weld tech training

8/9/2019 Weld Tech Training

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Weld Tech Training

Instructor Ray Angus


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Program Objective

To provide technical training and information of robotic

weld operations and provide a first response contact for

robotic or weld related issues


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!"pectations for a Weld Tech

As a Weld Tech you will be the first point of contact for robot androbotic weld cell malfunction

As a Weld Tech you will be e"pected to provide robotic support formaintenance when malfunctions re#uire the assistance of themaintenance staff to repair

In addition to robotic troubleshooting as a Weld Tech you will bere#uired to document any issues you encountered and the time ittoo$ you to resolve those issues

As a Weld Tech you will report to the engineer or supervisor any andall issues encounter during the shift and any measures or corrective

action ta$en to resolve those issues As a Weld Tech you will agree to rapidly respond to all robotic weld

cell issues minimi%ing downtime from those issues and helping toensure the dept meets its daily production schedule


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&ourse &ontent

' (afety

) Robot anatomy

* Teach pendent+ &ontrols and ,otion

- Robot problems

. (tud welding problems

/ Weld cell problems

0 Weld Tech specifics

1 !ngineering problems

2 Preventative maintenance


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(afety

Definitions

Wor$ !nvelope3 The area within ma"imum e"tension of either the

robot and or the positioner+ fi"ture+ and part

Pinch Point3 Any area )ft or less between a hard surface and the wor$

envelopeT&P3 The Tool &enter Point is the very end of the robot tool+ in the case

of a weld gun the T&P is the tip of the wire


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This is the wor$ing

envelope of the robot

arm or its potential

range of motion

,a"imum rotational

motion

,a"imum

hori%ontal reach

,a"imum height


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Indicates the

rotational

envelope of

the fi"ture

Indicates the

hori%ontal

envelope ofthe robot

Indicates the

wor$ing

enveloperestricted by

Indicates

vertical

rotational

envelope of

the Positioner


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Potential pinch

points are

highlighted


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Electrical Hazards


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Entry Detection Devices


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Emergency Stops

There are 5manually

activated emergency

stops located around

the cell+ become very

familiar with them

On the operator podium

The training or multiple

person dead man switchOn the front of the teach

pendantThe dead man switches on

the bac$ of the teach

pendant

On the robot controller


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Robot AnatomyJoint 6:Roll a"is4rotates the tool

Joint 5:Pitch a"is4angles the tool in orout

Joint 4:5aw a"is4angles the tool left or

right

Joint 3:6 a"is4moves the tool up and

down

Joint 2:5 a"is4moves the tool forward

or bac$

Joint 1:7 a"is4moves the tool left or

right

Tool:Attachment on the end of the

robot+ ie stud gun+ weld gun

Tool changer:mounted to the end of

joint /

Home limit switch:indicates the robot

is in the home position and will not run

a new program in automatic unless theswitch is depressed


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Controller

Hour meter: records the operating

hours of the robot

Speed limiting switch:Allows the

operator to choose between automatic

mode+ full speed teach mode+ and

limited speed teach mode

ser !uttons:Allows operator to set

up specific setting for individual users

"ault #eset:Resets current faults on

the robot after issue has been

resolved

$%cle start:initiates cycle start in

automatic mode

&'(&"" !utton:powers up an down

the robot

)mergenc% Stop: stops the robot and

activates all a"is8 bra$es

Disconnect switch:cuts all power to

the controller


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Teach Pendant

and &ontrols

)mergenc% Stop:shuts down all power to the robot

internal and e"ternal a"is+ and applies the bra$es to

all a"is

&n(&ff switch: activates teach pendent to for robot

control

&perating screen: show current running program+

speed+ errors+ activated signals+ program name+ andmotion type

*enu +e%: opens a list of menus such as utilities+

alarms+ I9Os+ files+ status+ user +etc Primary use of

this button for weld techs will be to view I9Os and

clear alarms+ and enter passwords

"unction +e%: opens supplementary menu with

options to abort current program or change group

$ursor ,e%s: used to scroll and navigate menus or

programs

Shift ,e%: must be held to allow motion in teach

modes+ jog the robot+ or s$ip multiple pages of a

menu+ program or screen

'e-t(.re/ious: moves forward or bac$wards through

menus or screens

#eset: used to reset faults or clear errors

H ld : d t t il t th ith t


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Hold: :sed to temporarily stop the program without

applying the bra$es as an ! stop would

" +e%s: toggles the corresponding menus locating on

the screen

.rogram +e%s: used to bring up the menus to select

programs+ edit current programs+ or edit program data.

