servo gun init calibration after revolution counter update

An update of the revolution counter must be performed if the position of the axis
is lost. If this happens, this is indicated by the calibration state Rev. Counter not
updated. These steps are required to update the counter.
Action Note
1 On the FlexPendant go to the Calibration
view, select the desired gun and tap Update
revolution counters.
There is no need to jog the axis to any partic-
ular position.
2 Run the service routine If the gun is considered to be force calib-
ManualServiceCalib option 1. rated, the gun will move slowly until tip
Follow the instructions in the routine. contact is detected, since the zero posi-
tion is unknown. Otherwise a warning
dialog will be displayed with a question
whether the gun has been force calibrated
or not. Answering Yes will perform the
service calibration anyway, No will end
the routine.

Note

If the gun is not force calibrated and

properly tuned, follow the tuning proced-
ure described in Application manu-
al - Servo Gun Setup.

3 As a result, the gun position is updated an

integer number of revolutions to be zero in
the position of contact. Tip wear of the gun
remains unchanged.
4 Ready.

Note

The first time this routine is run and if working from a servo gun template file, a
default force table with 2 forces based on the entered max force will be created.
Follow the instructions in the routine.

Note

It will not be possible to run any Spot instructions until a gun init calibration has
been done.

WARNING

If the force calibration procedure has not been done properly, the servo gun can
be damaged, please make sure that the servo gun is force calibrated and tuned
and that the force calibration values are correct, see Application manual - Servo
Gun Setup.

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6.5 Installation and service
Continued

Disconnect and reconnect a servo gun, tool changing

If the servo gun is deactivated, using the DeactUnit instruction, it may be
disconnected and removed. The gun position at deactivation will be restored when
the gun is connected and reactivated. Make a tool change calibration to make
sure the tip position is OK in case the gun arm has moved while it was disconnected.
Simplified tool change procedure.
1 Run the routine DeactUnit.
2 Disconnect the gun.
3 Connect the second gun.
4 Run the routine ActUnit.
5 Perform a tool change calibration for the second gun.
6 Start using the second gun.
For more information about tool changing see Servo tool change on page 211.

Recover from accidental servo gun disconnection

If the motor/resolver cables are disconnected by accident when the servo gun is
activated, the servo gun must be deactivated in order to move the robot to a service
position.
1 To deactivate the gun, tap Deactivate in the Jogging window and deactivate
the mechanical unit.
2 Move the robot to a service position and repair the gun.
3 Perform a revolution counter update since the position has been lost.
4 Perform a gun position init calibration option 1, see Servo gun init calibration
on page 205.

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Continued

Replace a servo gun

Normally there is no need to replace the gun parameters if the the new gun is
identical to the old one.
1 Connect the new gun.
2 Startup the system.
3 Perform a fine calibration of the gun.
4 Perform a gun position init calibration, see Servo gun init calibration on
page 205.
5 Perform a force calibration if it is not done before for that gun, see Servo gun
force calibration on page 203.

Note

The spare gun must have same parameter names as the original gun, otherwise
the installation will just add the new gun, keeping the old gun in parallel. Eg
SGUN_1.

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6.6 Stationary gun

6.6 Stationary gun

Description
A stationary servo gun is mounted on the floor and the robot is holding the work
piece. The only difference when using a stationary servo gun is that the robot tool
(RAPID tooldata) should be defined as stationary (robhold = false), and the used
work objects as robot held.

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6.7 Servo tool change

6.7 Servo tool change

Description
It is possible to change servo gun during production. The functionality is realized
as the option Servo Tool Change. There is no software limitation in how to combine
different kinds of servo guns (for example brands, sizes or motors) with a tool
changer.
The used servo guns share the same drive unit, and the same node on the
measurement board. They are activated as different mechanical units, but of course
never at the same time. They may use the same or different logical axis.

Prerequisites
Changing gun requires a deactivation of the operating gun and then unplugging
its motor cables. The motor cables are plugged in to the next gun, and this gun is
activated and ready to run. The plug-in mechanism requires a mechanical tool
changer interface to the guns. One individual set of gun parameters are installed
for each gun.

Limitations
Servo tool change can be used up to 8 different tools but is limited by 14 axes in
total for the drive module. E.g if robot is on a track motion or if another additional
axis is connected to a drive module it reduces that number of allowed tools that
can be used with servo disconnect.

Note

Tool changing with servo guns requires the option Servo Tool Change.

Changing Motion parameters

The system parameters in type Mechanical Unit and Relay and Measurement
Channel (topic Motion) should be set like this when tool changing.
1 Set Activate at StartUp to No.
2 Set Deactivate Ptc at Disconnect to Yes.
3 Define Use Connection Relay with the same name as defined in Name, for
example SGUN1.
4 Define an Input Signal in type Relay with a signal that is defined in the topic
I/O (EIO.cfg),
For example diMecUnitName, and this input signal should be connected to
a sensor on the tool stand or the tool changer.
5 Set the parameter Disconnect at Deactivate in type Measurement Channel
to Yes.

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6.7 Servo tool change
Continued

If this setup is used a safe tool change functionality will be achieved.

Note

To be sure that the right servo gun is activated and have a safe way to tool
change, it is recommended that the connection relay functionality is used when
tool changing.

