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IRC5PROGRAMMING AND OPERATION
ABBLimited-Robotics
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Facilities Guide
Workshop Area
Must be accompanied by a member of ABB staff
Health & Safety / Customer confidentiality
Please ask if you would like a guided tour
Phones, Faxes and Internet access
Outgoing calls - Phones available in training rooms and reception
relay
Internet access - via terminal in main training area
Password: Trainme2day11
Contacting ABB personnel
Please ask instructor if you would like to contact or meet up withfriends or acquaintances at ABB
Smoking area
Access via main entrance
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Site Map
VisitorsParking
Fire Assembly point
Employee parking
SmokingArea
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Training Suite
Room3
PaintTrainingroomsOffice
Auriga House Ground Floor Plan
Fire Exit
Workshop gangways
MechTraining
Area
Fire Exit
Room 1
Weld Trainingrooms
Reception
Smoking shelter
Please use main entrance
TechnicalHelp desk
Robot Spare Parts
SolutionsCentre
Main Entrance
Fire Exit
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Programming&
Operation5 day
Programming &Operation for
Mig / Mag5 day
Operator
2day
IRC5 Training course scheme
RobotStudio 5Certified User
3 da
Mig MagProcess
Appreciation3 da
Electrical
4 da
MultiMoveProgramming
3 da
RotaryExternal AxisProgramming
2 day
AdvancedStage1
5 day
Advanced
Stage2
3 day
SmarTac
2 day
PickMaster
5 day
Mechanical
4 day
WebWare
2 day
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System warm start up, shut down and error recovery
Basic program operation
Basic production programming techniques
Course Objectives
Safety requirements for basic programming and operation
System warm start up, shut down and error recovery
Basic program operation
Basic production programming techniques
Create and use routines
Use input output instructions
Flexpendant communication instructions
Numerical data instructions
Saving and opening programs
Create and use routines
Use input output instructions
Flexpendant communication instructions
Numerical data instructions
Saving and opening programs
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Potential Accident Risks
Modifying program within robot cell
Test run
Fault tracing
Repair Process hazards
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ABB Safety Solutions an Overview
Emergency stop
Operating mode
Auto
Manual < 250 mm/s
Manual 100%
Enabling device
Hold-to-run
Safeguard stop(Auto and Manual)
Limiting the workspace Lockouts and Interlocks
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Law Demands
The construction design for the robot is to comply withrequirements that are stated in ISO 10218, Jan 1992,
industrial robot safety. Robot also comply with
requirements for ANSI/RIA 15.06-1999. Definition of safety function / regulations:
Emergency stop IEC 204-1, 10.7
Enabling device ISO 11161, 3.4 Safeguard ISO 10218 (EN 775), 6.4.3
Reduced speed ISO 10218 (EN 775), 3.2.17
Interlock ISO 10218 (EN 775), 3.2.8
Hold to run ISO 10218 (EN 775), 3.2.7
ANSI: American National Standards Institute
RIA: Robotics Industries Association
ISO: International Standards Organisation
IEC: International Electrotechnical Commission
EN: European Normalisation
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Emergency Stop
Built in emergency stop
pushbuttons are found bothon the FlexPendant andController-X-module as
default.
be connected to the robotsystems safety chain.
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Operating Mode
Automatic mode
Production mode (no speed limit)
Manual mode < 250 mm/s max velocity 250 mm/s
100 % Option, robot can beogge teste w t no spee m t.
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Enabling Device (Dead Mans Grip)
The enabling device is a press switch with threepositions
The switch must be in the middle positions in order toactivate the motors
All robot movement will immediately stop if the switch is
re ease or presse o e o om
Enabling device
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Hold-to-Run (Manual 100 %)
Only found on Version 1 FlexPendants
Hold-to-run buttons removed on Version 2 FlexPendant
Option (this function can be selected in the parameters)
The enabling device and one of the hold-to-run buttonsmust be pressed simultaneously to start the motors
Enabling device
Hold-to-run buttons
(for left or right hand)
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Version 2 FlexPendant Hold-to-Run
Hold-to-Run buttons and
prompt message removed
Hold down the play key, to run the program
Hold down the FWD or BWD key to step through program
Release the pressed key to stop execution
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Safeguard Stop
The connection of safeguard stop enables inter-locking
of external safety equipment, such as: doors, photo-electric trip device, photo cells or pressure mats.