Step +e%:Activate the step function of the robot+ which

allows you to step through the motion of the program

one line at a time

!ac,space: delete lettering or numbering

0tem +e%:Allows you to enter in a line number and

jump to that line without scrolling through the program

)nter +e%: used to select options+ programs or menus

'umeric +e% pad: used to enter values whereprompted

eld )nale: used to activate welding capabilities of

the robot

ire "eed +e%s: used to feed wire in and out of the

weld gun

*anual "unction ,e%: allows for e"ecution of macro

programs

Diagnosis ,e%: when shift is held and this button is

pressed this brings up the error code of the robot and

provide information on potential causes and remedys

.osition +e%: shows the current position of the robot in

in reference to the &artesian coordinate plane

Status +e%: show the current status of timers+ weld

data+ positional data+ etc

&ne the "l% ,e%: allows you to adjust the weld settings

while the robot is in active


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*otion +e%s: while holding shift this allows you to jog the

robot through a program (hift $ey must be held through

entire motion

$oordinate +e%: changes the motion type of the robot+

between world+ joint+ tool+ user+ jog frame+ and path

Speed +e%s: &hanges the speed off the robot by

percentage of the programmed motion speedJog +e%s:Allows you to jog the robot in the direction

specified or the joint type specified by the $ey This

movement is determined by the &oordinate motion that is

selected

Dead *an Switch: This is a safety device used to ! stop

the robot while in a teach mode If too little pressure is

applied the robot will e stop if too much pressure is

applied the robot will e stop Only one needs to bedepressed


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(tud Welder Pendant&utput uttons; these buttons are used to

select which output is being controlled


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(tud Welder PendantHead ad/ance utton; this button e"tends

and retracts the servo head

#eference !utton; This button is used to

reference the location of the stud inrelationship to the part

$lamp utton; releases the clamp on the

servo head which allows it to be free

moving

Stud "eed utton;manually feeds a stud

"orce complete utton; this button sends afinished contact to the robot interface

$%cle start; runs a complete weld cycle

including servo head advance+ weld+

retract+ and feed

)nter utton; used to ac$nowledge an

inputted value or fire a selected function.ower suppl% on(off This is the main

disconnect for the stud welder power

source

"eeder reset this will reset the circuit board

in the feeder unit which also interprets

output signals from the stud gun


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Motion Types

,otion types for the robot can be changed by using the &OOR> $ey on the

teach pendent ?elow are the most common motion types and a description

of there movements; Joint: this mode allows you to control each joint independently @or every a"is on the robot

there are corresponding jog $eys to move in the positive or negative directions A

demonstration will be provided

; orld: this mode allows you to move the three lower a"is+ or major a"is+ according to the

&artesian coordinate system


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External Axis

)-ternal -is:Any a"is not used

in conjunction with the robot+ but is

not a part of the robots original

design ie positioners

To control an e"ternal a"is press

the function $ey on the teach

pendant+ and select change groupfrom the menu The robot is

defaulted to group one and any

positioners are setup to be

additional groups ?y changing the

group you will no longer have

control of the robot+ but instead the

positioner The top jog $eys will

control the major a"is of thesecond group and additional a"is

will be controlled by additional jog

$eys


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Locating and Selecting Jobs and rograms

Jos: Cobs are the high level files consisting of the

programs used to produce the part @or e"ample the R(R

file is a job

.rograms: Programs are the logic or code use to produce

the motion of the robot or produce the weld .DROP6 is a

program

*acros: macros are smaller sub programs that are made to

do common tas$s EO,!FG' is a macro

Selecting a program: to select a program from the main

screen or any screen+ press the (!B!&T $ey and a list of

programs+ jobs+ and macros will come up :se the cursor

$eys to scroll up and down and highlight the program you

want

To (ee the details of the program+ its creation date+ last

modification date+ name+ comments+ etc+ use the @ $ey that

corresponds with details button show on the screen+ if it is

not showing hit the ne"t $ey to cycle through the ne"t set of

@ $ey functions

Press the previous $ey to get bac$ to the program select

screen To select the program highlight it and hit the enter

$ey


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!"# Men$s

0(& menu: The I9O menu can be found by

pressing the menu button on the teach pendentscroll using the arrow $eys to the I9O menu and

