Basic Description

The ArcTool™ application softwarepackage, integrated with a FANUCRobot and SYSTEM R-J3Controller, provides the user with aunique process solution to roboticarc welding requirements.

The ArcTool Application Softwarepackage is designed to simplify and standardize the setup andoperation of FANUC robot arcwelding applications. Built-in arcwelding functionality and point-and-shoot position teaching allow theoperator to program the robot easily.With ArcTool, the operator has full control over the welding process.Arc welding instructions are writtenin easy to understand English rather than coded commands.

Full functionality is provided at theteach pendant for welding processsetup, operation and trouble-shooting, including diagnostics,status reporting and error recovery information.

Features

� Full interface and controlthrough an arc welding specific,easy-to-read teach pendantwith large display for full view of programs and data allowstotal application functionality.

� “Plug and play” simplicity withLincoln Electric’s PowerWave455™, 450™, or STT™ (SurfaceTension Transfer) powersources.

� Multi-tasking capability reduces execution time andallows control of externaldevices usually controlled by a programmable logic cell controller.

� Arc process and motion controlimproves weld process qualitywith the ability to look ahead,

resulting in faster arc starts and increased productivity.

� Power fail recovery capabilityincreases production byallowing program and datarecovery in the event of powerloss.

� Configurable to work with allmajor brands of weldingequipment.

� Interfaces with most types ofservo driven or indexingpositioners.

� TurboMove™ advanced servocontrol features allow quick,smooth point-to-point motion,which increases arc on-timeand cycle speeds.

� Independent control of up tofive motion groups supportsoverlapping motion of servocontrolled peripheral devices.

Benefits

� Scratch start function reducesarc start faults with anautomatic recovery process.

� Easy-to-load software is pre-packaged to match the robotconfiguration for ease of setup.

� Arc welding specific softwaremakes it quick and easy forusers to setup, teach andoperate their system.

� Easy-to-use teach pendanteditor allows quick setup andprogramming using commonwelding terminology.

� Arc and weave schedule datacan be entered directly at theinstruction or in an easy-to-useschedule data table; users areprovided the most appropriatelevel of flexibility for their needs.

� Hot edit of positional data allows program positionadjustment while production isrunning; this results in morerobot uptime and partthroughput.

� The “on-the-fly” feature permitschanging of weld process datawhile the program is runningproduction; operators can finetune process data on-the-fly,improving weld quality withoutunnecessary downtime.

� I/O menu utilizes English labelson dedicated weld process I/Oand peripheral device controlI/O; this capability speeds uptroubleshooting and repair.

ArcTool™

Application SoftwareRo

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tics

� Sinusoidal, circular and figure8 weave patterns improveweave performance, weldability and quality.

� Process feedback (voltage,current and wirefeed speed) is displayed in large characterson the teach pendant. Thisallows more flexibility in weldequipment placement.

Sensing Options

Thru-Arc Seam Tracking (TAST)tracks weld seams by monitoringchanges in welding signals andautomatically adjusting the robotpath to improve finished partquality. TAST can be used tocompensate vertically and/orlaterally to maintain the desired arc length and wire placement.SuperTAST option enhances the TAST package by providingadditional setup and diagnosticinformation to increase trackingspeeds and track on thinner lapjoints.

Touch Sensing quickly locateseach part (up to 75 mm/sec search speed), stores positioninformation and offsets the robotpath. The ability to search for part movement in 1, 2, or 3dimensions allows compensationfor part variation and reduces the need for trimmed parts orexpensive fixtures. Easy to usesearch patterns find parts shiftingwith parallel and rotational motion.Touch Sensing is highly accurateby quickly stopping the robotmotion upon completion of asearch and therefore reduces wire bend.

TorchMate II™ builds on the highly dependable TorchMate™

option by reducing the cycle time and increasing the accuracyof each adjustment cycle.TorchMate II™ automatically adjusts for changes in the toolcenter point, improving systemuptime. Works with all majorbrands of torches to compensatefor bent torch barrels and worncontact tips. It also reduces weld repair requirements.