Safeguard stop can be connected in two ways:
Always active regardless of operating modes
n y act ve w en automat c mo e s se ecte
Possibility to activate Delayed Safeguard Stop.A delayed stop gives a smooth stop. The robot stops inthe same way as at a normal program stop with no
deviation from the programmed path.
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Limiting the Workspace
To avoid the risk of getting
caught between the robot andthe outer safe equipment, e.g.a fence, the robots workspace
can be limited:
All axis can be software controlled
Axis 13 can be limited byadjustable mechanical stops andcontrolled by limit switches
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Safety Regarding Grip Device
All grip devices must be designed so the work piece will
be held on power failure and other disturbances in therobot system
Make yourself familiar with the output used to activatethe gripper
n your ngers w en manua y opera ng gr pper romFlexPendant
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Electrical Safety
Hazardous power in both the cabinet and the robot
Net power 400 VAC
Transformer 260 VAC Rectifier 260 VAC and 370 VDC
Power supply 370 VDC
Power supply to robot motors up to 370 VDC
Customer equipment
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Safety Regarding Releasing the Breaks
The breaks on the robot motors can be manually
released.
Before the breaks are released, be sure that the weightof the robot arm is supported and wont cause damage toindividual or equipment
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Operational Exercise
Execute program
Manual reduced speed
Enabling device
Manual Full speed
Enabling device and Hold-to-run
Automatic
Stepwise Operation
Fwd Bwd and limitations
E-Stop and recovery
Debug menu
Starting program from cursors position
Program Reset
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Jogging the robot
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Robot Axis
Axis 1
Axis 2
Axis 3
Axis 4
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Jogging The Robot
Motion Types
Robot
Major Axes 1,2,3
Minor Axes 4,5,6
Line r / Reorient tion
Base
World
Tool
Workobject
Can Jog the Robot in Incremental steps.
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QuickSet menu
With the QuickSet menu you can access some oftenused settings
Mechanical unit
Jogging mode
(1-3, 4-6, linear or reorient)
Increment
Running Mode
Step Mode
Override Speed
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The Jogging Window
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Exercise 1Programming movements
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ABB Main Menu
Programming with the FlexPendant
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Creating a new Program File
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Creating a new Program File
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Programming Positions
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MoveJ - moves the TCP in a way which is
easiestfor the robot and not in a straight line
Speed Data ToolData
Positional Movements Instructions
MoveJ *, v1000, z50, tool0;
Robot Position Zone Data
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Zone
Zone data describes how close to the destinationposition the axes must be before the next instruction
can be executed.
Robot path in automaticmode. Programmedposition.
MoveL p2, v100, z10, tool0;
Zone size.
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Joint & Linear Move
Joint Move
P1
near ove
P2
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MoveL - moves the TCP in a Linear direction
or straight line
Speed Data ToolData
Positional Movements Instructions
MoveL *, v1000, z50, tool0;
Robot Position Zone Data
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Modifying the position in a positioning instructions Move robot to desired position
Select the instruction or target to be changed
Press Modify position
ModPos
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Program Edit Menu
T l C P i
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Tool Centre Point
Tool MountingFlange
+X
Relative Directions X, Y & Z.
+Y
+Z
T l C t P i t
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Tool Centre Point
Position & movement of robot always related to TCP.
Defined as being somewhere at the end of the tool.
Many can be defined but only one active at any one time.
Can be programmed manually but only if accurate data.
Normally use robot to define TCP.
If tool is damaged or replaced, dont change program justredefine the tool.
T l C t P i t D fi iti M th d
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Tool Centre Point Definition Methods
Default Orientation (same direction as tool0)
TCP & Z Just Z direction defined (X stays in same plane as tool0)
TCP & Z, X both Z and X defined
From 3 to 9 approach points
TCP D f lt O i t ti
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TCP Default Orientation
No rotation about X, Y or Z
X
Y
Z
TCP & Z
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TCP & Z
Z direction defined
TCP Z & X Mag welding and Water cutting
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TCP Z & X Mag welding and Water cutting
.
