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R-30+B CONTROLLER

Servo Gun Function

OPERATOR'S MANUAL

B-83264EN/03
 • Original Instructions

Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand
the content.

• No part of this manual may be reproduced in any form.

• All specifications and designs are subject to change without notice.

The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.

In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as ”impossible”.
B-83264EN/03 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
Thank you for purchasing FANUC Robot.
This chapter describes the precautions which must be observed to ensure the safe use of the robot.
Before attempting to use the robot, be sure to read this chapter thoroughly.

Before using the functions related to robot operation, read the relevant operator's manual to become
familiar with those functions.

If any description in this chapter differs from that in the other part of this manual, the description given in
this chapter shall take precedence.

For the safety of the operator and the system, follow all safety precautions when operating a robot and its
peripheral devices installed in a work cell.
In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.

1 WORKING PERSON
The personnel can be classified as follows.

Operator:
• Turns robot controller power ON/OFF
• Starts robot program from operator’s panel

Programmer or teaching operator:

• Operates the robot
• Teaches robot inside the safety fence

Maintenance engineer:
• Operates the robot
• Teaches robot inside the safety fence
• Maintenance (adjustment, replacement)

- An operator cannot work inside the safety fence.

- A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The
working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance,
etc.
- To work inside the fence, the person must be trained on proper robot operation.

During the operation, programming, and maintenance of your robotic system, the programmer, teaching
operator, and maintenance engineer should take additional care of their safety by using the following
safety precautions.

- Use adequate clothing or uniforms during system operation

- Wear safety shoes
- Use helmet

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 SAFETY PRECAUTIONS B-83264EN/03

2 DEFINITION OF WARNING, CAUTION AND

NOTE
To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution
on safety with "Warning" or "Caution" according to its severity. Supplementary information is indicated
by "Note". Read the contents of each "Warning", "Caution" and "Note" before attempting to use the
robots.

WARNING
Applied when there is a danger of the user being injured or when there is a
danger of both the user being injured and the equipment being damaged if the
approved procedure is not observed.

CAUTION
Applied when there is a danger of the equipment being damaged, if the
approved procedure is not observed.

NOTE
Notes are used to indicate supplementary information other than Warnings and
Cautions.

• Read this manual carefully, and store it in a sales place.

3 WORKING PERSON SAFETY

Working person safety is the primary safety consideration. Because it is very dangerous to enter the
operating space of the robot during automatic operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful consideration must be made to ensure
working person safety.

(1) Have the robot system working persons attend the training courses held by FANUC.

FANUC provides various training courses. Contact our sales office for details.

(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is
waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working
person safety, provide the system with an alarm to indicate visually or aurally that the robot is in
motion.
(3) Install a safety fence with a gate so that no working person can enter the work area without passing
through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that
the robot is stopped as the safety gate is opened.

The controller is designed to receive this interlocking signal of the door switch. When the gate
is opened and this signal received, the controller stops the robot (Please refer to "STOP
TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). For connection, see
Fig.3 (a) and Fig.3 (b).

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B-83264EN/03 SAFETY PRECAUTIONS

(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools
such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm
that stops the robot when a working person enters the work area.
(8) If necessary, install a safety lock so that no one except the working person in charge can turn on the
power of the robot.

The circuit breaker installed in the controller is designed to disable anyone from turning it on
when it is locked with a padlock.

(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot
(10) Operators should be ungloved while manipulating the operator’s panel or teach pendant. Operation
with gloved fingers could cause an operation error.
(11) Programs, system variables, and other information can be saved on memory card or USB memories.
Be sure to save the data periodically in case the data is lost in an accident.
(12) The robot should be transported and installed by accurately following the procedures recommended
by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe
injury to workers.
(13) In the first operation of the robot after installation, the operation should be restricted to low speeds.
Then, the speed should be gradually increased to check the operation of the robot.
(14) Before the robot is started, it should be checked that no one is in the area of the safety fence. At the
same time, a check must be made to ensure that there is no risk of hazardous situations. If detected,
such a situation should be eliminated before the operation.
(15) When the robot is used, the following precautions should be taken. Otherwise, the robot and
peripheral equipment can be adversely affected, or workers can be severely injured.
- Avoid using the robot in a flammable environment.
- Avoid using the robot in an explosive environment.
- Avoid using the robot in an environment full of radiation.
- Avoid using the robot under water or at high humidity.
- Avoid using the robot to carry a person or animal.
- Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.)
(16) When connecting the peripheral devices related to stop(safety fence etc.) and each signal (external
emergency , fence etc.) of robot. be sure to confirm the stop movement and do not take the wrong
connection.
(17) When preparing trestle, please consider security for installation and maintenance work in high place
according to Fig.3 (c). Please consider footstep and safety bolt mounting position.

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 SAFETY PRECAUTIONS B-83264EN/03

RP1
Pulsecoder
RI/RO,XHBK,XROT
RM1
Motor power/brake

EARTH

Safety fence

Interlocking device and safety plug that are activated if the

gate is opened.

Fig. 3 (a) Safety fence and safety gate

Dual chain Emergency stop board

(Note)
orPanel
Panelboard
board （Note）

EAS1 In case
In caseofofR-30iB,
R-30iAR-30iB Mate
TerminalsEAS1,EAS11,EAS2,EAS21
Terminals EAS1,EAS11,EAS2,EAS21 areorprovided
FENCE1,FENCE2
on the
EAS11 are provided
emergency onboard.
stop the operation box or on the terminal block
of the printed circuit boar d.
EAS2
Refer
In casetoof R-30iA
the ELECTRICAL
Mate CONNCETIONS Chapter of
EAS21 CONNECTION of
Terminals EAS1,EAS11,EAS2,EAS21 are provided
R-30iB controller maintenance
on the emergency stop board manual (B-83195EN)
or connector panel. or
(in caseMate
R-30iB of Open air type)
controller maintenance manual (B-83525EN)
for details.
Termianls FENCE1,FENCE2 ar e provided
on the emergency stop board.
Single chain
Panel board
Refer to controller maintenance manual for details.
FENCE1

FENCE2

Fig. 3 (b) Limit switch circuit diagram of the safety fence

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B-83264EN/03 SAFETY PRECAUTIONS

Hook for safety belt

Fence

Steps

Trestle

Footstep
for maintenance

Fig.3 (c) Footstep for maintenance

3.1 OPERATOR SAFETY

The operator is a person who operates the robot system. In this sense, a worker who operates the teach
pendant is also an operator. However, this section does not apply to teach pendant operators.

(1) If you do not have to operate the robot, turn off the power of the robot controller or press the
EMERGENCY STOP button, and then proceed with necessary work.
(2) Operate the robot system at a location outside of the safety fence
(3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering
the work area unexpectedly and to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator’s reach.

The robot controller is designed to be connected to an external EMERGENCY STOP button.

With this connection, the controller stops the robot operation (Please refer to "STOP TYPE
OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type), when the external
EMERGENCY STOP button is pressed. See the diagram below for connection.

Dual chain (Note)

External stop button Connect EES1 and EES11, EES2 and EES21
Emergency stop boa rd
Panel board
o r Pane l boa rd In case R-30iB, R-30iB Mate
EES1 EES1,EES11,EES2,EES21 are on the emergenc y stop board
（Note）
EES11 Connect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2.
Refer to the ELECTRICAL CONNCETIONS Chapter of
EES2 In case of R-30iA
CONNECTION of
EES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board.
EES21 R-30iB controller maintenance manual (B-83195EN) or
In case of
R-30iB R-30iA
Mate Mate maintenance manual (B-83525EN)
controller
EES1,EES11,EES2,EES21 are on the emergency stop board
for details. panel (in case of Open air type).
or connector
Single chain EMGIN1,EMGIN2 are on the emergency stop board.
External stop button Refer to the maintenance manual of the controller for details.
Panel board
EMGIN1
EMGIN2

Fig.3.1 Connection diagram for external emergency stop button

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3.2 SAFETY OF THE PROGRAMMER

While teaching the robot, the operator must enter the work area of the robot. The operator must ensure
the safety of the teach pendant operator especially.

(1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal
operating condition.
(3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and
other conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN
switch on the teach pendant) before entering the area.
(4) The programmer must be extremely careful not to let anyone else enter the robot work area.
(5) Programming should be done outside the area of the safety fence as far as possible. If programming
needs to be done in the area of the safety fence, the programmer should take the following
precautions:
－ Before entering the area of the safety fence, ensure that there is no risk of dangerous situations
in the area.
－ Be prepared to press the emergency stop button whenever necessary.
－ Robot motions should be made at low speeds.
－ Before starting programming, check the entire system status to ensure that no remote instruction
to the peripheral equipment or motion would be dangerous to the user.

Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the
automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety
fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent
other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened
with the automatic operation mode set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type). After the switch is set to a teach mode, the safety gate is disabled. The
programmer should understand that the safety gate is disabled and is responsible for keeping other people from
entering the inside of the safety fence.

Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and
switch function as follows:
(1) Emergency stop button: Causes an emergency stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY
PRECAUTIONS for detail of stop type) when pressed.
(2) DEADMAN switch: Functions differently depending on the teach pendant enable/disable switch setting
status.
(a) Disable: The DEADMAN switch is disabled.
(b) Enable: Servo power is turned off when the operator releases the DEADMAN switch or when the
operator presses the switch strongly.
Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or
presses the pendant strongly in case of emergency. The R-30iB/R-30iB Mate employs a 3-position
DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed
to its intermediate point. When the operator releases the DEADMAN switch or presses the switch
strongly, the robot stops immediately.

The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the
teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator
should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.

Based on the risk assessment by FANUC, number of operation of DEADMAN SW should not exceed about 10000
times per year.

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The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the
validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator
panel, the teach pendant enable switch and the remote condition on the software.

In case of R-30iB Controller

Software
Teach pendant
Mode remote Teach pendant Operator panel Peripheral device
enable switch
condition
Local Not allowed Not allowed Not allowed
On
AUTO Remote Not allowed Not allowed Not allowed
mode Local Not allowed Allowed to start Not allowed
Off
Remote Not allowed Not allowed Allowed to start
Local Allowed to start Not allowed Not allowed
On
T1, T2 Remote Allowed to start Not allowed Not allowed
mode Local Not allowed Not allowed Not allowed
Off
Remote Not allowed Not allowed Not allowed
T1,T2 mode:DEADMAN switch is effective.

(6) To start the system using the operator’s panel, make certain that nobody is the robot work area and
that there are no abnormal conditions in the robot work area.
(7) When a program is completed, be sure to carry out a test operation according to the procedure
below.
(a) Run the program for at least one operation cycle in the single step mode at low speed.
(b) Run the program for at least one operation cycle in the continuous operation mode at low
speed.
(c) Run the program for one operation cycle in the continuous operation mode at the intermediate
speed and check that no abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous operation mode at the normal
operating speed and check that the system operates automatically without trouble.
(e) After checking the completeness of the program through the test operation above, execute it in
the automatic operation mode.
(8) While operating the system in the automatic operation mode, the teach pendant operator should
leave the robot work area.

3.3 SAFETY OF THE MAINTENANCE ENGINEER

For the safety of maintenance engineer personnel, pay utmost attention to the following.

(1) During operation, never enter the robot work area.

(2) A hazardous situation may arise when the robot or the system, are kept with their power-on during
maintenance operations. Therefore, for any maintenance operation, the robot and the system should
be put into the power-off state. If necessary, a lock should be in place in order to prevent any other
person from turning on the robot and/or the system. In case maintenance needs to be executed in the
power-on state, the emergency stop button must be pressed.
(3) If it becomes necessary to enter the robot operation range while the power is on, press the
emergency stop button on the operator panel, or the teach pendant before entering the range. The
maintenance personnel must indicate that maintenance work is in progress and be careful not to
allow other people to operate the robot carelessly.
(4) When entering the area enclosed by the safety fence, the maintenance worker must check the entire
system in order to make sure no dangerous situations exist. In case the worker needs to enter the
safety area whilst a dangerous situation exists, extreme care must be taken, and entire system status
must be carefully monitored.
(5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off
and the pressure in the piping should be reduced to zero.
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 SAFETY PRECAUTIONS B-83264EN/03

(6) Before the start of teaching, check that the robot and its peripheral devices are all in the normal
operating condition.
(7) Do not operate the robot in the automatic mode while anybody is in the robot work area.
(8) When you maintain the robot alongside a wall or instrument, or when multiple workers are working
nearby, make certain that their escape path is not obstructed.
(9) When a tool is mounted on the robot, or when any moving device other than the robot is installed,
such as belt conveyor, pay careful attention to its motion.
(10) If necessary, have a worker who is familiar with the robot system stand beside the operator panel
and observe the work being performed. If any danger arises, the worker should be ready to press
the EMERGENCY STOP button at any time.
(11) When replacing a part, please contact FANUC service center. If a wrong procedure is followed, an
accident may occur, causing damage to the robot and injury to the worker.
(12) When replacing or reinstalling components, take care to prevent foreign material from entering the
system.
(13) When handling each unit or printed circuit board in the controller during inspection, turn off the
circuit breaker to protect against electric shock.
If there are two cabinets, turn off the both circuit breaker.
(14) A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction
or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used.
Such a fuse may cause a fire.
(15) When restarting the robot system after completing maintenance work, make sure in advance that
there is no person in the work area and that the robot and the peripheral devices are not abnormal.
(16) When a motor or brake is removed, the robot arm should be supported with a crane or other
equipment beforehand so that the arm would not fall during the removal.
(17) Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent
dangerous falls.
(18) The following parts are heated. If a maintenance worker needs to touch such a part in the heated
state, the worker should wear heat-resistant gloves or use other protective tools.
－ Servo motor
－ Inside the controller
－ Reducer
－ Gearbox
－ Wrist unit
(19) Maintenance should be done under suitable light. Care must be taken that the light would not cause
any danger.
(20) When a motor, reducer, or other heavy load is handled, a crane or other equipment should be used to
protect maintenance workers from excessive load. Otherwise, the maintenance workers would be
severely injured.
(21) The robot should not be stepped on or climbed up during maintenance. If it is attempted, the robot
would be adversely affected. In addition, a misstep can cause injury to the worker.
(22) When performing maintenance work in high place, secure a footstep and wear safety belt.
(23) After the maintenance is completed, spilled oil or water and metal chips should be removed from the
floor around the robot and within the safety fence.
(24) When a part is replaced, all bolts and other related components should put back into their original
places. A careful check must be given to ensure that no components are missing or left not mounted.
(25) In case robot motion is required during maintenance, the following precautions should be taken :
- Foresee an escape route. And during the maintenance motion itself, monitor continuously the
whole system so that your escape route will not become blocked by the robot, or by peripheral
equipment.
- Always pay attention to potentially dangerous situations, and be prepared to press the emergency
stop button whenever necessary.
(26) The robot should be periodically inspected. (Refer to the robot mechanical manual and controller
maintenance manual.) A failure to do the periodical inspection can adversely affect the performance
or service life of the robot and may cause an accident
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B-83264EN/03 SAFETY PRECAUTIONS

(27) After a part is replaced, a test operation should be given for the robot according to a predetermined
method. (See TESTING section of “FANUC Robot series R-30iB/ R-30iB Mate CONTROLLER
OPERATOR’S MANUAL (Basic Operation)(B-83284EN)”.) During the test operation, the
maintenance staff should work outside the safety fence.