Example, tool change procedure

The procedure to switch between gun 7A and gun 7B must includes these minimal
actions (excluded here is the needed communication with the tool changer, the
tool stand and necessary robot movements):
1 Deactivate gun SGUN1.
The position of gun SGUN1 is stored.
2 Disconnect gun SGUN1.
Disconnect the servo gun motor cables.
3 Connect gun SGUN2.
Connect the motor cables to motor SGUN2.
4 Activate gun SGUN2.
The latest position of gun SGUN2 is restored.
5 Run a tool change calibration of gun SGUN2.
Make sure the position is correct.

WARNING

If the servo gun axis has been moved during deactivation, the position of the
axis might be wrong after activation, and this will not be detected by the controller.
The position after activation will be correct if the axis not has been moved, or if
the movement is less than 0.5 motor revolutions. Always use the tool change tip
calibration after activation. The tool change calibration will adjust any positional
error caused by gun movements during deactivation.

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6.7 Servo tool change
Continued

WARNING

It is important that no other mechanical units that are used with a tool changer,
are activated but only the one corresponding to the currently connected servo
gun!
An activation of wrong mechanical unit may cause unexpected movements or
errors. Some tool changers support I/O signals that specifies which gun is
currently connected. That information may be used to make sure correct
mechanical unit is activated. It is also possible to lock activation of not connected
mechanical units by specifying a digital input (DI) in the connection relay which
is a motion system parameter (type Relay in topic Motion) for each servo gun.
This digital input, which also is setup in the EIO.cfg, is read when the mechanical
unit is activated. If set to 1 the activation will take place normally, otherwise a
recoverable motion error will occur and the activation will be denied.

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 7 FlexPendant Interface
7.1 Application Overview

7 FlexPendant Interface
7.1 Application Overview

Introduction
This chapter describes the Spot FlexPendant interface intended to simplify the use
of the spot welding functionality. The operator have the most common information,
data and signals collected together in one place, easy to use and understand. This
is not a replacement for the standard FlexPendant functionality, but it can be seen
as a complement. Spot related information are presented in an instructive way,
enabling operators to easily and quickly get their every day tasks done.
To start RobotWare Spot, tap the ABB menu and then tap RobotWare Spot. The
RobotWare Spot main view will be started. From here all spot related functions in
the GUI can be accessed. For further information on using the FlexPendant, see
Operating manual - IRC5 with FlexPendant.

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Topics
The Spot GUI covers following topics:
• Main View
• Process Signals
• Process Data
• Manual Actions
The Spot main view provides basic information about the current executing spot
program with possibilities to reach other views and sub views. You can follow the
welding process in every instruction by looking in the welding progress part of the
window. It is also possible to quickly change or edit some of the data used in a
spot instruction by tapping the blue colored text, spotdata and gundata. The
equipment I/O status is shown in this window and the spot process status, also

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7.1 Application Overview
Continued

the latest errors and warnings are shown and can be accessed from here. The
manual actions can be accessed and run from this view also.

Tip

It is possible to configure an additional test view to be able to run RAPID program

from the FlexPendant Interface. Go to, ABB/Control Panel/FlexPendant/Additional
Test View.

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7.2 Main View

7.2 Main View

Basic functionality in the main view

1 Tap the ABB menu and then select RobotWare Spot. A window will appear
containing functionality to follow the welding progress step by step, view the
latest/current spot instruction, see the name and path to the executing weld
program, access manual actions, access and edit the process data types
and also see the overall status of the equipment signals connected to the
welding equipment.

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2 Tap the Welding Progress control to access and edit simulation data.
3 Tap Process Data to view and edit the process data.
4 Tap Manual Actions to access an run the spot service routines.
5 Tap Process I/O to view the connected equipment signals.
6 Tap the Process Event Log to view the latest spot error or warning messages
(the latest 20 messages will be stored.)
7 Tap Task button to view another spot welding robot.

Viewing or editing data

1 Tap the blue colored data or tap Process Data.
2 Select the data to be changed.

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7.2 Main View
Continued

3 View or edit the value.

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4 Tap OK to write the new value to the controller and to leave the data dialog
and return to the Status window.
Tap Undo to reset the window from all changes.
Tap Cancel to return to the Status window without any changes.

Simulation
If you change the sim_type in simdata, when the value is separated from 0 (0 means
weld mode) a little stop sign with a status text is visible at the top right corner in
every window. Tap the Welding Progress control to edit the simdata, see picture
below. For more information about simulation see Simulation modes on page 72.

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7.2 Main View
Continued

Process Event Log

Information in this area shows if there is a new Spot error. Touching the button will
open a list with the latest Spot errors from the error log, with possibilities to get
more information about the problems. The error information in the Main View will
be cleared when a new Spot instruction is executed.

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7 FlexPendant Interface
7.3 Process Signals

7.3 Process Signals

Process Signals
Process Signals displays the input and output signals of the configured and
connected spot process equipment, media panel, weld timer and gun.
Digital signals are show in an illustrative way, reflecting the real equipment of the
specific spot system in use. When running the system in manual mode, it is possible
not only to view but also to set new values to process signals.