then scrolling over to the digital menu This will

bring up all digital inputs and outputs triggered

with in the program logic of the R(R As a weld

tech your only need to be in this menu is to

trigger an one of the I9Os manually @or

e"ample if the weld cell has completed weldingthe cab and does not unclamp and the door

does not open+ you may need to manually

trigger the signal for Hcycle complete To trigger

the I9O you will need to enter the password first

under the setup menu and then go to the I9O

menu to trigger the input >o this by

highlighting the status ne"t to the input+ and

press the @ $ey that corresponds with the greenon button+ then immediately turn it off again+ by

pressing the @ $ey corresponding to the red off

button ,ost I9O have separate macro

programs that can be ran to trigger them with

out having to go to this menu and without

re#uiring a pass word A demonstration will be

provided


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Proper (hutdown and (tart up

In most situations there is no need to shut down the robot cells unless

maintenance needs to be performed+ thereby maintenance willperform the shutdown+ or the weld tech is instructed by the !ngineer

or (upervisor to shutdown for special purposes


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!rrors and Recovery

Robot !rrors

&hain Abnormal !rror

Arc (tart @ailure

&ollision >etect

&ontrol (top

T' or T) selected

Teach Pendant disabled

Run failure3 bloc$ by other tas$

T!>


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&hain Abnormal error

&ause3

; This error occurs when one of the robot motors cause the drive chain to slip This is usually

random and rarely occurs

Remedy3

; Turn the teach pendant to on

; Press the menu button to locate the setup menu

; Bocate passwords under the setup menu

; !nter press the login button twice to enter the password

; Once the password is entered press the menu button to locate the Alarm menu

; :nder the alarm menu go to active alarms

; This screen will show you the active alarms one should be the &hain abnormal error

; Bocate the @ $ey that corresponds with the chain reset button and reset the chain+ hit 5es to

reset; Eit the reset button on the teach pendent

; This may ta$e several attempts+ if so release the dead man switch and repeat the two

previous steps

; Once the error is cleared logout and turn the pendant off and restart the cycle


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Arc (tart @ailure &ause3

; This error is caused when the robot goes to initiate the arc and burns bac$ the wire or the

wire stic$s to the wor$ piece

Remedy3

; Jerify if it is a wire stic$ or burn bac$ If it is a wire stic$ trim the wire if possible and restart

the cycle If it is a burn bac$ proceed with the following steps

; Turn the controller to T' mode and turn on the teach pendant

; Press the &oordinate button to change the motion type to TOOB

; Press and hold shift while pressing the C*K $ey to move the robot away from the part farenough to change the tip if needed

; Remove the gas no%%le and clean or replace the contact tip and diffuser if needed

; Once the tip is cleaned or changed+ scroll up in the program using the arrow $eys to the arc

start line of the weld that was about to be made

; Turn the pendant off+ and the controller to auto mode and restart the cycle The robot may

not go+ if this is the case+ loo$ at the pendant A yellow bo" will appear as$ing if you would

li$e to move to this line in the program Eighlight yes and hit enter; Eit the cycle start button on the operator podium again to start the cycle


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&ollision >etect

&ause3

; This error is caused because the robot has collided with an object in its motion path This is

usually a piece of tooling that never closed+ or a foreign object that was left In the cell+ or a

part that was not located properly

Remedy3

; Put the controller into T' mode and turn the teach pendent on

; &lear the error by hitting the reset ?utton on the control pendent

; ,ove the robot so that it clears the obstruction

; Remove the obstruction or fi" the problem what ever it is

; Press the step $ey to activate the single step function

; Cog the robot to the point it was heading to before the collision

; Turn the step function off

; Turn the teach pendant off and the controller to auto and restart the cycle


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&ontrol (top9>oor open

&ause3

; This error is caused when one of the e"ternal entry device is active+ such as the garage door

is open+ or access door is open or the hold button on the pendant was pressed This will

cause the robot motion to come to a controlled stop+ but not activate the a"is bra$es

Remedy3

; &hec$ all doors and entry devices and verify that they have been close and there are no

obstructions

; Press the reset button on the teach pendant and restart the cycle


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T' or T) selected

&ause3

; This is caused when the robot controller is still in T' or T) speed control while the teach

pendant is turned off

Remedy3 depending on the situation

; If trying to put the robot into a teach mode turn the teach pendent on+ reset the error and

resume

; If trying to turn the robot into auto mode+ turn the controller $ey to auto and reset the error