4 SAFETY OF THE TOOLS AND

PERIPHERAL DEVICES
4.1 PRECAUTIONS IN PROGRAMMING
(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the
program to stop the robot when the sensor signal is received.
(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or
peripheral devices, even though the robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care
must be taken in programming so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect
the states of all devices in the system and can be stopped according to the states.

4.2 PRECAUTIONS FOR MECHANISM

(1) Keep the component cells of the robot system clean, and operate the robot in an environment free of
grease, water, and dust.
(2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid.
(3) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot or cable does
not strike against its peripheral devices or tools.
(4) Observe the following precautions about the mechanical unit cables. When theses attentions are not
kept, unexpected troubles might occur.
• Use mechanical unit cable that have required user interface.
• Don’t add user cable or hose to inside of mechanical unit.
• Please do not obstruct the movement of the mechanical unit cable when cables are added to
outside of mechanical unit.
• In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a
protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the
cable.
• Please do not interfere with the other parts of mechanical unit when install equipments in the
robot.
(5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please
avoid the system construction that power-off stop would be operated routinely. (Refer to bad case
example.) Please execute power-off stop after reducing the speed of the robot and stopping it by
hold stop or cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in
SAFETY PRECAUTIONS for detail of stop type.)
(Bad case example)
• Whenever poor product is generated, a line stops by emergency stop.
• When alteration was necessary, safety switch is operated by opening safety fence and
power-off stop is executed for the robot during operation.
• An operator pushes the emergency stop button frequently, and a line stops.
• An area sensor or a mat switch connected to safety signal operate routinely and power-off stop
is executed for the robot.
(6) Robot stops urgently when collision detection alarm (SRVO-050) etc. occurs. The frequent urgent
stop by alarm causes the trouble of the robot, too. So remove the causes of the alarm.
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5 SAFETY OF THE ROBOT MECHANISM

5.1 PRECAUTIONS IN OPERATION
(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can
manage the robot in any eventuality.
(2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the
jog mode.

5.2 PRECAUTIONS IN PROGRAMMING

(1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere
with each other.
(2) Be sure to specify the predetermined work origin in a motion program for the robot and program the
motion so that it starts from the origin and terminates at the origin.
Make it possible for the operator to easily distinguish at a glance that the robot motion has
terminated.

5.3 PRECAUTIONS FOR MECHANISMS

(1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water,
and dust.

5.4 PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER

IN EMERGENCY OR ABNORMAL SITUATIONS
For emergency or abnormal situations (e.g. persons trapped in or by the robot), brake release unit can be
used to move the robot axes without drive power.
Please refer to controller maintenance manual and mechanical unit operator’s manual for using method of
brake release unit and method of supporting robot.

6 SAFETY OF THE END EFFECTOR

6.1 PRECAUTIONS IN PROGRAMMING
(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time
delay after issuing each control command up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of
the end effector.

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B-83264EN/03 SAFETY PRECAUTIONS

7 STOP TYPE OF ROBOT

The following three robot stop types exist:

Power-Off Stop (Category 0 following IEC 60204-1)

Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is
moving, and the motion path of the deceleration is uncontrolled.
The following processing is performed at Power-Off stop.
- An alarm is generated and servo power is turned off.
- The robot operation is stopped immediately. Execution of the program is paused.

Controlled stop (Category 1 following IEC 60204-1)

The robot is decelerated until it stops, and servo power is turned off.
The following processing is performed at Controlled stop.
- The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the
program is paused.
- An alarm is generated and servo power is turned off.

Hold (Category 2 following IEC 60204-1)

The robot is decelerated until it stops, and servo power remains on.
The following processing is performed at Hold.
- The robot operation is decelerated until it stops. Execution of the program is paused.

WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for
the whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when Controlled stop is used.

When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Power-Off
stop or Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop
pattern is different according to the controller type or option configuration.

There are the following 3 Stop patterns.

Emergency External
Stop Servo
Mode stop Emergency FENCE open SVOFF input
pattern disconnect
button stop
AUTO P-Stop P-Stop C-Stop C-Stop P-Stop
A T1 P-Stop P-Stop - C-Stop P-Stop
T2 P-Stop P-Stop - C-Stop P-Stop
AUTO P-Stop P-Stop P-Stop P-Stop P-Stop
B T1 P-Stop P-Stop - P-Stop P-Stop
T2 P-Stop P-Stop - P-Stop P-Stop
AUTO C-Stop C-Stop C-Stop C-Stop C-Stop
C T1 P-Stop P-Stop - C-Stop P-Stop
T2 P-Stop P-Stop - C-Stop P-Stop
P-Stop: Power-Off stop
C-Stop: Controlled stop
-: Disable

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 SAFETY PRECAUTIONS B-83264EN/03

The following table indicates the Stop pattern according to the controller type or option configuration.
Option R-30iB/ R-30iB Mate
Standard A (*)
Controlled stop by E-Stop (A05B-2600-J570) C (*)
(*) R-30iB / R-30iB Mate does not have servo disconnect. / R-30iB Mate does not have SVOFF input.

The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please
refer to "Software version" in operator's manual of controller for the detail of software version screen.

"Controlled stop by E-Stop" option

When "Controlled stop by E-Stop" (A05B-2600-J570) option is specified, the stop type of the following
alarms becomes
Controlled stop but only in AUTO mode. In T1 or T2 mode, the stop type is Power-Off stop which is
the normal operation of the system.

Alarm Condition
SRVO-001 Operator panel E-stop Operator panel emergency stop is pressed.
SRVO-002 Teach pendant E-stop Teach pendant emergency stop is pressed.
SRVO-007 External emergency stops External emergency stop input (EES1-EES11, EES2-EES21) is
open.
SRVO-408 DCS SSO Ext Emergency Stop In DCS Safe I/O connect function, SSO[3] is OFF.
SRVO-409 DCS SSO Servo Disconnect In DCS Safe I/O connect function, SSO[4] is OFF.

Controlled stop is different from Power-Off stop as follows:

- In Controlled stop, the robot is stopped on the program path. This function is effective for a system
where the robot can interfere with other devices if it deviates from the program path.
- In Controlled stop, physical impact is less than Power-Off stop. This function is effective for
systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be
minimized.
- The stopping distance and stopping time of Controlled stop is longer than the stopping distance and
stopping time of Power-Off stop, depending on the robot model and axis. Please refer to the
operator's manual of a particular robot model for the data of stopping distance and stopping time.

When this option is loaded, this function cannot be disabled.

The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.

WARNING
The stopping distance and stopping time of Controlled stop are longer than the
stopping distance and stopping time of Power-Off stop. A risk assessment for
the whole robot system, which takes into consideration the increased stopping
distance and stopping time, is necessary when this option is loaded.
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TABLE OF CONTENTS
SAFETY PRECAUTIONS............................................................................s-1
1 OVERVIEW ............................................................................................. 1
1.1 FEATURES OF FANUC SERVO GUN .......................................................... 1
1.2 BASIC SPECIFICATION ............................................................................... 1
1.3 NAMES OF MAJOR SERVO GUN COMPONENTS ..................................... 1
1.4 CONTROL METHOD (MULTI-GROUP) ........................................................ 1
2 INITIAL SETTING.................................................................................... 3
2.1 SERVO GUN AXIS INITIALIZATION............................................................. 3
2.2 SETTING THE COORDINATE SYSTEM .................................................... 15
2.3 SETTING THE GUN CLOSE DIRECTION .................................................. 16
2.4 SETTING THE MAX PRESSURE................................................................ 17
2.5 SERVO GUN SETUP AND AUTOTUNING UTILITY................................... 17
2.6 PRESSURE CALIBRATION ........................................................................ 26
3 SERVO GUN MAIN SETUP SCREEN .................................................. 30
3.1 SERVO GUN SETUP SCREEN .................................................................. 30
3.2 SERVO GUN GENERAL SETUP SCREEN ................................................ 30
4 MANUAL OPERATIONS....................................................................... 33
4.1 MANUAL PRESSURIZATION (Shift + GUN)............................................... 33
4.2 MANUAL BACKUP (Shift + BU) .................................................................. 38
4.3 MANUAL WELDING .................................................................................... 40
4.4 GUN JOG OPERATION .............................................................................. 41
4.5 THICKNESS MEASUREMENT ................................................................... 45
4.5.1 Initial Setting ..........................................................................................................45
4.5.2 Thickness Measurement from Editor .....................................................................45
4.5.3 Thickness Measurement from MANUAL Screen ..................................................46
4.5.4 Dual Gun ................................................................................................................47

5 PROGRAMMING................................................................................... 48
5.1 SPOT WELDING INSTRUCTIONS ............................................................. 48
5.1.1 SPOT Instruction Format .......................................................................................48
5.1.2 Welding Sequence..................................................................................................53
5.1.3 Teaching Position ...................................................................................................54
5.1.4 Hold ........................................................................................................................55
5.1.5 E-Stop.....................................................................................................................55

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5.1.6 Single-Step .............................................................................................................55

5.1.7 Backward................................................................................................................57
5.1.8 Tips to Using SPOT Instruction .............................................................................59
5.2 OTHER INSTRUCTIONS ............................................................................ 59
5.2.1 Press Motion Instruction ........................................................................................59
5.2.2 Pressure Instruction ................................................................................................60
5.2.3 Gun Zero Master Instruction ..................................................................................61
5.2.4 TIPDRESS Instruction ...........................................................................................62

6 TIP WEAR DOWN COMPENSATION................................................... 65

6.1 OVERVIEW ................................................................................................. 65
6.2 STANDARD TIP WEAR PROGRAM LIST................................................... 66
6.3 PREPARATIONS FOR TIP WEAR DOWN COMPENSATION.................... 67
6.3.1 Preparations ............................................................................................................67
6.3.2 Preparation of TWO-STEP ....................................................................................67
6.3.3 Confirmation of Register & Position Register Number .........................................67
6.4 TWO-STEP MEASUREMENT METHOD .................................................... 70
6.4.1 Teaching Position ...................................................................................................70
6.4.2 Initial Setup ............................................................................................................71
6.4.3 Update Tip Wear Amount ......................................................................................72
6.4.4 Example of Tip Wear Down Measurement............................................................73
6.5 ONE-STEP MEASUREMENT METHOD ..................................................... 73
6.5.1 Initial Setup ............................................................................................................73
6.5.2 Update Amount of Wear Down..............................................................................74
6.5.3 ONE-STEP Measurement with Multi Task............................................................75
6.6 COMBINATION 2 STEP METHOD AND 1 STEP METHOD ....................... 76
6.6.1 Overall ....................................................................................................................76
6.6.2 Procedure to Use ....................................................................................................76
6.7 OPERATIONAL SETTING AND ALARM PROCESSING ............................ 77
6.7.1 Tip Wear Detect Setup Screen ...............................................................................77
6.7.1.1 Setup for tip wear down measurement .............................................................. 78
6.7.1.2 Setup for tip wear down alarm process.............................................................. 78
6.7.1.3 Setting of calculation and updating wear ratio .................................................. 79
6.7.1.4 Confirmation of wear ratio ................................................................................ 80
6.7.2 Tip Wear Standard Screen......................................................................................80
6.8 AUTO UPDATING WEAR RATIO................................................................ 81
6.8.1 Overall ....................................................................................................................81
6.8.2 Procedure to Use ....................................................................................................81

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6.8.3 Sample for Introduction..........................................................................................83

6.9 DATA RECOVERY ...................................................................................... 85
6.9.1 Recovery Mastering Data .......................................................................................85
6.9.2 Recovery from Lost of Tip .....................................................................................85
6.10 ACTIVE STROKE LIMIT PROTECTION ..................................................... 86
6.11 COMPATIBILITY OF TIP WEAR MEASUREMNET PROGRAMS............... 87
6.12 TIP WEAR DOWN COMPENSATION FOR MULTI-EQUIPMENT .............. 89
6.12.1 Standard Tip Wear Program List for Multi-Equipment .........................................89
6.12.2 Initial Setup of 2-step method for Multi-Equipment ..............................................90
6.12.3 Update Tip Wear Amount of 2-step method for Multi-Equipment........................92
6.12.4 Initial Setup of 1-step method for Multi-Equipment ..............................................94
6.12.5 Update Tip Wear Amount of 1-step method for Multi-Equipment........................95

7 GUN SAG COMPENSATION................................................................ 98

8 EXT. TIP STICK SIGNAL DETECTION ................................................ 99
9 SERVO GUN MONITORING ............................................................... 103
10 TEST CYCLE ...................................................................................... 105
11 PRESSURE RELATED I/O SIGNALS ................................................ 107
11.1 EQUALIZE SIGNAL................................................................................... 107
11.2 PRESSURE ENABLE SIGNAL.................................................................. 109
11.3 NEXT STEP ENABLE................................................................................ 110
11.4 PRESSURIZATION NOTIFICATION SIGNAL ........................................... 111
11.5 NEXT STEP ENABLE FROM WELD CONTROLLER ............................... 112
12 PRESSURE PROFILE CONTROL FUNCTION .................................. 114
12.1 OVERVIEW ............................................................................................... 114
12.2 PROFILE DATA......................................................................................... 114
12.2.1 Operation ..............................................................................................................114
12.2.2 Meaning of Each Items.........................................................................................115
12.2.3 Example................................................................................................................117
12.2.4 Limitations............................................................................................................119