Note

In order to set signals, the right access is needed, IO write access. This gives
the possibility to set I/O signal values. For more information about grants see
Operating manual - IRC5 with FlexPendant.

Basic functionality in the Process Signals window

1 Tap the Process I/O button in the RobotWare Spot main view. A window
appears containing functionality for viewing digital input signals connected
to different parts of the equipment and for setting/resetting some output and
group signals.

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7.3 Process Signals
Continued

2 Tap View to change to other parts of the equipment.

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3 Tap Gun to switch between all available guns in the system.

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Setting or resetting process signals

1 Select the signal to be changed.
Depending if it is an output or a group signal to change you get different
behavior in the command bar.

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2 To change an output signal toggle between 1 and 0 to set or reset the signal.

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3 To change a group signal tap 123... to open a numeric pad to written in a

new value. Then tap OK to close the pad.

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7.4 Process Data

7.4 Process Data

Process Data
Process Data presents spot specific data types and lists all instances of a selected
data type, thus offering a quick and easy way to edit or view simdata, forcedata,
gundata, or spotdata in order to improved the system performance.

Note

In order to edit RAPID data, the right access is needed, Modify current value.
This gives access to modify the value of RAPID variables. For more information
about grants see Operating manual - IRC5 with FlexPendant.

Basic functionality in the Process Data window

1 Tap Process Data in the command bar in RobotWare Spot main view. A
window appears containing functionality for viewing and editing data types
connected to the spot welding functionality.

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2 To update the window and do a new search for the selected data type tap
Refresh.

Viewing data types

The data types available from the menu Data Type are simdata, forcedata,
gundata, and spotdata. Each type is thoroughly described in Programming on
page 63.
1 Tap Data Type. Select the data type you want to view or edit.

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2 To change the data of the listed data type, tap the data.

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3 Tap the value. The declaration of the data is displayed.

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Editing data types

1 Select the data instance you wish to edit from the list.
2 Select the component you want to edit in the Data dialog.
3 Depending on the component data type, enter the new value in the numeric
or alphabetic pad that will appear.
4 When ready tap OK button to close the pad.
5 Tap Refresh to cancel all changes and start from the beginning again.
6 Tap OK to write the new value to the controller and to leave the Data dialog.

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7.4 Process Data
Continued

More information on the individual components can be found in spotdata - Spot

weld data on page 140, gundata - Equipment specific weld data on page 135, forcedata
- Spot gun force data on page 143, and simdata - Simulation data on page 146.

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7.5 Manual Actions

7.5 Manual Actions

Manual Actions
Manual Actions contains all available spot related service routines in the system.
The user can easily start any routine by tapping the button for the action he would
like to run.

Basic functionality in the Manual Actions window

1 Tap Manual Actions button in the RobotWare Spot main view. A window
appears containing all available spot related service routines in the system.

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Starting a service routine

1 Make sure that a program is loaded without errors and set the system in
MotorsOn state.
2 Tap the service routine you would like to run.
For a complete description of the available service routines, see Manual actions
on page 74.

Manual versus Automatic mode

If the system is in manual mode you can run service routines, view or edit data
and set or reset output signals. When you switch to automatic mode you loose the
possibility to edit data and set or reset output signals but you can still view the
current data or output signals.

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 7 FlexPendant Interface
7.6 Customizing the GUI

7.6 Customizing the GUI

Configuration of the Process Signals view

The I/O signal content of the Process Signals view can be modified if needed. The
signal names used are defined in the process configuration.
The configuration is separated for each view:
Process Cabinet: See The type Spot Weld Equipment on page 27
Gun: See The type Spot Gun Equipment on page 31.
Water And Air Unit: See The type Spot Media Equipment on page 37.

Tip

It is also possible to add custom signals in each view if needed in User defined
gui signal1-10 in the process configuration. These signals are not used in
the spot process, only used to show additional signals in the spot gui.

Configuration of visible Process Data

The simdata and forcedata can be hidden if needed in the Process Data view. See
The type Spot GUI on page 41

Configuration of the Manual Actions view

The Manual Actions view can be modified to fit the current configuration. Possible
configurations are routines for a Servo, Pneu or Combined system. See The type
Spot GUI on page 41

Configuration of automatic startup of the Spot GUI

It is possible to configure automatic startup of the GUI via process configuration,
Show Spot GUI at startup. See The type Spot GUI on page 41

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 8 Bosch FlexPendant Interface
8.1 Application Overview

8 Bosch FlexPendant Interface

8.1 Application Overview

Introduction
This chapter describes the user interface intend to simplify the use of the Bosch
weld timer functionality. To access the Bosch FlexPendant interface you need the
software option Bosch Weld Timer Interface. You also need recommended hardware
(Bosch weld timer, cable for communication).
The operator has the most common data and weld timer errors and fault collected
together in one place, easy to use and understand. To start Bosch Timer tap the
ABB menu and then tap Bosch Weld Timer. The Bosch Timer desktop shows all
common weld timer functions. For further information on using the FlexPendant,
see Operating manual - IRC5 with FlexPendant. For information about weld
parameters, see Bosch operating and programming manual volume 2.

en1200000605

Bosch Timer desktop has four function buttons:

• Pre Warning
• Weld Fault
• Last Weld
• Weld Parameters

Pre Warning
Pre Warning present information about all electrodes configured for a certain weld
timer.