Automatic Voltage Control (AVC) tracks voltage duringwelding and adjusts the robot path to compensate for partdistortion or irregularity. Designed for GTAW or PAWwelding. The AVC option can be used with constant or pulsed current welding.

MIG EYE™ is a laser-based trackingsensor designed specifically for arcwelding metal stampings. MIG EYEprovides real time control of therobot path, maximizing weld travelspeeds and quality. MIG EYEfeatures include: adaptive bias,adaptive weld schedules and ROOTPass Memorization (RPM).

Motion Options

Coordinated Motion simplifiessetup and reduces expense whenapplying auxiliary axis positioners.The Coordinated Jogging featureallows quick program creation byenabling the programmer to jog the robot and positionersimultaneously, maintaining relative gun angles and stand-offdistances.Weld travel speedremains con-stant while the robotmoves in conjunction with theauxiliary axis.

Coordinated Motion works with mostmulti-axis positioner configurations,eliminating the need for specializedor standardized mechanisms. Withthis option, users can achieve highquality welds with minimal taughtpoints.

ArcTool Setup and Teaching: Arc welding specific teachpendant hard keys provide single key stroke access to most frequentlyused functions.

Teach Pendant 3 ScreenAccess Keys

Arc WeldingApplicationKeys

3 Arcweldingstatusindicators

ALARM

HOLD

STEP

BUSY

RUNNING

WELD ENBL

ARC ESTAB

DRY RUN

JOINT

XYZ

TOOL

OFF ON

WIREINCHKEYS

MANFCTNS

STATUSPOSN

WIREINCHKEYS

DISPLAYWELD

STATUS

ENABLE/DISABLEWELDINGPROCESS

Weave

Vertical tracking

Torch

Lateral tracking

Stickout

Resistance

Arc

GrooveMetal

TAST Function

Example of Search Offset

Collision Guard™ protects not only end-of-arm-tooling, but alsoprotects part tooling and the entire robot arm. It does this byinstantly stopping robot motionwhen a collision is detected,reducing downtime associated with collisions. Collision Guardalso minimizes the costsassociated with tool, part and torch replacement.

Process Options

Bumpbox provides operators aneasy way to adjust weld placementto match minor intermittent changesin joint position. Each adjustmentcan be maintained for a batch ofparts. The operator can shiftspecified welds within pre-determined limits, during productionon the robot teach pendant or aseparate interface box.

Multi-equipment option providessystem flexibility by allowing onerobot to work with two weldingprocesses, such as Tandem MIG or switching between two differentwelding processes such as MIGand TIG. Using this option for aTandem MIG application has shown higher deposition rates,allowing a cycle time reduction of up to 50%. By allowing twocomplete welding systems to be setup, the operator can easily switch between the twoprocesses, reducing down timebetween applications.

Lincoln Electric PowerWave455/R welding power source issupported through a DeviceNetCommunications Interface.Reduced integration time isachieved from the DeviceNetinterface, which performs all setup, scaling and initialization. All weld procedure setup isremoved from the power supply’sfront panel and moved to the robot teach pendant. A weldprocedure database on thePW455/R can be queried from the robot teach pendant to selectthe correct waveform.

Additional process welding I/Ointegrates multi-channel weldingequipment such as 4 channel TIG and 3 channel MIG.

System Options

Error recovery offers the userseveral options for arc faultrecovery. User-defined programsenable the robot to move to a repair position then return andresume welding after repairshave been made, reducing system downtime and scrap. The operator does not have to jog the robot to recover.

Password protection restrictsuser access beyond designatedareas, preventing unauthorizedusers from modifying critical control data. Password protectionoffers four levels of protection and can accommodate up to 100 users with text strings for each user name. Remote accessis also available through anEthernet connection.

ArcTool event logging recordsoperational changes made to the teach pendant programs and system data structure. Userlogin/ logout time is recorded along with any changes each user has made to the system. This information allows systemmanagers to track changes thataffect production quality.