Both X and Z directions defined
TCP Definition Default Orient
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TCP Definition Default Orient
1
2
3 4
1
4
23
Plan view
TCP Definition Z & X
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TCP Definition Z & X
5
Jog robot so the tools intended Z and Xdirections, visually align to the basecoordinates Z and X axis.
Z Elongator point
Tool orientations are defined by the direction the tool ispositioned away from the datum point.
136
4 Jog along Base coordinate Z Axis to definetools Z direction
Jog along Base coordinate X Axis to define
tools X direction
2
X Elongator point
Tool Centre Point Definition Method
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Tool Centre Point Definition Method
Menu
Program data
Selecttooldata
Show data
New Name tool
Initial value orOK and select tool in list andEdit Value
ass:= type n g
Press OK
For RW5.06 Press and hold on tool in list to get context menu
For RW5.07 Press Edit
Select Define
SelectMethod and number ofPoints
SelectPoint 1,jog robot to calibration position and pressModify Position
Repeat for remaining points
Press OK
You will need to activate your TCP in the jog window
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Exercise 2Create a Tool Centre Point
Logical
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Set - turns ON a Digital Output.
Set doGripper;
Logical
Reset- turns
OFFa
Digital Output.
Reset doGripper;
Logical
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SetDO - changes the value of a Digital Output.
SetDO do15, 1;
Logical
orSetDO \SDelay := 0.2, do15, 1;
SetDO \Sync do15, 1;
Routines and program flow example
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Routines and program flow example
PickPen;MoveJ ,v200,
Main
main
PickPen PutPen
,
MoveL
v100,MoveL v300,MoveL v200,MoveL v200,MoveJ ,v200,PutPen;
MoveJ ,v200,MoveL v1000Set doGripper;MoveL v200,
Main routine Sub routines
MoveJ ,v200,MoveL v1000Reset doGripper;MoveL v200,
Routines
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Repetitive instruction sequences, that occur frequently in the program,should form their own routines.
Routines separate the program into smaller more easily understoodparts, these can then be called anywhere in the program using the
ProcCall instruction.
A Max of 16 characters are allowed for naming routines, meaningfulnames such as PickBlock, CutSquare and Put_Part etc will make
the program easier to follow and operate.
Routines can be tested by moving the Program Pointer to a routine.
Routines Exercise
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Create a new routine called PickPen
Activate your TCP
Program the robot to pick up the pen using the minimum amount of instructions
Test this routine
up ca e s rou ne an e e ou pu ns ruc on o pu e pen own
Call these routines in your main routine
Test your Main Routine
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Create Routine to pick and place
Pen
Work Object Coordinate System
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p10
j y
z
(900, 60, 500)
All program positions are attached to a work object
Wobj0 is the default coordinate system
It is advisable to use custom work objects
BaseWobj0
x
(0,0,0)
Work Objects
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Custom Work ObjectX1
Work Objects contain both User and Object Frames
Userframe
Objectframe
World
Work Object Frames
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p10(200, 0, 450)
User
Object
World
(400, 0, 50)
(300, 60, 0)
Work Objects and External Axis
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Workobject disconnected from robot worldand attached to mechanical unit
Object frame may be transposed
Defining a Work Object frames
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User and Object Coordinate Systems are usually both defined
at the same position.
World
World
Work Object Definition Methods
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User and Object Coordinate Systems are usually both definedat the same position.
Jogging along axis Work Objects
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Y
X
X
Y
Work Objects Summary
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WObjData is used to describe the area that the robot welds, processes,moves within etc.
If position Data is entered manually, the values can be taken from a
drawing.
Programs can be reused quickly following changes in the robot installatione.g. a x ure s move , us re e ne user coor na e sys em.
Variations in how the work object is attached can be compensated for. Forthis, however, some sort of sensor will be required to position the workobject.
Robot can be jogged along the axes of the work object.
Work Object Definition Method
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In the jogging windowactivate the TCP that you will use to define Workobject
Menu
Program data
Select wobjdata and tapShow Data
SelectNew
Name work object
Press OK
.