13 GUN CHANGE FUNCTION................................................................. 120

13.1 OUTLINE ................................................................................................... 120
13.1.1 Feature of Function ..............................................................................................120
13.1.2 Basic Specification ...............................................................................................120
13.1.3 Restrictions...........................................................................................................120
13.1.4 System Configuration...........................................................................................121
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13.1.5 Outline of Installation...........................................................................................122

13.2 INITIAL SETUP.......................................................................................... 123
13.3 GUN CHANGE SETUP ............................................................................. 123
13.4 SETTING THE REFERENCE POSITION .................................................. 128
13.4.1 Battery-less Type Guns ........................................................................................128
13.4.2 Battery-mounted Type Guns ................................................................................129
13.5 GUN CHANGE INSTRUCTION ................................................................. 129
13.5.1 GUN DETACH Instruction..................................................................................129
13.5.2 GUN ATTACH Instruction..................................................................................130
13.5.3 Sample Program ...................................................................................................130
13.5.4 Forward Execution ...............................................................................................131
13.5.5 Backward Execution.............................................................................................131
13.6 GUN CHANGE SEQUENCE ..................................................................... 132
13.7 GUN CHANGE STATUS ........................................................................... 132
13.8 SERVO GUN SETUP ................................................................................ 133
13.9 TEACHING ................................................................................................ 133
13.9.1 Notice for Teaching..............................................................................................133
13.9.2 Sample Program ...................................................................................................135
13.9.3 Gun Change by Multi-task ...................................................................................135

14 OVERTORQUE PROTECTION FEATURE ......................................... 137

14.1 OVERVIEW ............................................................................................... 137
14.2 OVERTRQUE PROTECTION SETUP....................................................... 137
15 PART THICKNESS CHECK FUNCTION ............................................ 143
15.1 THICKNESS CHECK CALIBRATION ........................................................ 143
15.2 THICKNESS CHECK GENERAL SETUP.................................................. 145
16 GUN OPEN FUNCTION AT WELD FAULT ........................................ 148
16.1 CONDITIONS OF GUN OPEN .................................................................. 148
16.2 GUN OPENING MOTION.......................................................................... 149
17 DUAL-GUN CONTROL ....................................................................... 150
17.1 OVERALL .................................................................................................. 150
17.2 DUAL-GUN EQUIPMENT AND AXIS SETUP ........................................... 150
17.3 DUAL-GUN OPERATIONAL SETUP......................................................... 151
17.3.1 Servo Gun Setup...................................................................................................151
17.3.2 Pressure Schedule, Distance Schedule, and Backup Schedule Table...................152
17.3.3 Gun Setup Utility Operation.................................................................................153
17.3.4 Pressure Calibration .............................................................................................154
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17.4 DUAL-GUN MANUAL AND PROGRAM OPERATION .............................. 155

17.4.1 Manual Operations ...............................................................................................155
17.4.2 Gun Jog Operation................................................................................................156
17.4.3 Programming Operation .......................................................................................156
17.4.4 Tip Wear and Gun Sag Compensation .................................................................158
17.4.5 Part Thickness Check ...........................................................................................158
17.4.6 Gun Open Function at Weld Fault .......................................................................158

18 SERVO GUN WEIGHT COMPENSATION.......................................... 160

18.1 OVERVIEW ............................................................................................... 160
18.2 SERVO GUN WEIGHT COMPENSATION FUNCTION ............................ 160
18.3 SETTING EACH WEIGHT COMPENSATION FUNCTION........................ 161
18.3.1 Initial Setting ........................................................................................................161
18.3.2 Setting Auto Weight Compensation Function......................................................164
18.3.3 Setting Semi-auto Weight Compensation Function .............................................166
18.3.4 Setting Manual Weight Compensation Function .................................................170
18.4 PRESSURE COMPENSATION ................................................................. 174
18.4.1 Setting Weight Compensation Type.....................................................................174
18.4.2 Weight Compensation Status ...............................................................................175
18.5 OTHER FUNCTIONS ................................................................................ 176
19 SERVO GUN TEMPERATURE COMPENSATION............................. 177
19.1 OVERVIEW ............................................................................................... 177
19.2 INITIAL SETTING ...................................................................................... 177
19.3 TEMPERATURE COMPENSATION SETTING SCREEN ......................... 178
19.4 PRESSURE COMPENSATION ................................................................. 180
19.4.1 Pressure Compensation Condition .......................................................................180
19.4.2 Temperature Compensation Status.......................................................................180

20 RELATED VIEW FUNCTION .............................................................. 182

20.1 RELATED VIEW FUNCTION..................................................................... 182
20.2 OPERATION FOR RELATED VIEW FUNCTION ...................................... 183
20.3 QUICK VIEW FUNCTION.......................................................................... 184
20.4 OPERATION FOR QUICK VIEW FUNCTION ........................................... 185
21 SPOT PROGRAM TOUCHUP FUNCTION ......................................... 186
21.1 OVERVIEW ............................................................................................... 186
21.2 INITIAL SETTING ...................................................................................... 188
21.3 SPOT PROGRAM TOUCHUP EXECUTION PROCEDURE ..................... 188
21.4 SPOT PROGRAM TOUCHUP SETUP SCREEN ...................................... 191
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21.5 MAX DETECTION DISTANCE .................................................................. 197

21.6 LOWER PANEL DETECTION DISTANCE CLAMP................................... 198
21.7 PARAMETER CALIBRATION SETUP....................................................... 199
21.8 SEARCH PARAMETERS SETUP ............................................................. 202
21.9 THICKNESS UPDATE SETUP.................................................................. 203
21.9.1 Search Sequence with Thickness Update .............................................................205
21.9.1.1 Prompt to confirm detected lower position and thickness ............................... 206
21.10 SPOT PROGRAM TOUCHUP STATUS SCREEN.................................... 207
21.11 SPOT PROGRAM TOUCHUP CHART SCREEN...................................... 210
21.12 TOUCHUP STATUS RECORDING FUNCTION........................................ 216
21.13 SPOT PROGRAM TOUCHUP DISABLE INSTRUCTION ......................... 218
21.14 SPTCH_OFS INSTRUCTION.................................................................... 219
21.15 SPTCH_RSD INSTRUCTION.................................................................... 220
21.16 SINGLE STEP MODE ............................................................................... 222
21.17 OTHER SPECIFICATIONS ....................................................................... 223
21.18 SPOT POINT TOUCHUP FUNCTION....................................................... 223
21.18.1 Over View ............................................................................................................223
21.18.2 Initial Setting ........................................................................................................225
21.18.3 Operating Procedure for Spot Point Touchup with Upper Panel Detection.........225
21.18.4 Operating Procedure of Spot Point Touchup without Upper Panel Detection .....229
21.18.5 Spot Point Touchup Cancellation.........................................................................233
21.18.6 Pressure Motion after Spot Point Touchup (single step)......................................234
21.19 GUN MECHANICAL COMPENSATION CALIBRATION ........................... 235
21.20 THICKNESS CHECK CALIBRATION ........................................................ 239
21.21 SIMPLE SEARCH MODE FOR UPPER DETECTION .............................. 240
21.21.1 UPDET_OFS INSTRUCTION ............................................................................241
21.21.1.1 SET OFFSET WITH SPOT POINT TOUCHUP ............................................ 241
21.21.1.2 SET OFFSET WITH PROGRAM TOUCHUP............................................... 242
21.22 PASS CHECK MODE................................................................................ 243
21.23 TROUBLESHOOTING............................................................................... 246
21.24 ALARMS.................................................................................................... 249
22 SERVO TIP DRESSER CONTROL..................................................... 261
22.1 OVERVIEW ............................................................................................... 261
22.2 SERVO TIP DRESSER AXIS SETUP ....................................................... 261
22.3 TIPDRESS INSTRUCTION ....................................................................... 265
22.4 TIP DRESS SETUP MENU ....................................................................... 266
22.5 OTHER FUNCTIONS ................................................................................ 269

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22.5.1 Last Dress / Master Dress Chart ...........................................................................269

22.5.2 Dress Summary Log File and Chart .....................................................................270
22.5.3 Servo Tip Dresser Drive Program ........................................................................273
22.6 ALARM ...................................................................................................... 273
23 WELDTIP INSPECTION...................................................................... 274
23.1 OVERVIEW ............................................................................................... 274
23.1.1 WeldTip Vision Model.........................................................................................274
23.1.2 Composition of Tip Inspection.............................................................................274
23.1.3 Related Function...................................................................................................275
23.2 HARDWARE SETUP................................................................................. 275
23.2.1 Inspection Box......................................................................................................275
23.2.2 Routing Method of Main Body Connection Cables（Camera, LED） ...............276
23.2.3 Installation of Calibration Plate............................................................................278
23.2.4 Periodic Maintenance ...........................................................................................278
23.2.5 Spare Parts List.....................................................................................................278
23.2.6 Connecting a Setup PC.........................................................................................279
23.3 CREATING VISION DATA ........................................................................ 279
23.3.1 Robot Homepage..................................................................................................279
23.3.2 Vision Setup .........................................................................................................280
23.3.3 Camera Setup Tool ...............................................................................................280
23.3.4 Camera Calibration...............................................................................................280
23.3.5 Vision Process Tools ............................................................................................280
23.3.5.1 New tip inspection ........................................................................................... 281
23.3.5.2 Dressed tip inspection...................................................................................... 283
23.3.5.3 Tip wear inspection.......................................................................................... 285
23.3.6 Note for Teaching Vision Process........................................................................290
23.4 INSPECTION PROCEDURE ..................................................................... 290
23.4.1 New Tip Inspection ..............................................................................................290
23.4.2 Dressed Tip Inspection .........................................................................................290
23.4.3 Tip Wear Inspection .............................................................................................291
23.4.4 Dressed Length Inspection ...................................................................................292
23.4.5 Examples ..............................................................................................................293
23.5 SETUP....................................................................................................... 294
23.5.1 Setup Menu ..........................................................................................................294
23.5.2 Status Menu..........................................................................................................296
23.6 ERROR CODES ........................................................................................ 297
23.7 SETUP MULTI GUN SYSTEM .................................................................. 298

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23.8 SHARE ONE LNSPECTION STATION WITH MULTI ROBOT.................. 299

23.9 RECOVER VISION DATA ......................................................................... 300
24 SERVOGUN DIAGNOSIS FUNCTION................................................ 301
24.1 OVERVIEW ............................................................................................... 301
24.2 SPECIFICATION ....................................................................................... 301
24.2.1 Parameters for Monitoring ...................................................................................301
24.2.2 Servogun Motion for Monitoring and Diagnosis .................................................301
24.2.3 Condition for Diagnosis .......................................................................................301
24.2.4 The Result of Diagnosis .......................................................................................301
24.2.5 Save Diagnosis Records .......................................................................................302
24.2.5.1 The details........................................................................................................ 302
24.2.5.2 Summary of diagnosis records......................................................................... 304
24.2.6 Save and Clear Diagnosis Data ............................................................................304
24.2.7 The Schedule of Diagnosis...................................................................................305
24.2.8 Multi Servogun.....................................................................................................305
24.3 USER INTERFACE ................................................................................... 305
24.3.1 Diagnosis Setup Screen ........................................................................................305
24.3.1.1 Gun No. ........................................................................................................... 306
24.3.1.2 Enable/Disable diagnosis................................................................................. 307
24.3.1.3 Override check................................................................................................. 307
24.3.1.4 Torque check ................................................................................................... 307
24.3.1.5 Diagnosis Program........................................................................................... 308
24.3.1.6 Diagnosis schedule .......................................................................................... 308
24.3.2 Diagnosis Status Screen .......................................................................................308
24.3.3 Chart Menu...........................................................................................................309
24.3.4 Alarm....................................................................................................................310
24.4 SYSTEM VARIABLE ................................................................................. 310
24.5 PRESSURE CHECK FUNCTION .............................................................. 311
24.5.1 Overview ..............................................................................................................311
24.5.2 Pressure Check/Adjustment Procedure ................................................................312
24.5.2.1 Pressure Check Calibration.............................................................................. 312
24.5.2.2 Pressure Check ................................................................................................ 313
24.5.2.3 Pressure Adjustment ........................................................................................ 314
24.5.3 Setup Screen .........................................................................................................314
24.5.4 Status Screen ........................................................................................................316
24.5.4.1 General Status Screen ...................................................................................... 316
24.5.4.2 Detail Status Screen......................................................................................... 317
24.5.4.3 History Screen ................................................................................................. 318
24.5.5 Log File ................................................................................................................318

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24.5.5.1 Summary of Record ......................................................................................... 318

24.5.5.2 Detail of Record............................................................................................... 319
24.5.5.3 Automatic Save to External Device................................................................. 320
24.5.6 Pressure Check/Adjustment Individually .............................................................320
24.5.6.1 Pressure Check Procedure ............................................................................... 320
24.5.6.2 Pressure Check Result / Status Screen............................................................. 321
24.5.6.3 Pressure Check by Multi Task ......................................................................... 321

25 EARLY WELD INIT FUNCTION.......................................................... 323

25.1 OVERVIEW ............................................................................................... 323
25.2 WELD DELAY TIME MEASUREMENT ..................................................... 323
25.3 EARLY WELDING CALIBRATION ............................................................ 324
25.4 SETUP EARLY WELD INIT FUNCTION ................................................... 325
25.5 EARLY WELD INIT FUNCTION OPERATION .......................................... 326

APPENDIX
A GUN CHANGE REFERENCE POSITION SETUP METHOD
(BATTERY-LESS TYPE)..................................................................... 331
A.1 REFERENCE POSITION SETUP.............................................................. 331
A.1.1 Reference Position Setup for Calibration Types 3 and 4 .....................................331
A.1.2 Reference Position Setup for Calibration Types 5 and 6 .....................................333
A.2 QUICK MASTERING REFERENCE POSITION SETUP ........................... 334
B TROUBLESHOOTING (GUN CHANGE) ............................................ 336
B.1 THE ATTACH INSTRUCTION IS EXECUTED WHEN THE GUN IS NOT
ATTACHED. .............................................................................................. 336
B.2 THE ROBOT STOPPED DURING CALIBRATION.................................... 336
B.3 CALIBRATION MOTION FAILED. ............................................................. 337
B.4 A DIFFERENT GUN FROM THAT SPECIFIED BY THE ATTACH
INSTRUCTION IS ATTACHED.................................................................. 337
B.5 THE ATTACHED GUN HAS BEEN DETACHED BY MISTAKE (WITHOUT
USING THE DETACH INSTRUCTION). .................................................... 338
B.6 THE GUN AXIS OF A DETACHED GUN HAS MOVED. ........................... 338
B.7 THE BATTERY VOLTAGE HAS FALLEN. ................................................ 339
B.8 THE BATTERY RAN LOW WHILE THE GUN WAS DETACHED. ............ 339
C GUN ZERO MASTERING ................................................................... 340
C.1 GUN MASTER UTILITY ............................................................................ 340
C.2 RESET ALARM ......................................................................................... 341
C.3 MAGNET PHASE DETECTION (MPDT) ................................................... 341