Programmable MachineController (PMC) providescapability to execute Ladder Logic on the robot controller,eliminating the need for someexternal PLC’s. PMC logicexecutes on the robot processorwithout any additional boards or hardware and interacts with all robot I/O and programs.Reduced system cost andcomplexity can be achieved byeliminating extra enclosures,wiring, and PLC components.

Process tracking adds two newvariable structures that captureinformation about arc starts, arcends, failed starts, scratch starts,aborted welds, burn back events and other pertinent weldinginformation. These statistics can then be displayed on the teachpendant or pulled offline to a PC to give a simplified production status report.

Available in both standard and long-armversions, FANUC Robotics’ ARC Mate120i robot sets the standard in roboticarc welding.

Easy-to-use TorchMate II software allowsusers to redefine the tool center point(TCP) of a welding torch that has becomedamaged or worn.

Process I/O DI/DO: 40 points and analog in/output (welding interface).EA Board Board is mounted in the operation box.

Input power source 7.5KVA: 440, 460, 480, 500, 550, 575VAC input

Weight Approx 100kg (220 lbs)

Installation Ambient temperature: 0-45˚Cenvironment Ambient humidity

Normal 75% RH or less (No dew or frost allowed)Short term Max 95% RH (within one month)

Vibration 0.5G or lessNo corrosive gas allowed

R-J3 Controller and Teach Pendant Specifications

Standard Integrated and Optional Remote Controller

Monitoring functions TAST Welding restart Super TAST Scratch start AVCOn-the-fly weld adjustment Touch sensingWeld from teach pendant MIG EYE™

Runin TorchMate II™

Burnback Coordinated motion32 weld schedules Error code outputWeave instructions Extended axes10 weave schedules Multi-group motionProgram shift utility Detached jogging of auxiliary axesReference position utility PLC I/OMulti-tasking utility KAREL Command Language (KCL)Mirror image utility GE Fanuc Genius I/O interfaceRegisters Allen Bradley I/O interfacePosition registers Root pass memorizationMACRO functions Multipass weldingTest cycle functions Analog rampingPlug and play capability Password protectionOriginal path resume FTPDry run mode TPP condition monitorJog speed control Collision Guard™

Path jogging Event loggingOverride select Error recoveryPower fail recovery Wrist axis weaveUser frame Small circleTool offset Data monitorI/O interconnect menus Programmable Machine Controller (PMC)UNDO Domain Name Service (DNS)Controller Backup/Resore Web serverProcess tracking Servo index

Menu utilitiesServo robot interfaceBump boxMulti-equipmentAccupathDeviceNetEthernetControlNetMulti-robot

ArcTool SpecificationsStandard Features Optional Features

FANUC Robotics’ arc welding teach pendant,which features application-specific hard keys,simplifies program-ming and operation.

The SYSTEM R-J3 Controller is completelyintegrated with the ARC Mate i Series robots for flexible work cell layout and easy installation.With no exposed robot connection cablesbetween the mechanical unit and controller, the R-J3 Controller provides an intelligent,compact and reliable design.

FANUC Robotics North America Charlotte, NC Toronto, Canada3900 W. Hamlin Road Phone (704) 596-5121 Phone (905) 812-2300Rochester Hills, MI 48309-3253Phone (248) 377-7000 Chicago, IL Montréal, QuébecFax (248) 276-4133 Phone (847) 898-6000 Phone (450) 492-9001

Cincinnati, OH Mexico City, Mexico1-800-47-ROBOT Phone (513) 754-2400 Phone 52 (5) 611-5998

Los Angeles, CA Aguascalientes, MexicoPhone (949) 595-2700 Phone 52 (49) 10-8000

Toledo, OH Sao Paulo, BrazilPhone (419) 866-0788 Phone (55)(11) 3955-0599

www.fanucrobotics.com

©2001 FANUC Robotics North America, Inc. All rights reserved. FANUC ROBOTICS LITHO IN U.S.A.

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