Weld Fault
Weld Fault lists all weld faults and warnings connected to the welding process and
the weld timer.

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8.1 Application Overview
Continued

Last Weld
Last Weld present information about the last weld performed by the weld timer.

Weld Parameters
Weld Parameters offering a quick and easy way to view or edit ordinary weld
parameters.

General information before start using the Bosch interface

The Bosch application cannot access all timer functions, so before using the Bosch
application some necessary offline setup is needed, use the PC software
BOS5000/BOS6000. Connect the PC to the X1 serial connection port on the timer.
• Transformer parameter setup.
• Gun force and weld current calibration of the electrodes.

Note

If or when an extra ordinary weld fault (hardware fault) occurs the user have to
connect the BOS5000/BOS6000 pc-software to get the real cause of the problem.

Note

To do a backup or restore the weld timer the user have to connect the
BOS5000/BOS6000 pc-software to take this action.

Note

Make sure you understand what happens to the welding sequence if you turn
off the Ignition parameter under the Settings or General node on the FlexPendant,
or if you change the simulation type in RobotWare Spot, see Simulation modes
on page 72.

Note

Avoid to close the application during loading or saving weld parameters in the
Weld Parameters window, this can lead to loss of data.

Limitations
• It is only possible to connect one weld timer to a robot controller.
• Avoid disconnecting the RS232 cable during loading or saving weld
parameters in the Weld Parameters window, the Bosch MMI application
should be closed before disconnecting the cable.
• It is not possible to access all timer functions and settings from the Bosch
MMI application.
• It is not possible to backup or restore weld parameters from the Bosch MMI
application.
• Not all possible timer faults will be visible in the Weld Fault view.
• Can not be combined with the option 634-1 MultiProcess.

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8.1 Application Overview
Continued

Manual versus Automatic mode

If the system is in manual mode you can view or edit weld parameters and see
information about the warning and error that can occur in the system. When you
switch to automatic mode or when executing a program you cannot open the Weld
Parameters window but you can still open the other windows.

General information
The information at the upper right side shows if the communication with the timer
is ok or not (if problem see the system Event Log for further information). In the
upper left side you have the information about the used device net protocol for the
connected timer.

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8.2 Pre Warning

8.2 Pre Warning

Basic functionality in the Pre Warning window

1 Tap Pre Warning.
A window will appear containing information of all configured electrodes in
the weld timer.

en1200000588

2 Tap Reset to reset the value of the selected electrode (only possible if a row
is selected in the list view).
3 Tap Update to search for new information about the electrodes.
4 Tap Close to return to the Bosch Timer desktop.

Resetting the value of an electrode

1 Select the electrode in the list view to be changed.
2 Tap Reset.

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8.3 Weld Fault

8.3 Weld Fault

Basic functionality in the Weld Fault window

1 Tap Weld Fault.
A window will appear containing information about all errors and warnings
connected to the welding process and the weld timer.

en1200000589

2 Tap twice on a row in the list view to open up a new window for more
information about the weld error or warning.

en1200000590

3 Tap Close to return to the Bosch Timer desktop or OK to return to the

previous window.

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8 Bosch FlexPendant Interface
8.4 Last Weld

8.4 Last Weld

Basic functionality in the Last Weld window

1 Tap Last Weld. A window will appear containing information about the last
weld performed by the weld timer.

en1200000591

2 Tap Close to return to the Bosch Timer desktop.

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8.5 Weld Parameters

8.5 Weld Parameters

Basic functionality in the Weld Parameters window

1 Tap Weld Parameters.
A window will appear containing information about the weld parameters that
is possible to view and edit in the weld timer (this view is not available in
automatic mode).

en1200000592

2 Tap Change Program No. to view weld parameters for different programs
in the weld timer.
3 Tap Browse Electrodes to change electrode number.
4 Tap Close to return to the Bosch Timer desktop.

WARNING

Changing parameters in this view requires very good knowledge about the welding
equipment and the welding parameters, otherwise it is easy to damage or destroy
the welding equipment and/or compromise the welding quality.

Note

In order to edit RAPID data, the right access is needed, Modify current value.
This gives access to modify the value of any RAPID variable. For more information
about grants see Operating manual - IRC5 with FlexPendant.

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8 Bosch FlexPendant Interface
8.5 Weld Parameters
Continued

Sheets node
The sheets node contains parameters related to the sheet thickness and sheet
tolerance for each welding program.
See Bosch weld timer manual volume 2 for more information about the parameters.

xx1600000035

1 Tap Change Program No. to view weld parameters for different programs
in the weld timer.
2 Tap Save to save the changes done to the parameters and stay in current
window.
3 Tap Close to close the window and return to the previous window.

Note

The values can be specified as a I/O group value. The values can be recalculated
into millimeters if configured, see How to use spot data programmed in the weld
timer on page 258.

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8.5 Weld Parameters
Continued

Settings node
The settings node contains parameters related to the selected welding program.
See Bosch weld timer manual volume 2 for more information about the parameters.

en1200000595

1 Tap Change Program No. to view weld parameters for different programs
in the weld timer.
2 Tap Save to save the changes done to the parameters and stay in current
window.
3 Tap Close to close the window and return to the previous window.