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C.4 MASTERING ............................................................................................. 342

C.5 AUTOMASTER FUNCTION ...................................................................... 343
C.5.1 Automaster Procedure ..........................................................................................343
C.5.2 Auto Zero Calibration Screen...............................................................................345
C.5.3 Zero Calibration Config Screen............................................................................346
C.5.4 Zero Calibration History Screen...........................................................................346

D SETTING GUN STROKE LIMITS........................................................ 347

E AUTOTUNE MACRO PROGRAM....................................................... 348
F PRESS ON NEW TIPS ........................................................................ 350
G TROUBLE SHOOTING (TIP WEAR COMPENSATION) .................... 352
G.1 WEAR DOWN AMOUNT IS NOT MEASURED CORRECTLY .................. 352
G.1.1 Gun Does Not Close Completely with Pressure Motion......................................352
G.1.2 Gun Tip Does Not Contact Fixture in Fixture Touch Motion..............................353
G.1.3 Position of Fixture Is Changed .............................................................................354
G.1.4 Gun Tip Contact Fixture Sidlingly in Fixture Touch Motion .............................354
G.1.5 Gun Zero Mastering with Worn Tip.....................................................................355
G.1.6 Init Setup of Wear Down Measurement with Worn Tip .....................................355
G.2 ALARM RELATED TO TIP WEAR DOWN MEASUREMENT.................... 355
H VARIABLE REMOTE TCP SETUP METHOD..................................... 358
H.1 SYSTEM CONFIGURATION ..................................................................... 358
H.2 CALIBRATING POSITIONER.................................................................... 358
H.2.1 Setting Tool Frame of the Positioner....................................................................358
H.2.2 Setting Tool Frame of the Robot (For Calibration)..............................................359
H.2.3 Calibration ............................................................................................................359
H.2.4 Other Notes...........................................................................................................362
H.3 SETTING SYSTEM VARIABLE ................................................................. 362
H.4 USING VARIABLE REMOTE TCP ............................................................ 363
H.4.1 Selecting Frame Number......................................................................................363
H.4.2 Setting up Servo Gun ...........................................................................................363
H.4.3 Jogging .................................................................................................................363
H.4.4 Teaching ...............................................................................................................364
H.4.5 Executing Program ...............................................................................................364
H.4.6 Limitation .............................................................................................................365

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B-83264EN/03 1.OVERVIEW

1 OVERVIEW
1.1 FEATURES OF FANUC SERVO GUN
• Many dedicated servo gun functions (such as manual operation, soft-touch operation, and tip wear
compensation).
• Automatic creation of tool paths optimized for spot welding.
• The same operations and instructions are usable for both air and servo guns. The interface for air or
servo guns has the same feel.

1.2 BASIC SPECIFICATION

Item Explanation
Pressure setting range 0.0-9999.9[N, kgf, lbf] (*1)
Stroke limit range 0.0-999.9[mm] (*1)
Gun axis speed setting range 0-2000[mm/sec] (or) 0-100[%] ratio of gun axis speed to its maximum
Number of controlled axes Number of axes that can be controlled simultaneously: 6 robot axes + 3
extended axes + 1 gun axis

*1 Practical values are determined according to the specification of the servo gun mechanics. User can
change pressure unit.

1.3 NAMES OF MAJOR SERVO GUN COMPONENTS

Motor for Servo Gun
Control movable tip.

Movable Tip
Servo gun axis
controlled by the above motor.

Fixed Tip
This tip controlled by 6axes of Robot

Fixed Arm
In this manual,
‘Arm’ usually indicates this Arm.

1.4 CONTROL METHOD (MULTI-GROUP)

This system controls a stationary tip (on six robot axes) and a movable tip (on a servo gun axis) in a
multi-motion group environment. Unlike extended axis control, multi-motion group control allows
control of the six robot axes and the servo gun axis in separate motion groups. This enables separate
control of the robot and the gun.
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1.OVERVIEW B-83264EN/03

Control method for servo gun system

Multi-Motion Group Control

Motion Group 1 Motion Group 2

6 Axes for Robot Axis for Servo gun

(1st axis of Group 2)

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B-83264EN/03 2.INITIAL SETTING

2 INITIAL SETTING
The following initialization is necessary to control the servo gun. Usually, the initialization needs to be
performed only once when the system is started.

1. Servo gun axis initialization

Initialize the settings related to the servo gun axis (such as motor size, gear ratio, and maximum speed).
2. Tool coordinate system setting
Define a tool coordinate system at the end of the stationary tip.
3. Closing direction of the gun setting
Define a tool coordinate system at the end of the movable tip.
4. Max pressure setting
Specify the max pressure for the servo gun based on gun mechanical limit. (gun manufacturer must provide
this information)
5. Gun setup utility
• Confirm motion sign of the gun
• Master gun axis
• Setting stroke limits & tip displacement
• Tune the servo parameters using autotuning
6. Pressure calibration
Calibrate the pressure applied to the tips using a certified and calibrated pressure gauge (load cell).

WARNING
Do not load system file for spot and servo gun : SYSSPOT.SV of other robot
controller on 7DC1. Do not load system file for servo gun : SYSSVGN.SV of other
robot controller on 7DC2 or later.

WARNING
Do not load R-30iA system files for servo gun (SYSSPOT.SV, SYSPRESS.SV,
SYSDIST.SV, SYSSTROK.SV).

2.1 SERVO GUN AXIS INITIALIZATION

Outline
This section describes how to start up the servo gun system with a new controller that is properly configured
with servo gun software option and hardware.
If additional axis control or multi-group control is being used or added to an existing system, a startup
procedure matched to the axis configuration must be evaluated.

Startup Procedure
The servo gun axis configuration begins by performing a Controlled Start. The servo gun axis is defined
here and is usually done only (1) time per gun. The remainder of the servo gun setup is done after
performing a Cold Start.

Servo Gun Axis Initialization

1. Perform a Controlled Start
2. Add the axis for the servo gun
3. Define the axis and equipment as a servo gun
4. Perform a Cold Start
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2.INITIAL SETTING B-83264EN/03

[1] Controlled Start

1 Turn the power ON while you press the PREV and NEXT keys on the teach pendant. The following
screen is displayed.

----------- CONFIGURATION MENU -----------

1. Hot start
2. Cold start
3. Controlled start
4. Maintenance

Select >_

2 Type "3" and press ENTER to select “3. Controlled start”. This starts the controlled start process. After
a while the Controlled Start menu is displayed.

SPOT CONFIG
1/34
1 F Number: F00000>
2 Load Spottool Macros: DISABLE
3 Number of equipments: 1
：

[ TYPE ]

NOTE
User can repower on R-30iB controller using Teach pendant.
Please operate the following.
Fctn key -> “0 -- Next --” -> “8 CYCLE POWER”

[2] Setting the Gun Axis

To display the Gun Axis Setup screen, perform the following procedure at the Controlled Start menu.

1 Press the MENU key, and select “9 MAINTENANCE” to display the Robot Setup screen. This screen
should display the equipment name of the No.1 operation group (robot) and the Servo Gun operation
group.
ROBOT MAINTENANCE
1/10
Setup Robot System Variables

Group Robot Library/Option Ext Axes

1 R-2000iB/165F 0
2 Servo Gun Axes 0

[ TYPE ] ORD NO AUTO MANUAL

2 Move the cursor to “Servo Gun Axes”, and press “F4 MANUAL”.
3 Type the FSSB line for servo gun axis.

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B-83264EN/03 2.INITIAL SETTING

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

-- FSSB configuration setting --

1: FSSB line 1 (main axis card)
2: FSSB line 2 (main axis card)
3: FSSB line 3 (auxiliary axis board 1)
5: FSSB line 5 (auxiliary axis board 2)
Select FSSB line >
Default value = 1
_

For example, when the system has basic hardware like robot axes and servo gun axes, FSSB line
usually is “1”. If system had special many axis hardware like multi arm or auxiliary axis board, FSSB
line usually would be “2” or “3”.

4 Type the hardware number for the starting axis. (Type "7" if the robot is a 6-axis robot, and the servo
gun axes are assigned to the 7th axis onwards.) Press ENTER.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

-- Hardware start axis setting --

Enter hardware start axis
(Valid range: 1 – 30)
Default value = 7
_

If you make a mistake when entering the hardware number for the starting axis, select 4. EXIT in the
menu displayed below to temporarily exit setup, and then perform the Servo Gun setting at the Robot
Setup screen again.

From here on, if you make any further mistakes, continue setting up the gun axis and complete the
setup. The menu below is displayed again. Correct the value at 1 Display/Modify Servo gun Axes.

5 Add an axis for servo gun by the following steps.

Configuration Procedure

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

*** Group 2 Total Servo Gun Axes = 0

1. Display/Modify Servo Gun Axis 1~9
2. Add Servo Gun Axis
3. Delete Servo Gun Axis
4. EXIT
Select ==> _

Type in 2 and Press ENTER, then the following screen is displayed.

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2.INITIAL SETTING B-83264EN/03

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

***** SETUP TYPE *****

If select 1, gear ratio is pre-set to
default value, which may be wrong.
Select 2,to set gear ratio correctly.

1: Partial (Minimal setup questions)

2: Complete (All setup questions)
Setup Type ==>
Default value = 1
_

5.1 Setup Type – Type in 1 or 2 and press ENTER

There are (2) modes available.
Please choose “Partial” or “Complete”
The following table is list of setting items in each mode.

Setting items in each mode

Item Partial Complete
Motor size ○ ○
Amplifier number ○ ○
Brake number ○ ○
Tip displacement ratio [mm/rev] ×( 5.00 ) ○
Gun close direction ×(＋) ○
Gun open stroke limit [mm] ×( 999 ) ○
Gun close stroke limit [mm] ×( 999 ) ○
Motion sign ×(TRUE ) ○
Max gun pressure [kgf], [lbl], [N] ×(500kgf) ○
Servo timeout △ △
Servo timeout value △ △
Max joint speed × ○

○: Set here.
×: Not set here. Default value in ( ) is applied. You can change it in another setting screen.
△: Need setting if you set brake number to a value other than 0.

NOTE
Specify a valid value based on the servo gun mechanical specification.

WARNING
If “Partial” is chosen, gun close direction, Motion sign, stroke limit, tip displacement
ratio, max gun pressure and max joint speed are not set to valid values. (Temporary
setting state). In this case, do not operate servo gun axis without gun setup utility
screen after cold start. “Complete” is recommended.

NOTE
Partial setup does not set up max gun pressure. The default value is 500kgf by kgf
unit.

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B-83264EN/03 2.INITIAL SETTING

NOTE
The units of pressure (force) are set by the value of the system variable
$SGSYSCFG.$PRS_UNITS:
0 = Kilogram-force (kgf)
1 = Pound-force (lbf)
2 = Newton (nwt)

NOTE
In this screen, it cannot display the previous screen.
If you specify an incorrect value, finish all setup once, and then select “1
Display/Modify Servo Gun Axes”. You can specify it again.

In the following case, user should choose “Partial”

- User can set the items omitted during Partial setup mode, with Gun setup utility

In the following case, user should choose “Complete”

- As soon as the cold start is performed, gun axis will be jogged without autotuning
- User knows gun specification clearly.

5.2 Motor Selection - Select the motor from the list by typing in the number associated with the
motor being used (or the special Motor ID number) and press ENTER.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

***** MOTOR SELECTION *****

1: ACa4/5000is 20A 6: ACAM6/3000 80A

2: ACa4/5000is 40A
3: ACa8/4000is 40A
4: ACa8/4000is 80A
5: ACa12/4000is 80A 0: Other
Select ==> _

If you are using a motor that is not included in the list, select “0: Other” to see a more detailed list
of FANUC motors. If you select it, the following screen is displayed and any motor can be
selected. Operation is different depending on the selected number.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

-- MOTOR SELECTION --

1: Standard Method
2: Enhanced Method
3: Direct Entry Method
Select ==> _

“1: Standard Method”

i) Select motor size.

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2.INITIAL SETTING B-83264EN/03

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

-- MOTOR SIZE (alpha iS) --

60. aiS2 64. aiS22

61. aiS4 65. aiS30
62. aiS8 66. aiS40
63. aiS12
0. Next page
Select ==> _

NOTE
If there is no choice of the appropriate motor type, please consult with FANUC.

ii) Select motor type.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

-- MOTOR TYPE --

1. /2000 11. /4000

2. /3000 12. /5000
13. /6000
Select ==> _

iii) Select current limit for the motor.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

-- CURRENT LIMIT FOR MOTOR --

2. 4A 10. 20A
5. 40A 12. 160A
7. 80A

Select ==> _

“2: Enhanced Method”

i) Select motor size.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

-- MOTOR SIZE (alpha iS) --

60. aiS2 64. aiS22

61. aiS4 65. aiS30
62. aiS8 66. aiS40
63. aiS12
0. Next page
Select ==> _

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B-83264EN/03 2.INITIAL SETTING

NOTE
If there is no choice of the appropriate motor type, please consult with FANUC.

ii) Candidate motors are displayed. please select motor.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

-- MOTOR SELECTION --

1: aiS8/4000 40A
2: aiS8/4000 80A
3: aiS8/6000 80A
Select ==> _

“3: Direct Entry Method”

NOTE
Direct Entry Method is only used when special case. FANUC will tell it to you if you
need to use Direct Entry Method.

i) Input motor ID.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

-- MOTOR SELECT (Direct Entry) --

Enter Complete Motor ID.

Select ==> _

NOTE
Consult with FANUC about Motor ID.

5.3 Amplifier Number - Select the Amplifier Number by typing the number associated with the
amplifier used to drive this motor, then press ENTER. The amplifier number will depend on the
hardware configuration being used. The robot amplifier is #1 and the 1st auxiliary axis amplifier
is #2 and so on.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

***** AMP NUMBER *****

Enter amplifier number (1~56) ==> _

If you select “Complete”, continue to set the following items. If you select “Partial”, please skip
procedure 5.4~5.9, and perform procedure 5.10~5.12.