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Teach pendant disabled

&ause3

; This error is caused when trying to perform a function or move the robot while the teach

pendant is off

Remedy3

; Turn the teach pendant $ey to on


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Run @ailure3 ?loc$ed by Other Tas$

&ause3

; This error occurs when you are trying to run two programs at the same time When

attempting to reset a program and return all groups to their home position+ this error may

occur if the original program is not aborted

Remedy3

; If the robot is not already in teach mode+ turn the controller to T' and turn the teach pendant

on

; Press the @T& button on the teach pendent to bring up a menu

; (elect the abort all function and press enter to abort the current program ?y doing this you can not return to that place in the original program unless the line of the program is

noted before aborting Re4running the aborted program will cause it to run from the start of the

program

; Once the e"isting program is aborted+ new programs can be selected from the select menu

by highlighting and pressing enter

; Once the program is selected press and hold shift and then press the @W> button to run the

program &ontinue to hold shift while program is running


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T!> evice=

&ause3

; This error is caused when there is an error in the >evice net (ystem of the PB& This error

usually re#uires an electrician or !lectrical !ngineer to repair the error

Remedy3

; To clear this error once the repair is made+ hit the reset button on the teach pendant

(ome suggested things to have the electrician chec$ to speed up the repair include

; )- volt fuse located in the rear relay bo" on the bac$ of the cell

; Power supply in the robot controller

; (ic$ relays in the relay panel

If this error persists+ notify the (upervisor and ,!


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!"ternal9Teach Pendant !4(top

&ause3

; This error occurs when e"ternal emergency stop is activated There are three e"ternal e

stops not including dead man switches which produce a different error One is located on

the operator podium+ a second on the teach pendant+ and a third on the robot controller

Remedy3

; &hec$ the three !4(tops and reset them as necessary To reset some re#uire a simple pull

of the button while others re#uire you to twist the button

& t t < t d ld =


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o &ontact


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@eeder low

&ause3

; This error occurs when the feeder is running low on studs This error does not usually stop

the robot until a miss feed

Remedy3

; Jerify that there is an ade#uate amount of stud in the feeder

; Remove or clear any obstruction that may be causing studs not to slide down the rail


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IO


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Wrong (tud

&ause3

; This error is cause when the gun conducts a push in to identify the stud or the ensure the

part is in the proper location

Remedy3

; &hec$ the teach pendant and ma$e sure the proper output is selected

; &hec$ to ma$e sure the stud is in contact with the part and the part is not out of position

; Reference the stud by pressing the reference button on the pendant and hit enter

; Press the &ycle start button on the pendant and hit enter to fire the stud

; Arrow down to the ne"t line in the robot program and restart the robot


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Weld &ell !rrors

The following are errors of the weld cell indicated % either the stac,lights7 operator podium7 or % lac, of motion from the root8

' If a Hclamp pressure not reach error shows on the operator podium perform thefollowing3

' :nclamp the part+ unload+ and reload the part and attempt to clamp it again

) If the first does not wor$ call maintenance and notify the supervisor

* If the maintenance can not resolve the issue notify the ,!

) If the (ic$ lights or light curtain are tripped while the cell is running' Put the robot into T) teach mode and run the remainder of the program in teach mode

) When complete reset all errors and verify the ne"t cycle start up

* If all signals indicate green and no errors are shown+ but the robot will not startperform the following chec$s3

' Jerify the sic$ lights indicate weld cell clear by displaying a yellow and green light' If not+ chec$ for obstruction if any+ or wipe the lens of the sic$ light with a clean dry cloth

) Jerify all light curtains are aligned with reflectors indicated by a red and green light' If not+ adjust the transmitter until the red and green lights are indicated

* Jerify robot is in the home position' If not+ turn the controller to teach mode and run the Eome program


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- If the operator is attempting to change over tooling and the positioner will not

rotate chec$ the following' Jerify all clamp pressure has been reached for both sides

' If the clamp pressure has not been reached you will need to rotate the fi"ture manually and ensure

both side are clamped If problem persists contact maintenance

) !nsure the robot is in the home position and the positioner is in the home position and

attempt to re4clamp

' If the positioner is not home+ use the teach pendant to rotate the positioner until the pro" switches

are lit* Rotate the fi"ture manually using the teach pendant and then try to reset any errors

. &ab not identified in the fi"ture

' Remove the cab and chec$ the pro" (witch for damage

' If damaged+ contact maintenance to change out pro"

) If problem persists contact (upervisor and ,!