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8.5 Weld Parameters
Continued

Slope node
The slope node contains parameters related to the welding sequence, if up and
down slope of the current is required changes are done here.
See Bosch weld timer manual volume 2 for more information about the parameters.

en1200000594

1 Tap Change Program No. to view weld parameters for different programs
in the weld timer.
2 Tap Save to save the changes done to the parameters and stay in current
window.
3 Tap Close to close the window and return to the previous window.

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8.5 Weld Parameters
Continued

Supervision node
The supervision node contains parameters related to the supervision of the current.
Each weld time (1, 2, 3) can be supervised separately.
See Bosch weld timer manual volume 2 for more information about the parameters.

en1200000601

1 Tap Change Program No. to view weld parameters for different programs
in the weld timer.
2 Tap Save to save the changes done to the parameters and stay in current
window.
3 Tap Close to close the window and return to the previous window.

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8 Bosch FlexPendant Interface
8.5 Weld Parameters
Continued

Cycle node
The cycle node contains parameters related to the welding sequence.
See Bosch weld timer manual volume 2 for more information about the parameters.

en1200000593

1 Tap Change Program No. to view weld parameters for different programs
in the weld timer.
2 Tap Save to save the changes done to the parameters and stay in current
window.
3 Tap Close to close the window and return to the previous window.

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8.5 Weld Parameters
Continued

HeatStepper node
The heatstepper node contains parameters related to the wear of the electrodes,
if the customer use this parameters changes are done continuously.
See Bosch weld timer manual volume 2 for more information about the parameters.

en1200000596

1 Tap Change Program No. to view weld parameters for different programs
in the weld timer.
2 Tap Browse Electrodes to change electrode number.
3 Tap Save to save the changes done to the parameters and stay in current
window.
4 Tap Close to close the window and return to the previous window.

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8.5 Weld Parameters
Continued

Stepper node
The stepper node contains parameters related to the wear of the electrodes, if the
customer use this parameters changes are done continuously.
See Bosch weld timer manual volume 2 for more information about the parameters.

en1200000597

1 Tap Change Program No. to view weld parameters for different programs
in the weld timer.
2 Tap Browse Electrodes to change electrode number.
3 Tap Save to save the changes done to the parameters and stay in current
window.
4 Tap Close to close the window and return to the previous window.

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8.5 Weld Parameters
Continued

Dress node
The dress node contains parameters related to the wear of the electrodes, if the
customer use this parameters changes are done continuously.
See Bosch weld timer manual volume 2 for more information about the parameters.

en1200000598

1 Tap Change Program No. to view weld parameters for different programs
in the weld timer.
2 Tap Browse Electrodes to change electrode number.
3 Tap Save to save the changes done to the parameters and stay in current
window.
4 Tap Close to close the window and return to the previous window.

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8.5 Weld Parameters
Continued

Electrode node
The electrode node contains parameters related to the electrode (electrode number),
changes to this parameters are done in the start phase or when a new gun is
initiated.
See Bosch weld timer manual volume 2 for more information about the parameters.

en1200000599

1 Tap Change Program No. to view weld parameters for different programs
in the weld timer.
2 Tap Browse Electrodes to change electrode number.
3 Tap Save to save the changes done to the parameters and stay in current
window.
4 Tap Close to close the window and return to the previous window.

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8.5 Weld Parameters
Continued

General node
The general node contains parameters related to the complete weld timer. They
are normally set up in the start up phase.
See Bosch weld timer manual volume 2 for more information about the parameters.

en1200000600

1 Tap Save to save the changes done to the parameters and stay in current
window.
2 Tap Close to close the window and return to the previous window.

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8 Bosch FlexPendant Interface
8.6 Communication and configuration

8.6 Communication and configuration

Configuration
The communication is done via an RS232 cable connected from the controller to
the weld timer.
The necessary configuration is loaded when installing the system, and it is located
in the SIO configuration, ABB/Configuration/Topics/Communication.
Example:
SIO:CFG_1.0:5:0::
#
COM_PHY_CHANNEL:
-Name "COM1" -Connector "COM1" -Baudrate 19200 -Parity "even"
#
COM_TRP:
-Name "trpbosv24_1:" -Type "BOSV24" -PhyChannel "COM1"
Currently it is not possible to connect more than one weld timer to the robot
controller.

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 9 Customizing RobotWare-Spot
9.1 Introduction

9 Customizing RobotWare-Spot
9.1 Introduction

Customizing possibilities
The Spot Options are general and can be extensively customized to fit to different
spotweld equipments. The have a default "ready to use" functionality after
installation, but can easily be customized by changing configuration data, RAPID
data, and RAPID routines from RobotStudio for example.
One purpose of the customizing process can be to reduce the amount of data and
number of variables presented to the operator.
The following customizing is described in this manual:
• How to remove not used signals from the process sequence on page 250
• How to remove not used process hooks on page 251
•
• How to change the number of guns equipments to be used on page 252
• How to define max/min values for data components on page 254
• How to change the Spot data types on page 255
• How to add functionality in the process sequence on page 256
•
• How to use spot data programmed in the weld timer on page 258
•
• How to set the number of automatic rewelds after weld error on page 260
•
•
• How to package and install the result from the customizing on page 261