5.4 Tip Displacement Ratio – Type in the distance that the gun tip moves motor revolution and press
ENTER.

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2.INITIAL SETTING B-83264EN/03

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

***** TIP DISPLACEMENT RATIO *****

The number of mm’s traveled for one

rotation of the motor (0 if unknown)
Enter Tip Displacement Ratio (mm) ==> _

5.5 Motor Direction – Type in the motor rotation direction (using the right-hand rule) that causes the
motor to move in the plus direction.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

***** MOTOR DIRECTION *****

Servo Gun 1 Motion Sign = TRUE

Enter (1: TRUE, 2:FALSE):
(Enter 1 if unknown) ==> _

If gun axis moves to plus direction when the motor rotates forward (clockwise as seen from
Pulsecoder), select “1: TRUE”. If gun axis moves to minus direction, select “2: FALSE”.
Select “1: TRUE” if unknown and use the Gun Setup Utility at a Cold Start to determine the
proper setting for this item automatically.

5.6 Gun Close Direction – Configure the axis jog key for closing the gun tip.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

***** GUN CLOSE DIRECTION *****

Servo gun close direction

(1: Positive, 2: Negative) ==> _

• If Positive is chosen, tip openings are displayed as negative values (+ jog key will close gun)
• If Negative is chosen, tip openings are displayed as positive values (- jog key will close gun)

5.7 Gun Open Stroke Limit – Type in the maximum tip opening for the gun in units of mm, then press
ENTER (always enter a positive value!)

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

***** GUN OPEN STROKE LIMIT *****

Stroke in mm from tip closed position

(positive value)
Enter Open Limit (mm) ==> _

5.8 Gun Close Stroke Limit – Type in the maximum tip travel available in the closing direction after
the tips touch, then press ENTER (always enter a positive value!)
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B-83264EN/03 2.INITIAL SETTING

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

***** GUN CLOSE STROKE LIMIT *****

Stroke in mm past tip closed position

(positive value)
Enter Close Limit (mm) ==> _

5.9 Max Gun Pressure – Type in the maximum pressure.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

***** MAX GUN PRESSURE *****

Maximum pressure that gun is rated for.

Default value(nwt): 4900.0
Enter Max gun pressure(nwt) ==> _

5.10 Brake Number - Type in the Brake circuit number that is used to brake the motor and press
ENTER. If no brake is used, type in 0.
If a brake is used, the Servo Off setup(5.11~5.12) must be completed.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

***** BRAKE SETTING *****

Enter Brake Number (0~32) ==> _

5.11 Servo Timeout – Type in whether to use a servo timeout, then press ENTER.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

***** SERVO TIMEOUT *****

Servo Off is Disable

Enter (1: Enable 2: Disable) ==> _

In the case servo timeout is enabled, an axis is automatically braked if the axis has not been used
for a specified time. The brake of the gun axis is released at the time a motion command is given,
and then start of movement is delayed 300ms to wait releasing the brake.

Servo timeout is enabled if you type in “1: Enable”. Servo timeout is disabled if you type in “2:
Disable”. If servo timeout is enabled, a timeout value is required in the next step.

5.12 Timeout Value – Type in the Timeout Value in seconds, then press ENTER.

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2.INITIAL SETTING B-83264EN/03

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

***** TIMEOUT VALUE *****

Enter Servo Off Time (0.0~30.0) ==> _

Axes are braked after waiting this time without robot motion.

5.13 Max Gun Speed – Type in the maximum gun speed.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

***** MAX GUN SPEED *****

Gear Ratio (mm/rev) = 10.400

Def. Max Motor Speed (RPM) = 4000
Def. Max Gun Speed (mm/sec) = 693.33
Cur. Max Motor Speed (RPM) = 4000
Cur. Max Gun Speed (mm/sec) = 693.33
Enter Max Gun Speed (mm/sec) : _

Type “Cur. Max Gun Speed” value if you don’t want to change maximum gun speed.
“Def. Max Gun Speed” shows maximum gun speed calculated from maximum motor speed and
tip displacement.

6. Setup for the gun axis is finished.

The following screen is displayed.

** GROUP 2 SERVO GUN AXIS SET UP PROGRAM

*** Group 2 Total Servo Gun Axes = 1

1. Display/Modify Servo Gun Axis 1~9
2. Add Servo Gun Axis
3. Delete Servo Gun Axis
4. EXIT
Select ==> _

Select 1, to display and/or modify any axis that is already defined

Select 2, to add another Servo Gun axis
Select 3, to delete the last Servo Gun axis
Select 4, to exit setup when done configuring all axes.

WARNING
If existed gun axis that has been set up is replaced to another gun, delete the setup at
once by selecting “3. Delete Servo Gun Axis”. After that, re-add gun axis by selecting
“2. Add Servo Gun Axis”. If you change the setup by selecting "1. Display/Modify
Servo Gun Axis 1~9" without deleting the setup, then replaced parameters are
completely uninitialized, so it does not work correctly.

7 Auto configuration of gun axis

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B-83264EN/03 2.INITIAL SETTING
When gun axis is correctly added, free equipment number is assigned to group of the added gun axis,
and the equipment type is changed to servo gun.

EQ1 was assigned to this group.

Press ENTER to Continue.

According to equipment number, group number and gun axis configuration, please verify / change in servo
gun configuration screen.

NOTE
In case of dual gun, when only a gun axis is added, this auto configuration is not
performed.

Even number of axes needed for dual gun.

EQ1 equip_type was changed to AIRGUN.

Press ENTER to Continue.

NOTE
When software does not have gun change option and more than 3 gun axes are
added, then this auto configuration is not performed.

Gun Change option is not installed.

EQ1 equip_type was changed to AIRGUN.

Press ENTER to Continue.

[3] Define the Axis and Equipment as a Servo Gun

1. Press the MENU key, then select “0 –next -- ”, “4 SETUP SERVO GUN”.
2. Specify Equipment Type.

SETUP Servogun
2/5 Press F4[CHOICE], and select a SERVO GUN

1 Equip number: 1
2 Equip Type: [SERVO GUN] Specify the motion group for controlling the servo
gun axis corresponding to the Equip Number
3 Motion Group(Gun): 2 selected.
4 Motion Group(Robot): 1
5 Axis data: <*DETAIL*> Specify an operation group for controlling the
robot axis.
[ TYPE ] EQUIP GUN_CFG [CHOICE]

Display gun axis data screen

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2.INITIAL SETTING B-83264EN/03

3. If this is a Gun Change system, the gun change function is enabled from this screen. Decide whether to
ENABLE the gun change function now.

4. Select Axis data <*DETAIL*>, then gun axis data screen is displayed. Some gun parameters can be
changed in the screen.

AXIS DATA If there are 2 more gun axis in system,

1/36
1 Hardware axis number 7 change axis number to display another axis.
Gun number 1
Motor type aiS8/4000 80A
Group number 2
Group axis number 1
Amp number 2
Amp type 2
Brake number 1
Load ratio 2.000
2 Liner(FALSE)/Rotary(TRUE) FALSE
3 Gear ratio 10.370
4 Max joint speed(mm/s) 518.000
5 Motion sign TRUE
6 Stroke upper limit(mm) 20.000 These parameters can be changed.
7 Stroke lower limit(mm) -120.000
8 Master position(mm) 0.000
9 Accel time1(ms) 200
10 Accel time2(ms) 100
11 Min accel time(ms) 150
12 Servo off when inactive FALSE
13 Servo off time(s) **********
14 Short motion margin .400
15 Min acc short motion(ms) 256
16 $sbr[].$param[6] 0
17 $sbr[].$param[17] 30
18 $sbr[].$param[18] -320
19 $sbr[].$param[24] -304
20 $sbr[].$param[47] 6598
21 $sbr[].$param[51] 4096
22 $sbr[].$param[112] 317
23 $sbr[].$param[113] 0
24 $sbr[].$param[181] 0
25 $sbr[].$param[182] 0
26 $sbr[].$param[183] 0
27 $sbr[].$param[184] 0
28 $sbr[].$param[185] 0
29 $sbr[].$param[191] 0
30 $sbr[].$param[192] 0
31 $sbr[].$param[193] 0
32 $sbr[].$param[194] 0
33 $sbr[].$param[195] 0
34 $sbr[].$param[196] 0
35 $sbr[].$param[291] 0
36 $sbr[].$param[292] 0

[4] Cold Start

1 Press the FCTN key in the Controlled Start menu, and select Cold Start, then press ENTER when
ready to perform a Cold Start

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B-83264EN/03 2.INITIAL SETTING

2.2 SETTING THE COORDINATE SYSTEM

• Carried gun
Executing the SPOT instruction automatically generates the route of the fixed side tip based upon the tool
coordinate system that is set here. Define the tool coordinate system as follows.

1. Take the end of the fixed side tip as the origin of the tool coordinate system. (Figure below: a)
2. Make sure that the close (longitudinal) direction of the fixed side tip is parallel with one of the X/Y/Z
axes of the tool coordinate system. (Figure below: b)
b: Make sure that one of the X/Y/Z tool coordinate axes is
parallel with the longitudinal direction of the fixed side tip
(Example: +Z)

a: Align the origin of the tool coordinate system with the end of
the fixed side tip.

• Pedestal gun
Executing the SPOT instruction automatically generates the route of the part based upon the user coordinate
system that is set here. Define the user coordinate system as follows.

1. Make sure that the close (longitudinal) direction of the fixed side tip is parallel with one of the X/Y/Z
axes of the user coordinate system. (Figure below: b)
b: Make sure that one of the X/Y/Z user coordinate
axes is parallel with the longitudinal direction of the
fixed side tip. (Example: -Z)

• Setting to Robot Close Direction to match the Coordinate System of the Gun

The robot close direction is used generating the proper trajectory to spot locations and for compensation (tip
wear down compensation and gun sag compensation).

1. Press the MENU key to display the Screen menu, and select 6 SETUP.
2. Press F1 TYPE to display the Screen Selection menu, and select Servo Gun.
3. Move cursor on “General Setup: <*DETAIL*>” and press ENTER key to display General Setup
screen.
4. Set the Close Direction (ROBOT) according to the following table.

SETUP Servogun
GENERAL / EQ:1 GUN:1 4/13
1 Tip Wear Comp DISABLE
2 Gun Sag Compensation DISABLE
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1 [+Z]

[ TYPE ] EQUIP GUN UF UT

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2.INITIAL SETTING B-83264EN/03

Close Direction (Robot) Carried gun

Specify the No. of the defined tool coordinate system. Also set the direction in which the
robot tip approaches the part.
Example) Set as follows if the direction is +Z in tool
coordinate system No.1:
UT:1 [+Z]

Pedestal gun
Specify the No. of the defined user coordinate system. Also set the direction in which the
robot must move to carry the part to the fixed tip.
Example) Set as follows if the direction is -Z in user frame
system No.1:
UF:1 [-Z]

2.3 SETTING THE GUN CLOSE DIRECTION

NOTE: If this step was already completed during the Axis setup at the Controlled Start, or with the Gun
Setup Utility, this section can be skipped

The gun close direction is used generating the proper trajectory to spot locations and for compensation (tip
wear down compensation and gun sag compensation).
Gun tip
In case of gun closing by “+” key, set to PULSE.
In case of gun closing by “-” key, set to MINUS.

Robot tip:
Specify the No. of the defined tool coordinate system and which
direction in that coordinate system is the longitudinal direction
(close direction) of the fixed side tip.(see 2.2)

1. Press the MENU key to display the Screen menu, and select 6 SETUP.
2. Press F1 TYPE to display the Screen Selection menu, and select Servo Gun.
3. Move cursor on “General Setup: <*DETAIL*>” and press ENTER key to display General Setup
screen.
SETUP Servogun
GENERAL / EQ:1 GUN:1 3/13
1 Tip Wear Comp DISABLE
2 Gun Sag Compensation DISABLE
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1 [+Z]

[ TYPE ] EQUIP GUN PLUS MINUS

4. Set the Close Direction (GUN) first according to the following procedure.

PROCEDURE
1. Set the Close Direction (GUN) to match the jog key that you want to feed the gun axis closed.
PLUS for using the +X key to jog gun closed
MINUS for using the –X key to jog the gun closed
2. If you will be using the Gun Setup Utility to confirm the close direction, skip ahead to step 2.5.
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B-83264EN/03 2.INITIAL SETTING

NOTE
In Gun Setup Utility, user can set motion sign for current gun close direction.
Please operate according to Gun Setup Utility.

WARNING
Please confirm max gun pressure before Gun setup utility

2.4 SETTING THE MAX PRESSURE

The max pressure of the servo gun should be defined prior to autotuning the gun.
1. Go to the servo gun general setup screen
2. Set the Max Pressure to match the pressure limit of the gun. (gun manufacturer must provide this
information).
3. Confirm the Max Motor Torque and set it if you need.

NOTE
Pay attention to the working units for Max Pressure. The units of pressure (force) are
set by the value of the system variable $SGSYSCFG.$PRS_UNITS:
0 = Kilogram-force (kgf)
1 = Pound-force (lbf)
2 = Newton (nwt)

SETUP Servogun
GENERAL / EQ:1 GUN:1 5/13
...
5 Max Motor Torque(%): 100.0
6 Max Pressure(nwt): 4000.0
Max Gun Torque: 45.8
...
[ TYPE ] EQUIP GUN

NOTE
Maximum value of the Max Motor Torque is usually 100%.
If the maximum value of the Max Motor Torque has been specified from us, please
make sure that it is less than the specified value to it.

2.5 SERVO GUN SETUP AND AUTOTUNING UTILITY

The FANUC servo gun software provides Gun setup utility to tune the servo parameters for the gun without
the aid of special tuning equipment, or user intervention.

The Gun Setup utility ensures that the servo gun is set up correctly before you autotune the gun. If you
try to autotune a gun that is set up incorrectly it can cause damage to the gun. This utility will take you
through some basic setup steps before the actual tuning exercises are initiated. This includes:
• MOTION SIGN SETTING
• MASTERING
• TIP DISPLACEMENT RATIO SETTING
• AXIS LIMIT (Stroke Limit) SETTING

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2.INITIAL SETTING B-83264EN/03

NOTE
If the BZAL or Pulse Not Establised faults exist, they need to be reset before jogging
and mastering of the gun axis can be executed. Refer to the Gun Master Utility in the
Appendix of the Servo Gun Manual for details on resetting these faults.