Weld &ell !rrors &ont


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>ocumentation

As a Weld tech you will have additional responsibilities above that of clearing robot faults

and errors One of which includes assisting the !ngineer in documenting and

resolving downtime issues As a weld tech you will be responsible for recording any

and all issues that occurred though your shift+ including robot error recoveries+ tooling

repairs+ program changes+ maintenance issues+ weld issues etc At each robot

station there is a binder with record sheets These sheets will need to be filled out for

each issue

(ample (heet3 >owntime Trac$ing (heet

At the end of the wee$ they will be collected by the !ngineer and trac$ed+ generating a

pareto chart of the issues seen and ran$ by highest occurrence @rom this chart the

engineer will consult with the weld techs possible solutions for these issues and &Iprojects will be developed based on the findings
http://../Robot%20stuff/Robot%20downtime%20tracking%20sheet.xlshttp://../Robot%20stuff/Robot%20downtime%20tracking%20sheet.xls


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Weld Touch :p PolicyAs a Weld Tech part of your job may be to touch up welds that are consistentlyout of

position The @ollowing is !ngineering8s policy and procedure supported by

(upervision and ,anagement+ for touching up a weld

.olic%: To touch up a weld re#uires the deliberate manipulation of the weldprogram to improve the #uality or correct a problem caused by+ but not limited to+serious crash of the robot arm+ unwarranted change in the program+ severedamage to robot tooling+ or the loss of robotic or fi"ture positioning

It will be left to the Weld Tech to determine if the situations re#uires a weld to betouched up after considering all potential causes and reasons why a particularweld is out of position as described in the procedures listed below The Weld Techmust understand that if the decision is made to touch up a weld+ only after theproper procedures have been followed and all considerations have been made+that the shift in which the change was made will still be e"pected to meet the >ailyProduction Re#uirements It is also re#uired+ as specified in the e"pectations ofthe weld tech+ that any changes is thoroughly documented in the downtime

trac$ing sheets+ specifying the weld location and joining parts as well as the linelocation within the program and program name It is a part of the departments payplan to reclaim poor robotic welds Therefore+ the alternative and preferredresponse+ to touching up a weld+ is to inform !ngineering and (upervision of theissue resulting in a thorough investigation prior to any changes The line may thencontinue to operate under current conditions by repairing the welds as needed tomeet their daily production schedule

W ld T h : P d


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Weld Touch :p Procedure If it appears that a weld is out of position or re#uires touch up in the weld program+

investigate the following prior to ma$ing any changes to the program

18 9erif% that this a consistent or continuing weld issue' &hec$ the ne"t * cabs that come out of the weld cell+ do they also have the same weld issueL

) &hec$ the previous * cabs+ do they have the same weld issueL

* If possible chec$ the previous shift8s cabs+ do they have the same weld issueL

28 #un the Torch mate program and chec, for an% changes

' Turn the controller to TI and turn the teach pendant on

) @rom the teach pendant under the select menu+ highlight the torchmate program and press enter

* Cog the robot through the program then press the data button

- :nder type+ select torchmate This will bring up a list of coordinates in 756+ verify that the topcoordinates are close to the ones below them

. Reset the cell

38 9erif% that the operator is loading it the same wa%' Watch him load a few cabs+ does it still have the same weld issueL

) Watch another certified operator load the cab+ does it still have the issueL

48 9erif% that the parts are consistent' Try a part from another batch or contico+ does it still have the weld issueL

58 0f the weld connects a part to an asseml%7 or an asseml% to an asseml%7 /erif%that the assemlies and the stations the% are welded in are correct8

' @ollow these same procedures for the assembled part

68 9erif% the tooling has not changed or een modified

' &hec$ the downtime log to see if a change was made by another shift


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Weld Touch :p Procedure8 0f the weld issue still persists7 document the prolem and %our findings from

following the procedure

' Record the necessary information in the downtime trac$ing sheet and email or leave a note with

the engineer+ a more detail record of your findings from the procedure;8 Touch up the weld

' Turn the controller to T) and the teach pendant on

) Run the program in teach mode through to the weld that needs touched up


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Weld Touch :p Procedure

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