For RW5.07 Press Edit Select Define
Select3 points for user frame andNo Change for Object frame definition
Jog the tool to the User X1 point select and Modify Position
Repeat for User X2 and User Y1
PressOK and view the calculated result
Press OK to close
You will need to activate your workobject in the Jogging window
in order to program or jog relative to it.
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Exercise 4Create a Work Object
Positional
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MoveC - moves the TCP in a Circular
direction using the mid& endpoint of a semicircle
Speed Data ToolData
MoveC *, *, v1000, z10, tool0;
Robot Positions Zone Data
Circular Move
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p1
p2p4
Pick MoveC here
MoveL p1, v100, fine, tool0;
MoveC p2, p3, v100, z1, tool0;
MoveC p4, p1, v100, fine, tool0;
p3ModPos MoveC here
Path Following Exercise
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Start / Finish Start / Finish
Start / Finish
Direction
Path Following Exercise
Path Following Exercise
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Example of main routine
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Exercise 5Programming with Routines
What is a module
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%%%
VERSION:1
LANGUAGE:ENGLISH%%%
MODULE EX1
= - -
The Internal Structure of Modules
CONST robtarget p2:=[[1270.77,-93.78,386.13],[0.567071,0.054457,0.82157,0.02211],[-1,0,-
CONST robtarget p1:=[[1312.4,-132.16,381.39],[0.567077,0.054431,0.821568,0.02209],[-1,0,-
PROC main()
MoveL p1,v1000,fine,tool0;
MoveL p2,v1000,fine,tool0;
MoveL p3,v1000,fine,tool0;
ENDPROC
ENDMODULE
IRC5 Task Structure
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Robot Task
MainModule.mod
Program File.pgf
MainModule.mod System Modules.sys
Program Data
Routines
Program Data
MainRoutine Routines
IRC5 Task Structure
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Robot Task
ModuleA.mod
ModuleB.mod
MainModule.mod
Program File.pgf
Program Data
Routines
Program Modules.mod System Modules.sys
Program Data
Routines
Program Data
MainRoutine Routines
What are Modules
A d l i f ti d d t
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A module is a group of routines and data.
The module that contains the main routine is the MainModule
System modules are always present in memory and can be used to saveyour default data
Filename extensions are
XXXXX.mod Module
XXXXX.sys System Module
XXXXX.cfg Parameter File
XXXXX.pgf Program File
Creating a new program in IRC5
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A new program file is created (.pgf)
A MainModule with main routine is created
Saving program in IRC5
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A folder with the same name as the program is created
This folder contains the MainModule, Sub modules and theprogram file
The program file (.pgf),is an extensible mark-up language,XML, file that lists all program modules in the task
System Modules are NOT saved
Folder created with
same name
Saving Individual Modules
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Individual, Program or System modules can be saved
Select in Program Editor and Save Module As from File menu
Loading Programs
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Loading whole programs will overwrite existing programs
Each task will have its own program
Loading Modules
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Loading Program and System modules from the Program Editor
1
2
IRC5 System backup
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Backup_20050117
BACK INFO RAPID SYSPARSystem parametersSystem ID
Text information,programme.id,
HOMEMost files off
Flash disk fromActive system
System.xml
TASK 1
PROGMOD SYSMOD
TASK 1
PROGMOD SYSMOD
TASK 1
PROGMOD SYSMOD
TASK 0
PROGMOD SYSMOD
EmptyEmpty
ey. ,keystr.txt,
system.guid,template.guid
TASK 1
PROGMOD SYSMOD
System modulesProgram modulesUsed by system only!
Multitasking
Backed up regularly !!!
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Exercise 6Backup and Restore
Logical
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WaitDI - Waits until a Digital Input is set to eitherhigh or low.
WaitDI di1, 1;
Logical
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WaitUntil - Waits until 1 or several Inputs havebeen set.
WaitUntil di1=1;
WaitUntil di1=1 AND di2=1;
AND, OR
Logical
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WaitTime - Waits a set amount of time.