WARNING
Jogging the gun fully open into the gun’s hardstops can cause damage to the gun.
Confirm stroke limit and mastering of the gun.

NOTE
If setting Mastering (Appendix C), Motion sign, tip displacement (gear ratio), gun
closing direction, stroke limit (Appendix D) is completed, gun tuning is executed by
autotune program. Please refer to Appendix E about more deatil.

NOTE
About weight comp setup, temperature comp setup, and thickness check calibration, these
are allowed to perform on this utility screen. About the above functions, please refer to the
function section in this manual.

Gun Setup Utility Execution Procedure

1. Press MENU.
2. Select UTILITIES.
3. Press F1, [TYPE] and select Gun Setup. You will see a screen similar to the following.
UTILS Gun Setup
EQ: 1 Gun:1 1/1
1.Set gun motion sign: INCOMP
2.Set Gun specs, master gun INCOMP
Tip Displacement: 5.000(mm/rev)
Open stroke limit: -999.99(mm)
Close stroke limit: 999.99(mm)
3.Auto Tune: INCOMP
4.Pressure Compensation Setup: <*DETAIL*>
5.Thickness Check calibration: INCOMP

[ TYPE ] EQUIP SKIP RESTART

4. Press F4, RESTART to set steps 1-2 to incomplete if they are not already.

NOTE
The F3 key, SKIP, can be used to set the status of Steps 1-2 to complete (COMP)
without actually performing the tasks. This can be done if the user is certain that
these items have been set correctly during the controlled start axis setup and that
mastering has already been executed. In this case, skip ahead to Step 3 of Gun
Setup Utility after these items are set to COMP.

5. Move the cursor to item 1 and press ENTER. You will see a screen similar to the following.

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B-83264EN/03 2.INITIAL SETTING
Set Motion Sign
EQ: 1 Gun:1 1/1
1. HOLD the SHIFT key and SLOWLY Jog
the Servo Gun movable tip using the
+X key (+Y if 2nd gun of dual gun)
2. Did the gun OPEN or CLOSE? *****
USE F4 or F5 to make selection.
3. Press F3 COMP when finished

[ TYPE ] COMP OPEN CLOSE

NOTE
This screen will allow you to set the gun motion sign. The gun should always close
when you press the jog key [+ or -] that matches the Close Direction (Gun) set on the
servo gun general setup screen. This step will set the internal motion sign variable to
make this happen.

6. Follow the steps listed on this screen in order.

7. When you are finished, press F3, COMP. Item 1 status is now complete. You will see a screen similar
to the following.

UTILS Gun Setup

EQ: 1 Gun:1 1/1
1.Set gun motion sign: COMP
2.Set Gun specs, master gun INCOMP
Tip Displacement: 5.000(mm/rev)
Open stroke limit: -999.99(mm)
Close stroke limit: 999.99(mm)
3.Auto Tune: INCOMP
4.Pressure Compensation Setup: <*DETAIL*>
5.Thickness Check calibration: INCOMP

[ TYPE ] EQUIP SKIP RESTART

8. Move the cursor to item 2 and press ENTER. You will see two screens consecutively similar to
followings.
Do you know your gun’s Tip
Displacement?

YES [NO]

Do you know your gun’s Tip

stroke limits ?

YES [NO]

WARNING
Please specify tip displacement and stroke limit according to gun manufactory’s
specification.
If gun specification is unknown, set the value according to actual gun.

Answering prompt massage decides next setting operation.

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2.INITIAL SETTING B-83264EN/03

Tip displacement Stroke limit Setting operation

YES YES 1
NO YES 2
YES NO 3
NO NO 4

If you would like to change setting operation, return by Prev key, then answer prompt massage again

Setting operation -1
Set Gun specs
EQ: 1 Gun:1 1/3
1.Move Servo Gun to closed position
Press F4 CLOSED when done.
2.Enter Tip Displacement here
*****(mm/rev)
3.Enter open limit here: *****(mm)
4.Enter close limit here: *****(mm)
5.Press F3 when done.

[ TYPE ] COMP CLOSED

a. Jog the gun slowly until the tips are touching each other and press F4, CLOSED. When you press F4,
CLOSED, the gun will be mastered.
b. Specify tip displacement into item 2, press ENTER key.
c. Specify open limit into item 3, press ENTER key. And Specify close limit into item 4, press ENTER
key.
d. All setting is completed, then press F3 ”COMP”.

Setting operation -2

Set Gun specs

EQ: 1 Gun:1 1/3
Set Tip Displacement,master,set limits
1.Move Servo Gun to closed position
Press F4 CLOSED when done.
2.SLOWLY jog to desired max opening
Press F5 OPEN when done.
3.Measure the distance between tips and
enter here:*****(mm)
3.Enter open limit here: *****(mm)
5.Enter close limit here: *****(mm)
6.Press F3 when done.

[ TYPE ] COMP CLOSED OPEN

a. Jog the gun slowly until the tips are touching each other and press F4, CLOSED. When you press F4,
CLOSED, the gun will be mastered, and one reference position for the tip displacement calculations
will be record.
b. Jog the gun SLOWLY until it is at the desired max stroke distance and press F5, OPEN. When you
press F5, OPEN, the second reference position for the tip displacement calculation is recorded.
c. Measure the distance in millimeters between the tips. Type that value on line 3, press ENTER。
d. Specify open limit into item 3, press ENTER key. And Specify close limit into item 4, press ENTER
key.
e. All setting is completed, then press F3 “COMP”.

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B-83264EN/03 2.INITIAL SETTING

Setting operation -3

Set Gun specs

EQ: 1 Gun:1 1/1
1.Move Servo Gun to closed position
Press F4 CLOSED when done.
2.SLOWLY jog to desired max opening
Press F5 OPEN when done.
3.Enter Tip Displacement here
*****(mm)
4.Press F3 when done.

[ TYPE ] COMP CLOSED OPEN

a. Jog the gun slowly until the tips are touching each other and press F4, CLOSED. When you press F4,
CLOSED, the gun will be mastered.
b. Jog the gun SLOWLY until it is at the desired max stroke distance and press F5, OPEN.
c. Type the tip displacement in mm/rev on line 3, press ENTER, then press F3, COMP.

Setting operation -4

Set Gun specs

EQ: 1 Gun:1 1/3
Set Tip Displacement,master,set limits
1.Move Servo Gun to closed position
Press F4 CLOSED when done.
2.SLOWLY jog to desired max opening
Press F5 OPEN when done.
3.Measure the distance between tips and
enter here:*****(mm)
4.Press F3 when done.

[ TYPE ] COMP CLOSED OPEN

a. Jog the gun slowly until the tips are touching each other and press F4, CLOSED. When you press F4,
CLOSED, the gun will be mastered, and one reference position for the tip displacement calculations
will be record.
b. Jog the gun SLOWLY until it is at the desired max stroke distance and press F5, OPEN. When you
press F5, OPEN, the second reference position for the tip displacement calculation is recorded.
c. Measure the distance in millimeters between the tips. Type that value on line 3, press ENTER.
d. Press F3, COMP

9. Completion of setting gun specification, you will see a series of prompt boxes similar to the following.

Propmt Box 1
This prompt box displays the old and new tip displacement so that the user can see how much it should be
changed. If the new tip displacement is acceptable, respond YES. Otherwise respond NO.
Tip displacement has changed
FROM: 5.00 TO: 10.00mm/rev
Do you accept the new value?

[YES] NO

Propmt Box 2
This prompt box displays the old and new max gun torque so that the user can see how much it should be
changed. If the new tip displacement is acceptable, respond YES. Otherwise respond NO.
Refer to 14. OVERTORQUE PROTECTION FEATURE about max gun torque.

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2.INITIAL SETTING B-83264EN/03

Max gun torque can be

updated, based on new gear
ratio. Torque limit changes
FROM: 55.00 TO: 19.00%
Do you wish to update
max gun torque ?

YES [NO]

Propmt Box 3
The servo gun setup utility always displays the new and old max tip speed so that the user can see how much
it should be changed. Adjusting the max tip speed now, based on the tip displacement ratio (called gear ratio
in system variable) allows the user to setup the gun for the correct max speed.

If the new velocity is different it is recommended to accept the update and respond YES, otherwise respond
NO.
Max tip speed can be
updated, based on new gear
ratio. Velocity changes
FROM: 333.3 TO: 666.7mm/sec
Do you wish to update the
max tip speed ?

YES [NO]

Prompt Box 4
This box displays what the Open Stroke limit will be set to based on the data provided during step 2. Unless
this value exceeds the gun specification for max tip opening, respond YES to this prompt.
Open Stroke Limit will be
set to magniture 40.00mm
Do you accept this value?

[YES] NO

Prompt Box 5
This box informs the user that the close stroke limit will be set to 20.0mm if the YES is selected. Yes is the
default value.
If the gun manufacturer specified a value that is differs from this, then repond NO and set the Close Stroke
Limit directly. If the close stroke limit has already been set in advance to the correct value, then respond NO.
Otherwise, respond YES.
Select YES to set the close
stroke limit magnitude to
20.00mm (default value).

Select NO, if you do not

wish to modify the close
stroke limit

[YES] NO

Please refer to Appendix D (the section on setting the Stroke limit) directly later in this chapter if needed.

10. After you have completed items 1 and 2, you will see a screen similar to the following. and the F3,
EXEC button will appear at the bottom
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B-83264EN/03 2.INITIAL SETTING

Tuning with the Gun Setup Utility (Step 3 of Gun Setup Utility)
UTILS Gun Setup
EQ: 1 Gun:1 1/3
1.Set gun motion sign: COMP
2.Set Gun specs, master gun COMP
Tip Displacement: 10.000(mm/rev)
Open stroke limit: -150.00(mm)
Close stroke limit: 20.00(mm)
3.Auto Tune: INCOMP
4.Pressure Compensation Setup: <*DETAIL*>
5.Thickness Check calibration: INCOMP

[ TYPE ] EQUIP EXEC RESTART

CAUTION
The Servo gun axis moves at max speed, during autotuning. Autotuning can be
performed with the teach pendant enabled or disabled.
Please make sure that no personnel are in the vicinity of the gun, when you execute
autotuning.

NOTE
The following conditions must be met for the tuning process to start from the Gun
Setup Utility:
¾ Not in STEP mode
¾ No faults exist
¾ No holds exist
¾ Servo gun is not in machine lock
¾ The control reliable keyswitch is in AUTO or T2.
¾ Gun is in STROKE mode

NOTE
After Auto tuning is started, the servo gun will perform the following by opening and
closing the gun:
¾ Acceleration settings
¾ Inertia measurements
¾ Friction measurements
¾ Spring constant measurements
¾ Force control gain settings
¾ Contact speed settings
¾ (If pressure profile control is ordered) Profile internal parameter settings
¾ (If spot program touchup is ordered) Spot program touchup internal parameter
settings
¾ Part thickness check internal parameter settings

NOTE
Auto tuning program uses No.99 of pressure shcdule and tip distance scheduel.
Do not use this schedule nomber in user’s program.

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2.INITIAL SETTING B-83264EN/03

NOTE
In case of T2 mode, enable TP, and do not release both of dead man swicth and shift
key during autotuning.
In case of AUTO mode, disable TP, and need not hold dead man swicth and shift key
during autotuning.

1. Move cursor to autotune, press SHIFT & F3 to start the auto tuning process.
2. Confirmation prompt will be displayed. Respond YES if you want to start autotuning.

UTILS Gun Setup Tuning exercises will begin

EQ: 1 Gun:1 1/3 and servo parameters will
1.Set gun motion sign: COMP change.
2.Set Gun specs, master gun COMP ARE YOU SURE YOU WANT TO DO
Tip Displacement: 10.000(mm/rev) THIS?
Open stroke limit: -150.00(mm)
YES [NO]
Close stroke limit: 20.00(mm)
3.Auto Tune: INCOMP
4.Pressure Compensation Setup: <*DETAIL*>
5.Thickness Check calibration: INCOMP

[ TYPE ] EQUIP EXEC RESTART Execute auto tune

3. If Autotuning completed successfully, a screen similar to the following should appear.

UTILS Gun Setup

EQ: 1 Gun:1 1/3
1.Set gun motion sign: COMP
2.Set Gun specs, master gun COMP
Tip Displacement: 10.000(mm/rev)
Open stroke limit: -150.00(mm)
Close stroke limit: 20.00(mm)
3.Auto Tune: COMP
4.Pressure Compensation Setup: <*DETAIL*>
5.Thickness Check calibration: INCOMP

[ TYPE ] EQUIP EXEC RESTART

4. Repower controller so that tuned parameter is applied.

If autotuning did NOT complete successfully (indicated by status FAILED instead of COMP), then try
the following:
• Make sure axis limits are set properly.
• Check motor selection.
• Make sure mastering of the gun axis is correct.
• Make sure max pressure of the gun axis is correct.
• Re-perform autotuning until it completes successfully.

NOTE
Please refer to the Servo Gun Weight Compensation section for details of weight
compensation. Please refer to the Servo Gun Temperature Compensation section
for details of temperature compensation. Please refer to the Part Thickness Check
section for details of thickness check calibration.

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B-83264EN/03 2.INITIAL SETTING

If autotuning fails:
If autotuning fails, carry out the following procedure according to failure status.

“SRVO-024 Move error excess” or “SRVO-046 OVC alarm” occurs:

Try the following in order of i) ~ iv).
i) Make sure the configuration
• Make sure axis limits are set properly.
• Check motor selection.
• Make sure mastering of the gun axis is correct.
• Make sure max pressure of the gun axis is correct.
• Re-perform autotuning until it completes successfully.

ii) Make sure the brake off

If the motor has brake, make sure the brake is released. If the brake is not released, make sure the
connection of brake and brake number is correct.

iii) Make sure the auxiliary axis amplifier

Make sure the amplifier used to drive the servo gun axis is adequate.

Try the following after trying the above i) ~ iii).

iv) Lower limit of accel time setting
Specify the lower limit of accel time by the following procedure
a. Set $SGSYSCFG.$SHO_ATUN_CF=TRUE from system variables screen. There is no need to
power off/on.
b. Redisplay servo gun setup utility screen, move cursor on autotune, and press ENTER key. The
following screen will be displayed.