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9 Customizing RobotWare-Spot
9.2 Files to be changed during customizing

9.2 Files to be changed during customizing

Description
Customizing can be done by changing a number of predefined data and routines,
preferably using a standard PC with RobotStudio. The following RAPID modules
and configuration files can be changed during the customizing process:

Customizable files in the system

System module SWUSER System module SWUSRM

Data Data

Routines Routines

proc.cfg eio.cfg mmc.cfg moc.cfg

xx1200000602

SWUSRM
This module can be modified if the the default data types are changed. Normally
there is no need to edit this module, but the possibility exists.
SWUSRM is running in all motion tasks and contains routines for data transfer
between the user code and the kernel code, for example DefineSpotData and
DefineGunData. This module can be changed from RobotStudio if needed.
See SWUSRM on page 164.

SWUSER
This module can be modified if there is a need to customize the process sequence,
ie add additional logic or conditions during the process, or change the content of
the default types. The data and routines in this module are possible to modify from
RobotStudio.
SWUSER is running in all task in the system and contains all the data definitions
for the Spot data types and current values for the different defined Spot related
data types. It also contains a number of process hook that can be modified if
needed. See SWUSER on page 158.

Process configuration
The process configuration is used to to setup the spot system. See Spot process
configuration on page 21.

Note

Depending on the spot configuration, different default process configuration will

be installed.

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 9 Customizing RobotWare-Spot
9.2 Files to be changed during customizing
Continued

I/O configuration
Depending on the spot configuration, a different default setup of spot weld signals
will be installed, and all signals are connected to virtual I/O units. See Spot I/O
configuration on page 42 or Spot Weld timer configuration options on page 55.

Tip

If a predefined Weld Timer Configuration option is installed, only signals for one
gun equipment will be defined.

MMC configuration
This configuration file contains for example information about which instructions
are included in the different instruction pick lists, and which routines are added to
the Debug/Call routine menu in the program editor, to be used as manual actions.
See Manual actions on page 74.

SYS configuration
This configuration file contains for example information about which tasks that the
user modules are loaded in. See System modules on page 158.

MOC configuration
This configuration file contains for example parameters for servo guns. See Servo
gun motion control on page 195

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9 Customizing RobotWare-Spot
9.3.1 How to remove not used signals from the process sequence

9.3 Customizing guides

9.3.1 How to remove not used signals from the process sequence

Description
Use RobotStudio or the FlexPendant to edit the process configuration.
Example on FlexPendant:
Remove the diWaterFlow2Ok signal from the Water flow sensor2 instance,
this will disable the function of the signal. See The type Spot Media Equipment on
page 37
1 Press ABB/Control Panel/Configuration/Process/Spot Media Equipment.
2 Replace the signal name with the predefined NO_SIGNAL string in the Water
flow sensor2 instance. See The type Spot Media Equipment on page 37
3 Save the configuration and restart the system.
The same procedure can be used on other not used signals if needed.

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 9 Customizing RobotWare-Spot
9.3.2 How to remove not used process hooks

9.3.2 How to remove not used process hooks

Description
Use RobotStudio or the FlexPendant to edit the SWUSER module.
By default the SWUSER module are setup with a number of process hooks (routines),
where custom code can be added if there is a need to add additional logic that is
not part of the default process.
These routines can be removed if not needed to get a cleaner code.
Remove the SwInitUserIO user routine from the SWUSER module. See Process
hooks on page 160
1 Save the module and/or apply the changes.
2 Restart the system, with Reset RAPID.
The same procedure can be used on other not used process hooks if needed.

Note

The user hook SwPostWeld is used to update the weld counter in the used
gundata. If this hook is removed the counter will not update after weld.

Note

Code changes in this module requires a restart using the mode Reset RAPID.

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9 Customizing RobotWare-Spot
9.3.3 How to change the number of guns equipments to be used

9.3.3 How to change the number of guns equipments to be used

Description
Use RobotStudio to edit the SWUSRM and SWUSER modules.
By default the user modules are setup for one gun equipment, or four gun
equipments depending on the selected configuration (Multiple Guns etc). But it is
possible to use and configure up to ten (10) gun equipments in the system if the
default configuration in not sufficient.
1 Add or remove the number of instances in following spot data releated arrays
in SWUSER.
• curr_gundata
• curr_spotdata
• curr_forcedata
Example:
PERS spotdata curr_spotdata{2} := [[0,0,0,0],[0,0,0,0]];
2 Add or remove the predefined gunnum gun index data in SWUSRM
accordingly, ie. gun1, gun2.
Example:
PERS gunnum gun1 := 1;
PERS gunnum gun2 := 2;
3 Add or remove spot equipments and the signals needed for that equipments
in the process configuration. See Spot process configuration on page 21.
Example:

xx1400002301

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 9 Customizing RobotWare-Spot
9.3.3 How to change the number of guns equipments to be used
Continued

4 Add or remove signals and I/O units in the I/O configuration for the
equipments to be used if required. See Spot I/O configuration on page 42 or
Spot Weld timer configuration options on page 55.