WaitTime 0.5;
(Waits 0.5 seconds)
WaitTime \ InPos, 0.5 ;(Optional Argument wait in position)
Logical
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Stop - is used to stop program execution.
Move J pTCPcheck, v100,fine,tGun;
Stop;
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Exercise 7Waiting for Inputs and Time
TPWrite
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TPWrite - writes Text/Data to FlexPendant.
TPWrite Execution Started;
TPWrite Num of produced parts= \Num:=reg1;
TPWrite String [\Num] | [\Bool] | [\Pos] | [\Orient]
TPErase
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TPErase - is used to clearthe display of the FlexPendant.
TPErase;
TPWrite Execution Started;
TPShow
TPSh i d i h h i d h Fl P d
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TPShow - is used to switch the window on the FlexPendant.
TPShow TP_PROGRAM;The Production Window will be active if the system is in AUTO mode.
Or
The Program Editor will be active if the system is in MAN mode.
TPShow TP_LATEST;
Show the previous FlexPendant Window before the current one.
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Exercise 8Operators Log Messages
C t I t li f t t t k it i t d t d
Comment
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Comment - Inserts a line of text so as to make it easier to understandthe program.
Comment / Uncomment Row
Comment Row Disabling Instructions sometimes better than delete!
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Comment Row Disabling Instructions, sometimes better than delete!
Compact IF where a single instruction is executed
CompactIF
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Compact IF - where a single instruction is executeddepending on whether a condition is met or not.
IF di1 = HIGH WaitTime 0.5;
or
IF di1 = HIGH PickPart;
The instruction may be a ProcCall which calls a
routine
IF where different instructions are executed
IF
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IF - where different instructions are executeddepending on whether a condition is met or not.
IF di1 = HIGH THEN
Circle;
IF di1 = HIGH THENCircle;
ELSEIF di2 = HIGH THEN
Outside;
ELSE
Oval;ENDIF
va ;
ENDIF
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Exercise 9Decision making with IF
TPReadNum - writes Text on FlexPendant and records
TPReadNum
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TPReadNum - writesText on FlexPendant and recordswhich Numbersare pressed.
TPReadNum reg1, How many Outsides should be produced?;
While - is used when a number of instructions are to be
While
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While - is used when a number of instructions are to berepeated as long as a given condition is met.
WHILE reg1> 0 DOOutside;
Decr reg1;
ENDWHILE
Repeats the instructions in the WHILE loop as long as
reg1 > 0
WHILE Condition DO... ENDWHILE
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Exercise 10Loops
ClkReset - is used to reset a clock that functions as a stop
Cycle Timing Instructions
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ClkReset is used to reseta clock that functions as a stopwatch, it sets it to 0.
ClkReset clock1;
ClkStart - is used to start a clock that functions as a stop.
ClkStart clock1;
ClkStop - is used to stopa clock that functions as a stop
watch.ClkStop clock1;
ClkRead() - is a function that reads a timing clock and
ClkRead()
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ClkRead() is a function that reads a timing clock andreturns its value.
ClkReset clock1;ClkStart clock1;
MoveJ *, v1000, fine, tool0;
ClkStop clock1;
TPWrite Cycle Time=\Num:=ClkRead(clock1);
TPReadFK - writestext on the FlexPendant and recordsa number.
TPReadFK
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TPReadFK nPress, Choose?, Outside, Circle, Oval ,,;
TEST - where different instructions are executed
TEST
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TEST where different instructions are executeddepending on the value of an expression or data.
TEST nPress
CASE 1:Outside;
Circle;
CASE 3:
Oval;
DEFAULT:
TPWrite Illegal choice;
Stop;
ENDTEST
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ProgrammingPractice
Course Objectives
Safety requirements for basic programming and operation
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System warm start up, shut down and error recovery
Basic program operation
Basic production programming techniques
Safety requirements for basic programming and operation
System warm start up, shut down and error recovery
Basic program operation
Basic production programming techniques
Create and use routines
Use input output instructions
Flexpendant communication instructions
Numerical data instructionsSaving and opening programs
Create and use routines
Use input output instructions
Flexpendant communication instructions
Numerical data instructionsSaving and opening programs