Autotune Setup
EQ: 1 GUN:1 6/6
1.Reload servo and motion prms: DISABLE
2.Starting load ratio: 3.0
3.Pushing depth: 10.0
4.Init filter: 0
5.Accel update mode: AUTO ESTIMATE2
6.Accel time1 minimum: 48

[TYPE] DEFLT DONE

c. Move cursor on “Accel time1 minimum” and specify the lower limit of accel time. At first, specify
100 for accel time1.
d. Press F3 “DONE” after changing the parameter, then return to previous screen.
e. Perform autotuning again.
f. If autotuing remains failure, return to procedure c, then add 50 further to accel time. Then try again
autotuning until completing autotuning.
g. If autotuning cannot be completed with accel time = 350, consult with us.

WARNING
Do not change the parameters that are not described here. If the parameters are
changed by mistake, autotuning cannot adjust parameters correctly. It causes slower
cycle time or breaking of the gun.

If alarms except the above occur:

Try the following in order of i) ~ iii).

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2.INITIAL SETTING B-83264EN/03

i) Make sure the configuration

• Make sure axis limits are set properly.
• Check motor selection.
• Make sure mastering of the gun axis is correct.
• Make sure max pressure of the gun axis is correct.
• Re-perform autotuning until it completes successfully.

ii) Make sure the brake off

If the motor has brake, make sure the brake is released. If the brake is not released, make sure the
connection of brake and brake number is correct.

iii) Make sure the auxiliary axis amplifier

Make sure the amplifier used to drive the servo gun axis is adequate.

2.6 PRESSURE CALIBRATION

This section describes the process for setting up pressure calibration (data). This data is used to obtain the
torque and speed settings that are used during execution of the SPOT or PRESS_MOTN instruction.

NOTE
• Calibration should be carried out with a certified and calibrated force/pressure
gage.
• When gun mechanism becomes aging, it pressure accuracy would be changed. In
the case, for the desired weld quality, calibration should be performed again.
Consult with the servo gun manufacturer for recommendations on calibration
settings and frequency.

NOTE
• When the temperature is low, please do warm-up beforehand to ensure the
pressure accuracy of pressure calibration. When the temperature is high, servo
gun temperature compensation function can improve the pressure accuracy.

PROCEDURE
1. Go to the Servo Gun General Setup screen.
2. Select Pressure Cal.
(Move the cursor to <*DETAIL*>, then press the ENTER key.)

SETUP Servogun
GENERAL / EQ: 1 Gun:1 11/13
...
9 Pressure Cal: COMP <*DETAIL*>
10 Tip Wear Standard: INCOMP <*DETAIL*>

[ TYPE ] EQUIP GUN

3. The Start Message screen is displayed. Select F4 YES.

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B-83264EN/03 2.INITIAL SETTING

To perform pressuring motion,

press SHIFT + F3:PRESSURE key.

After pressuring motion,

set the measured pressure value.

Do you want to start calibration?

YES NO

4. The Pressure Calibration screen is displayed. Set the following items.

SETUP Servogun
PRESSURE CALIB PARMS / EQ:1 Gun:1 1/14
1 Calibration Status: INCOMP
2 Pressuring Time(sec): 1.5
3 Thickness of Gauge(mm): 12.7
4 Gun Open Value(mm): 115.0
Torque(%) Speed(mm/sec) Press(nwt)
5 5.0 % 100 mm/sec 1000.0 nwt
6 10.0 % 100 mm/sec 2000.0 nwt

[ TYPE ] CANCEL PRESSURE COMP INCOMP

Pressuring Time (sec): Dwell time for pressuring

measurement
Thickness of Gage (mm): Thickness of gage (*1)
Gun Open Value (mm): Gun axis open value after
pressuring ends (*2)
The maximum stroke in the
open direction is set as
the standard value.

Open value (*2)

Load cell

Thickness of gage
(*1)

5. Bring the fixed side tip into contact with the base of the force gauge.
WARNING
At first, execute pressure motion with low override to confirm tip contacts with gauge
correctly. To calibrate pressure, execute pressure motion with 100% override.

6. Specify torque, then speed will be automatically set. Press the Shift key and F3 “PRESSURE”. The
movable tip executes the following sequence:
• Move from current position to contact the pressure gauge at the specified speed and torque.
• Continue to apply pressure, for the specified pressuring time (dwell)
• Move to specified gun Open value

7. Speed will be automatically set the recommended value, but you can change it if you need.

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2.INITIAL SETTING B-83264EN/03

SETUP Servogun
PRESSURE CALIB PARMS / EQ:1 Gun:1 1/14
1 Calibration Status: INCOMP
2 Pressuring Time(sec): 1.5
3 Thickness of Gauge(mm): 12.7
4 Gun Open Value(mm): 115.0
Torque(%) Speed(mm/sec) Press(nwt)
5 5.0 % 25 mm/sec 1000.0 nwt 1000N
6 10.0 % 100 mm/sec 2000.0 nwt

[ TYPE ] CANCEL PRESSURE

Press the Shift key and F3 PRESSURE,

Move the cursor to the Torque line before executing then The movable tip closes
the pressuring operation. If the cursor is on a line
that does not designate the torque, the pressuring
operation is not carried out.

WARNING
Confirm pressure waveform if you change contact speed.

WARNING
• Character of pressure response is affected by character of gun mechanism
( Strength of gun arm, Inertia of gun axis ).
• If contact speed is too fast, gun tip would make a dent in panel surface. After
calibration, pressure panel, confirm the surface. Adjust it again if necessary.
• If contact speed is too fast, panel or body is vibrated with impact when gun tip
contacts. Adjust it again if necessary.

8. Specify the torque(%) and repeat steps 6, 7, for the desired number of calibration points. Up to 15
(minimum two) torque and gun close speed values can be set.
If the your process requires a force of 100-500Kgf , then include measurements at or near 100 kgf and
500kgf (min and max force).

WARNING
In pressure calibration, larger torque than max gun torque is allowed to specify. At
first, check pressure of max gun torque, then pressure with over max gun torque if
the pressure of max gun torque is not larger than max pressure of gun.

NOTE
New calibration point is allowed to add to the last line.
The calibration points do not have to be entered in ascending (force) order.
Calibration points are sorted automatically when pressure calibration is complete.

9. After measuring the pressure several times, move the cursor to Calibration Status, and press F4 COMP
to accept the new calibration data.
10. Calibration points are checked, and if criteria are not met, an alarm is posted, and cal status is set to
incomplete.

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B-83264EN/03 2.INITIAL SETTING
Pressure Pressure Pressure

Torque Torque Torque

OK NG(Alarm) NG(Alarm)
11. After the pressure calibration is completed, the screens(above-mentioned 1 and 2) concerning the
servo gun weight compensation function are displayed.
• Select "OK" in screen 1.
• Select "NO" in screen 2 when you do not use the servo gun weight compensation function.
Screen1 :

Data of pressure calibration for weight

compensation function was changed.

Setting of semi-auto/manual weight

compensation function is automatically
changed to INCOMP.

OK
Screen2 :

Is angle at pressure calibration used by

weight compensation function changed?

Yes(F4 key): New value

Angle at press calib: 90.0(deg)

No (F5 key): Old value

Angle at press calib: 0.0(deg)

YES NO

NOTE
Select "YES" in screen 2 when you use servo gun weight compensation function.
Please refer to section 18 about servo gun weight compensation function.

12. If calibration points are ok, then calibration complete screen is displayed. Press either F2 END or the
PREV key to exit pressure calibration screen.
SETUP Servogun
1/5
Pressure Calibration
Equipment number:1 Gun: 1

Calibration Status: COMP

Point Torque Speed Pressure

1 5.0% 25mm/sec 1000.0 nwt
2 10.0% 50mm/sec 2000.0 nwt
3 15.0% 75mm/sec 3000.0 nwt
4 20.0% 100mm/sec 4000.0 nwt

[ TYPE ] END COMP INCOMP

NOTE
After calibration, confirm pressure accuracy or weld quality with 100% override.

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3.SERVO GUN MAIN SETUP SCREEN B-83264EN/03

3 SERVO GUN MAIN SETUP SCREEN

This section explains the setup items on the servo gun setup screen.
These items should be set correctly prior to welding operation with the servo gun.
Many of the items in this setup screen are explained in other sections of this document.

WARNING
Do not load system file for SPOT and servo gun : SYSSPOT.SV of another robot
controller on 7DC1. Do not load system file for servo gun : SYSSVGN.SV of other
robot controller on 7DC2 or later.

WARNING
Do not load R-30iA system files for servo gun (SYSSPOT.SV, SYSPRESS.SV,
SYSDIST.SV, SYSSTROK.SV).

3.1 SERVO GUN SETUP SCREEN

Specify details of settings related to servo gun-based spot welding by referring to the descriptions of the
corresponding items (listed on the subsequent pages):
1 Press the MENU key to bring up the screen menu.
2 Select “6 SETUP”.
3 Press F1“[TYPE]” to display the pull-up menu.
4 Select “Servo Gun” to display the SERVO GUN SETUP screen.

SETUP Servogun
SERVO GUN SETUP 1/3
1 Equip number: 1
2 General Setup: <*DETAIL*>
3 Manual Operation Setup: <*DETAIL*>

[ TYPE ] EQUIP

Descriptions of items for spot weld sequence setup

Equip number Equipment number shows the number of the selected weld controller is displayed.
General setup The features of the servo gun are set in General setup screen.
Put the cursor on the <*DETAIL*>, then press enter key to display the General setup screen.
Manual Operation The setups related to the manual operation are set in the Manual Operation setup screen.
setup Put the cursor on the <*DETAIL*>, then press ENTER to display the Manual Operation setup
screen. Refer to the Manual Operation section for more detail

3.2 SERVO GUN GENERAL SETUP SCREEN

Specify the setting details related to the servo gun by referring to the descriptions of the corresponding
items (listed on the subsequent pages):
1. Press the MENU key to bring up the screen menu.
2. Select “6 SETUP”.
3. Press F1“[TYPE]” to display the pull-up menu.
4. Select “Servo Gun” to display the SERVO GUN SETUP screen.
5. Select “8 General Setup” by placing the cursor on <*DETAIL*> and pressing the ENTER key. The
General Setup screen appears.
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B-83264EN/03 3.SERVO GUN MAIN SETUP SCREEN
SETUP Servogun
GENERAL / EQ:1 GUN:1 1/13
1 Tip Wear Comp: DISABLE
2 Gun Sag Compensation: DISABLE
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1 [+Z]
5 Max Motor Torque(%): 100.0
6 Max Pressure(nwt): 4900.0
Max Gun Torque(%): 10.5
7 Tip stick detect distance(mm): 5
8 Tip Wear Detection: <*DETAIL*>
9 Pressure Cal: COMP <*DETAIL*>
10 Tip Wear Standrd: INCOMP <*DETAIL*>
11 Thickness check: <*DETAIL*>
12 Gun Stroke limit: <*DETAIL*>
13 OverTorque protection <*DETAIL*>

[ TYPE ] EQUIP GUN ENABLE DISABLE

NOTE
Setting items depend on software version and/or software option configuration.

Descriptions of items for servo gun setup

Tip Wear Comp Tip Wear Down Comp specifies whether to perform tip wear compensation.
Default value: DISABLE = current tip wear measurement values are NOT applied as compensation to spot
DISABLE locations
ENABLE = current tip wear measurement values are applied as compensation to spot
locations.

To use the tip wear compensation function, it is necessary to acquire a reference position
and calculate a compensation value using TP programs. See Tip wear Compensation
section for details.
Gun Sag Gun Sag Compensation specifies whether to perform the spot gun deflection compensation
Compensation based on the Gun Sag amount for the pressure schedule selected
Default value: DISABLE = gun deflection compensation is not performed.
DISABLE ENABLE = the gun deflection compensation is performed.
Refer to Gun Sag Compensation section for details.
Close Direction (Gun) Close Direction specifies the direction in which the movable tip is to be closed.
Default value: PLUS Refer to Initial Settings section for details.
Close Direction Close Direction specifies the tool coordinate system frame number and which axis of the
(Robot) tool coordinate system indicates the direction in which the stationary tip closes.
Default value: UT:1 +Z Refer to Initial Settings section for details.
Max Motor Torque (%) Max Motor Torque specifies a limit to the maximum torque of the servo gun motor in usual
Default value: 100.0 operation. The torque specified here is applied to the servo gun axis when pressurization is
not taking place. Usually, the limit should not be adjusted by the user.
The valid data range is between 1.0 and 100.
Max Pressure (Kgf) Max Pressure specifies a limit to the pressure to be applied during pressurization. Any
Default value: 500.0 pressure higher than specified here will not be generated. A similar limit is also placed
kg during pressure input. This value should be specified by the gun manufacturer.
Refer to Initial Settings section for detail on how to set this item and change the units.
The valid data range is between 1.0 and 9999.9.
Tip stick detect Sets the tip opening after the weld complete signal to check the tip stick detection signal, if
distance [mm] used. Set the tip stick detection signal in the weld I/O screen.
Default: 5 Refer to tip stick detection section for more details.

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3.SERVO GUN MAIN SETUP SCREEN B-83264EN/03

Tip Wear Detection Items in this screen are used to specify how tip wear measurements are executed and how
to process tip wear related alarms.
Refer to Tip Wear Compensation section for details.
Put the cursor on the <*DETAIL*>, then press ENTER to bring up this screen.
Pressure Cal Open the pressure calibration screen. Pressure Cal specifies the motor torque to be
generated, then measuring the pressure applied by the specified torque can yield a
relational expression between the motor torque and pressure. When pressure adjustment
is completed, the display changes from INCOMP to COMP. If the display remains at
INCOMP, it is impossible to perform a spot welding sequence, manual welding, manual
pressurization, and pressurization operation.
Refer to Initial Settings section for more detail.
Put the cursor on the <*DETAIL*>, then press ENTER to bring up this screen.
Tip Wear Standard This screen displays information about the status of tip wear compensation including data
recorded during tip wear setup/initialization. When the reference positions are set, the
display changes from INCOMP to COMP. See Tip wear Compensation section for details.
Put the cursor on the <*DETAIL*>, then press ENTER to bring up this screen.
Thickness Check This screen displays information about the setup of Part Thickness check.
Refer to Part Thickness Check Function section for more details.
Gun Stroke Limit This screen displays the stroke limits for the gun axis. These limits are the “reference zero
position” when tip wear compensation is initialized. During tip wear compensation , actual
axis limit is decided based on these limit.
Refer to Appendix D and tip wear compensation for more detail
Overtorque Protection This screen displays the Overtorque Protection status and settings. It is recommended to
keep this function enabled to protect the gun axis from damage caused by the user jogging
the tips to a high pressure.
Refer to Overtorque Protection section for more details.
Weight compensation This screen displays weight compensation setting. Refer to Appendix D and weight
compensation for more detail. This function is supported since 7DA4 software.