Tip

If an additional spot weld timer option is selected when creating a new system,
that is, a Bosch weld timer option (options 782-X), only one process task and
configurations for one gun equipment will be installed. The installed I/O
configuration can then be easily modified in RobotStudio to fit the required
equipment.

Note

Code changes in this module requires a restart using the mode Reset RAPID.

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9 Customizing RobotWare-Spot
9.3.4 How to define max/min values for data components

9.3.4 How to define max/min values for data components

Description
Use RobotStudio to access the process configuration.
It is possible to change the max and min values for a number of data components.
The limits will be tested at runtime. See The type Spot System on page 23.

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 9 Customizing RobotWare-Spot
9.3.5 How to change the Spot data types

9.3.5 How to change the Spot data types

Description
Use RobotStudio to edit the SWUSER and the SWUSRM modules.

To... Note
Change the definition of the Spot data types in SWUSER It is possible to:
to desired. For more information see SWUSER on • Add or delete data compon-
page 158. ents
Example: add new components for second gun force in • Move data components
forcedata. from for example gundata
RECORD forcedata to spotdata
num tip_force; • Change the names of the
num force_time; data components
num plate_thickness;
num plate_tolerance;
num tip_force2;
num force_time2;
ENDPROC

Change the structure and the default values of following • curr_gundata

arrays in SWUSER (if corresponding data type is • curr_spotdata
changed). • curr_simdata
Example new components in forcedata: • curr_forcedata
PERS forcedata force1 :=
[1000,2,0,0,500,2];

Change corresponding instructions in the data definition • DefineSpotData

routines in SWUSRM if needed. These routines are used • DefineGunData
to connect the user defined data components to internal • DefineForceData
data. For more information see SWUSRM on page 164.
• DefineSimData

Note

Code changes in this module requires a restart using the mode Reset RAPID.

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9 Customizing RobotWare-Spot
9.3.6 How to add functionality in the process sequence

9.3.6 How to add functionality in the process sequence

Description
Use RobotStudio to edit the SWUSER module.
If the supervision during the weld process needs to be changed, add code to the
process hooks.
For example:
Add an ErrWrite instruction in the error handling sequence and set a custom
signal doMyAlarmSignal.
PROC SwPreWeld(num GunNum, INOUT string ErrText)
VAR bool timeout;
! Wait for my equipment ok signal, max 2 seconds.
WaitDI diMyEquipmentOK, 1 \MaxTime := 2 \TimeFlag := timeout;
IF timeout THEN
ErrText := "My equipment is not ok";
SetDO doMyAlarmSignal, 1;
RETURN;
ENDIF
ENDPROC
1 Add or change the code in the process hooks in SWUSER. See description
of the process hooks in Process hooks on page 160.
2 Apply changes and perform a Restart Rapid restart.
If the default autonomous supervision has to be changed, the supervision task
routine in SWUSER has to be changed.
The normal way to add supervisions is to connect the supervised signal to a trap
routine, e.g. (MySupTrap) and create a new supervision routine which is called
from the trap routine.
For example:
PROC SupervisionInit()
IDelete my_sup_init;
CONNECT my_sup_init WITH MySupTrap;
ISignalDO doMySupSignal, 1, my_sup_init;
ENDPROC
TRAP MySupTrap()
TEST INTNO
CASE my_sup_init:
MySupervisionProc;
ENDTEST
ENDTRAP
PROC MySupervisionProc()
TPWrite "Executing MySupervisionProc";
SetDO doMyAlarmSignal, 1;
ENDPROC

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9.3.6 How to add functionality in the process sequence
Continued

See the predefined supervisions in Supervision task hook on page 163.

Note

Code changes in this module requires a restart using the mode Reset RAPID.

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9.3.7 How to use spot data programmed in the weld timer

9.3.7 How to use spot data programmed in the weld timer

Description
Some weld timers are prepared for storing data like tip_force and
plate_thickness for each weld program in the timer. When the robot controller
sends a new program number the timer responds with this data (for example on
separate input groups). Then it is possible to use this data instead of corresponding
data from the current spotdata.
1 Make sure that the process configuration is setup to use weld timer data
instead of the default spotdata parameters, see The type Spot Weld
Equipment on page 27.
If the optional group signals Gun force from timer [GI], Plate
thickness from timer [GI] and Plate tolerance from timer
[GI] are used, the default data in spotdata will be disabled if the
corresponding data are set to -1.
Using the optional Gun force from timer [GI signal group will also
enable the possibility to use multiple forces during the weld cycle, that is
after the weld start signal has been set and before the weld complete signal
is set. The kernel will supervise this signal during the weld and change to a
higher or lower value when the group value changes. See Multiple gun forces
during welding on page 86.

Note

This functionality may already be prepared depending on the spot

configuration.

Note

To activate the use of the timer input signals the corresponding parameter
in spotdata must be set to -1, e.g. my_spot.tip_force := -1;
See spotdata - Spot weld data on page 140.

2 If needed, not used data components can be removed from spotdata in

SWUSER. Do not forget to modify the default data declarations int the
modules. See How to change the Spot data types on page 255.
For example, remove all parameters except the weld program parameter.
Definition of default process spot data:
RECORD spotdata
num prog_no;
num tip_force;
num plate_thickness;
num plate_tolerance;
ENDRECORD

Continues on next page

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 9 Customizing RobotWare-Spot
9.3.7 How to use spot data programmed in the weld timer
Continued

Definition of customized process spot data:

RECORD spotdata
num prog_no;
ENDRECORD

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9 Customizing RobotWare-Spot
9.3.8 How to set the number of automatic rewelds after weld error

9.3.8 How to set the number of automatic rewelds after weld error

Description
By default the automatic reweld function is deactivated.
Use RobotStudio to change the number of automatic rewelds, set the data Number
of automatic rewelds in the system configuration to the desired value. See
The type Spot Error Handling on page 25.
•
•
•

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 9 Customizing RobotWare-Spot
9.3.9 How to package and install the result from the customizing

9.3.9 How to package and install the result from the customizing

Description
After customizing the default template user modules and configuration files, it is
appropriate to create a new directory with the changed files for each customized
variant and load it as an RobotWare Add-In. This add-in can then be included via
Installation Manager in RobotStudio.
When the Add-In is loaded into the system, the default spot user modules located
in the home directory and configuration files will be replaced with the customized
modules and configuration files included in the Add-In.
Fore more information about RobotWare Add-Ins, see Application
manual - RobotWare Add-Ins.

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This page is intentionally left blank
 Index

Index ManualSpot, 74
MeasureWearL, 118
Multiple gun forces during weld, 86
7
782-11 Bosch PROFINET MFDC, 59 O
782-7 Bosch DeviceNet MFDC, 55 OpenHighLift , 133
782-1 Bosch DeviceNet AC, 55 options
782-11 Bosch PROFINET MFDC, 59
A 782-7 Bosch DeviceNet MFDC, 55
Additional axes, 195
782-1 Bosch DeviceNet AC, 55
B Servo Tool Change, 211
BOS5000/BOS6000, 230 Simulated Weld Timer I/O, 43, 47, 51
Bosch FlexPendant Interface, 229 Spot, 15
Spot Servo, 15
C Spot Servo Equalizing, 15
CalibJ, 108
CalibL, 108 P
Calibrate, 114 Power failure behaviour, 79
Changing Motion parameters, 211 Process configuration, 21
CloseHighLift, 133 Process data, 223
Configuration, 21 Process sequence, 76
Customizing Spot, 247 Process signals, 220
Customizing the GUI, 227 Programming example pneumatic gun, 67
Programming example servo gun, 66
D Programming principles, 19
Deflection Compensation, 170 Programming spot welding instructions, 70
Program stop behaviour, 79
E
Editing instructions, 71 Q
Error handling, 81 Quick start for servo gun, 64
Error handling, user defined, 85 Quick stop behaviour, 79
Example tool change procedure, 212
R
F ReCalcTCP, 126
Fine calibration, 64 Replace servo gun, 209
FlexPendant Interface, 215 Reweld process, 85
Forcedata, 143
S
G safety, 14
Gripper and pneumatic gun, 93 Service routines, 74
Gun Arm Release, 170 Servo gun activation, 196
Gun closure, 77 Servo gun deactivation, 196
Gundata, 135 Servo gun disconnection, 91
Gun equalizing, 73, 76 Servo gun force calibration, 203
Gun force calibration, 64 Servo gun force gravity compensation, 204
Gun init after fine calibration, 206 Servo gun tuning, 63
Gun init after updated revolution counters, 207 Servo Tool Change, 211
Gun opening, 78 SetForce, 104
Gun preclosing, 73 Simdata, 146
Simulated welding, 80
I Simulated Weld Timer I/O, 43, 47, 51
I/O configuration, 42 Simulation, 80
Independent gun movement, 197 Simulation mode, 72
IndGunMove, 130 Skip process, 84
IndGunMoveReset, 132 Smeqdata, 148
Install servo gun parameters, 202 Software Equalizing, 169
Spotdata, 140
M SpotJ, 65, 95
Manual actions, 74, 226 SpotL, 65, 95
ManualCalib, 75 SpotMJ, 68, 100
ManualCheckMeasPos, 75 SpotML, 68, 100
ManualForceCalib, 75 Spot options, 15
ManualGunControl, 74 Spot welding data, 65
ManualGunPosition, 74 Stationary servo gun, 210
ManualGunSearch, 74 Step backward behaviour, 80
ManualServiceCalibceCalib, 75 Step forward behaviour, 79
ManualSetForce, 74 Supervision, 81–82, 85

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Index

SwGetCurrSpotName, 151–155 Tip management, 200

SwGetCurrTargetName, 150 Tip wear, 200
SwGetCurrThickness, 156–157 Tool change, 200
SWUSER, 158
SWUSRM, 164 V
Synchronous gun movement, 196 Virtual I/O unit, 47

T W
TCP, 171 Weld error, 84
Tip change, 200 Welding, 78
Tip dressing, 92 Weld process timing, 88–89

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ABB AB, Robotics
Robotics and Motion
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Telephone +46 (0) 21 344 400

ABB AS, Robotics

Robotics and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics and Motion
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SHANGHAI 201319, China
Telephone: +86 21 6105 6666

ABB Inc.
Robotics and Motion
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000

abb.com/robotics
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