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B-83264EN/03 4.MANUAL OPERATIONS

4 MANUAL OPERATIONS
The following functions are available for manual operations, at the teach pendant.

1. Manual Pressurization (Shift + GUN)

Close gun to a specific pressure by pressing Shift + GUN keys on the teach pendant
2. Manual Backup (Shift + BU)
Move to a specific gun open distance by pressing Shift + BU keys on the teach pendant.
3. Manual Welding
Execute weld with condition specified on the manual welding screen.
4. Jog operation
Move gun to any open distance by jogging in the same manner as a robot axis.
5. Thickness measurement
Measure thickness of panel between gun tips automatically.

4.1 MANUAL PRESSURIZATION (Shift + GUN)

Close the gun to a pre-defined pressure via the GUN key on the teach pendant

Procedure
Specify the following items prior to operation
1. Pressuring time, start distance, and end distance type. See Detail [1].
2. Pressure value (and other Pressure Schedule parameters). See Detail [2]
3. Thickness value. See Detail [3]

SETUP Servogun
MANUAL / EQ:1 Gun:1 1/6
Manual Pressure
1 Pressuring Time(sec): 0.0
2 Start distance type: INITIAL DIST
3 End distance type: INITIAL DIST
4 Thickness table(presets): <*DETAIL*>
Manual Backup
5 Backup Speed(%): 100
6 Backup stroke: <*DETAIL*>

[TYPE] EQUIP GUN

SERVO GUN DATA

PRESSURE / EQ:1 Gun:1 1/99
No. Press(Nwt) Manual Comment
1 100.0 TRUE [ ]
2 200.0 TRUE [ ]
3 300.0 TRUE [ ]
4 0.0 FALSE [ ]
5 0.0 FALSE [ ]
6 0.0 FALSE [ ]
7 0.0 FALSE [ ]
8 0.0 FALSE [ ]
9 0.0 FALSE [ ]
10 0.0 FALSE [ ]

[TYPE] EQUIP GUN DETAIL COPY

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4.MANUAL OPERATIONS B-83264EN/03

SERVO GUN DATA

THICKNESS / EQ:1 Gun:1 1/10
No. Thickness(mm) Comment
1 1.0 [thk1 ]
2 2.0 [thk2 ]
3 3.0 [thk3 ]
4 4.0 [thk4 ]
5 5.0 [thk5 ]
6 ****** [ ]
7 ****** [ ]
8 ****** [ ]
9 ****** [ ]
10 ****** [ ]

[TYPE] EQUIP GUN RECORD MEAS THK

• Press the GUN key to display a popup window that shows current Pressure Schedule, and thickness.
• Press one of the following keys to change pressure value (schedule), while popup window displays.
• GUN to select next manual pressure in table.
• Down arrow to select next manual pressure in table.
• Up arrow to select previous manual pressure in table.
• Press one of the following keys to change thickness value, while popup window displays.
• Right arrow to select next thickness value in table.
• Left arrow to select previous thickness value in table.
• Popup window is cleared.
• If a key other than GUN, or Up/Down/left/right arrow is pressed.
• If no key is pressed for 2.5 seconds.

Selection of pressure Selection of thickness Displaying popup window

Selection of pressure

(ascending order)

Gun number

GN 1- 1 GN 1- 2 GN 1- 3 Pressure
FRNT PANEL FRNT PANEL FRNT PANEL schedule #
1800.0 N 1950.0 N 1850.0 N GN 1- 1
2.2mm 2.2mm 2.5mm FRNT PANEL Comment
1800.0N Pressure
2.2mm

It is possible to alter Thickness

Combination of pressure and thickness

• Press GUN key while also pressing SHIFT to execute pressurization.

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B-83264EN/03 4.MANUAL OPERATIONS

+ ：Specified Pressuring

• The gun will move to specified start distance, then close to specified pressure.
• GUN key can be released, after pressurization starts - pressurization persists until pressure time
expires.
• Release the SHIFT key, to stop pressuring.
• After the specified pressuring time expires, the gun will open to the specified End distance.
• The stationary tip (on the robot) does not move during pressurization - gun sag compensation and
fixed tip wear compensation are NOT performed.

NOTE
User macros assigned to UK1, SU1, UK3, and SU3 have precedence over
manual pressurization function. If a user macro is assigned to one of these keys,
user MACRO will execute, instead of manual pressurization, when key is
pressed.
UK[1]/UK[3] correspond to GUN1 key/ GUN2 key, respectively.
SU[1]/SU[3] correspond to SHIFT+GUN1 key/ SHIFT+GUN2 key respectively.

NOTE
In dual gun case, UK3, and SU3 operate Gun “B”.
UK3, and SU3 are not used if equipment type = Single.

Detail [1]
Specify Pressuring details

1. Display the SERVO GUN SETUP screen.

MENU key → “6 SETUP” → F1“[TYPE]”→ “Servo Gun”
2. Select “Manual Operation Setup” (place cursor on <*DETAIL*>, then pressing ENTER key). The
Manual operating screen appears.

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4.MANUAL OPERATIONS B-83264EN/03

SETUP Servogun
SERVO GUN SETUP 1/3
1 Equip number: 1
2 General Setup: <*DETAIL*>
3 Manual Operation Setup: <*DETAIL*>

[TYPE] EQUIP GUN

SETUP Servogun
MANUAL / EQ:1 Gun:1 1/6
Manual Pressure
1 Pressuring Time(sec): 0.0
2 Start distance type: INITIAL DIST
3 End distance type: INITIAL DIST
4 Thickness table(presets): <*DETAIL*>
Manual Backup
5 Backup Speed(%): 100
6 Backup stroke: <*DETAIL*>

[TYPE] EQUIP GUN

3. Specify the following items:

Pressuring Duration of pressurization (dwell time)

Time (default value : 0 s)
Start Gun position before pressuring starts
Distance • INITIAL DIST: loc=current position. Gun closes to pressure, directly from current position
Type • BACKUP STROKE: loc=backup distance. Gun moves to selected manual backup (*1), then
closes to pressure
End Gun position after pressuring ends
Distance • INITIAL DIST: loc=original position: Gun opens to the position at gun key press
Type • BACKUP STROKE: loc=backup distance. Gun opens to the selected Manual Backup
• PART THICKNESS: loc=panel surface. Gun opens to the programmed part thickness.

*1: Selected manual backup: Backup distance specified by manual backup condition which is selected by
BU keys.

Detail [2]
Specify Pressure value (and pressure schedule) details

1. Display the Pressure Schedule screen.

DATA key → F1“[TYPE]” → “Pressure”
2. Press F4“DETAIL” displays the servo gun Pressure Schedule detail screen.

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B-83264EN/03 4.MANUAL OPERATIONS

Pressure schedule List screen

SERVO GUN DATA
PRESSURE / EQ:1 Gun:1 1/99
No. Press(Nwt) Manual Comment
1 1800.0 TRUE [ ]
2 1950.0 TRUE [ ]
3 1850.0 TRUE [ ]
4 2000.0 TRUE [ ]
5 0.0 FALSE [ ]
Pressure value is selectable
6 0.0 FALSE [ ]
7 0.0 FALSE [
by ]GUN keys, if Manual = TRUE

[TYPE] EQUIP GUN DETAIL COPY

Prev F4 DETAIL

Pressure schedule
detail screen

SERVO GUN DATA

PRESSURE / EQ:1 Gun:1 1/4
No. Press(Nwt) Manual Comment
1 Comment : [panel ]
2 Weld Pressure(Nwt): 0.0
3 Pressure profile: DISABLED <*DETAIL*>
4 Gun Sag Comp Value(mm): 0.0

[TYPE] EQUIP GUN DETAIL COPY

NOTE
Depending on your software or setup, displayed screen structure may differ.

Detail [3]
Specify Thickness details

1. Display the Thickness table screen by one of the following procedures.

Procedure A: DATA key → F1“[TYPE]” → “Thickness”
Procedure B: MENU key → F1“[TYPE]” → “Servogun” → “Manual Operation Setup”. Place cursor
on Thickness table (presets) : <*DETAIL*> and press enter
Procedure C: Press and hold gun hardkey for > 1.5 seconds.
Note: $SGSYSCFG.$HKYSETUPDLY specifies duration. Default=1500ms.

List screen
SERVOGUN DATA
THICKNESS / EQ:1 Gun:1 1/10
No. Thickness(mm) Comment
1 1.0 [thk1 ]
2 2.0 [thk2 ]
3 3.0 [thk3 ]
4 4.0 [thk4 ]
5 5.0 [thk5 ]
6 ****** [ ]
7 ****** [ ]
8 ****** [ ]
9 ****** [ ]
10 ****** [ ]

[TYPE] EQUIP GUN RECORD MEAS THK

• Set one or more values into the thickness table. You can choose No. from number which is set
thickness.
• You can initialize (****) set value by pressing F6“CLEAR”.
• You can set thickness value up as current gun open distance by pressing F4“RECORD”.
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4.MANUAL OPERATIONS B-83264EN/03

• You can measure thickness by pressing Shift + F5“MEAS THK”. Pressing shift + F5“MEAS THK”,
movable tip automatically closes and measures thickness. Please refer to 4.5 ‘Thickness measurement’
for detail.

WARING
Use measure thickness function in the condition where robot tip is on the work.

4.2 MANUAL BACKUP (Shift + BU)

The open position of the Servogun can be changed to pre-set values by operating the BU key on the teach
pendant.

1. Display the BACKUP screen.

Procedure A: DATA key → F1“[TYPE]” → “6 Manual Bkup”
Procedure B: MENU key → F1“[TYPE]” → “Servogun” → “Manual Operation Setup”. Place cursor
on Backup stroke : <*DETAIL*> and press enter.
Procedure C: Press and hold gun hardkey for > 1.5 seconds. Note: $SGSYSCFG.$HKYSETUPDLY
specifies duration. Default=1500ms.

SERVOGUN DATA
BACKUP / EQ:1 Gun:1 1/30
No. comment Stroke(mm) Manual
1 [OPEN SMALL] 5.000 TRUE
2 [OPEN MID ] 50.000 TRUE
3 [OPEN LARGE] 100.000 TRUE
4 [ ] 10.000 FALSE
5 [ ] 10.000 FALSE
6 [ ] 10.000 FALSE
7 [ ] 10.000 FALSE
8 [ ] 10.000 FALSE

[TYPE] EQUIP GUN

2. Place cursor on stroke number and specify the gun open distance.
3. Place cursor on “Manual” and select “TRUE” to make a backup position selectable.

Procedure
• Press the BU1 key to display a popup window that shows current backup value
• After popup window displays, press one of the following keys to change backup value (open
distance)
• BU1 to select next backup in table
• Down arrow to select next backup in table
• Up arrow to select previous backup in table
• Popup window is cleared
• If a key other than BU1, Up/Down arrow is pressed
• If no key is pressed for 2.5 seconds.
• Note: this time is specified via $SGSYSCFG.$HKYPOPUPDWL( default=2500ms)
• Set $SGSYSCFG.$ENB_ARW_SEL = FALSE, to disable selection via arrow key.

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B-83264EN/03 4.MANUAL OPERATIONS

Selection of backup
Displaying popup window
Selection of stroke schedule
(ascending order)

Gun number
BU 1- 1 BU 1- 2 BU 1- 3
Stroke
OPEN SMALL OPEN MID OPEN LARGE schedule #
5.00mm 50.00mm 100.00mm
BU 1- 1
OPEN SMALL Comment
5.00mm
Stroke
t

• Press BU1 key while also pressing SHIFT to move to backup position.

+ ：Specified Pressuring

• The gun will move to specified open distance

• Once motion starts, the BU1 key can be released – gun will continue to move until specified open
distance is reached
• Release the SHIFT key, to stop motion
• The stationary tip (on the robot) does not move during backup operation

NOTE
User macros assigned to UK2, SU2, UK4, and SU4 have precedence over
manual backup function. If a user macro is assigned to one of these keys, user
MACRO will execute, instead of manual backup, when key is pressed.
UK[2]/UK[4] correspond to BU1 key/ BU2 key, respectively
SU[2]/SU[4] correspond to SHIFT+BU1 key/ SHIFT+BU2 key respectively

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4.MANUAL OPERATIONS B-83264EN/03

NOTE
In dual gun case, press UK4, and SU4 operate Gun “B”.
UK4, and SU4 not used if equipment type = Single.

4.3 MANUAL WELDING

Welding can be performed manually by using the Manual welding screen.

NOTE
Weld schedule is asserted during welding. Refer to R-30iB CONTROLLER Spot
Welding OPERATOR’S MANUAL (B-83284EN-4) for weld schedule setup.
Alternatively, use weld IO simulation if weld controller is not configured. Please refer to
10.TEST EXEXUTION for weld IO simulation.

Procedure
x Display the Manual weld screen.
1. Select the MENU key to bring up the screen menu.
2. Select “MANUAL FCTNS”.
3. Press F1“[TYPE]” to display the pull-up menu.
4. Select “Manual weld”. The MANUAL FCTNS Spot screen appears.

Previous welding schedule settings

are displayed in left column. If
welding has not been performed,
values displayed as (***).

MANUAL FCTNS
1/5
MANUAL Weld (Last Weld)
1 Start distance sched: ( 1) 1
2 Pressure schedule: ( 1) 1
3 Weld sched: ( 1) 1
4 End distance sched: ( 1) 1
5 Weld ID: ( 0) 1
6 Thickness: ( 0.0) 0.0
Weld duration(ms): 480

Press SHIFT F3 to perform weld.

[TYPE] EQUIP EXEC RECD THK MEAS THK

Current welding schedule settings

are displayed in right column.

• Specify the parameters to use during welding

• Press F3“EXEC” while pressing the SHIFT key, to causes pressurize, and weld
• Once welding has started, you need not keep pressing F3“EXEC”.
• If you want to discontinue the movement, release the SHIFT key.
• The stationary tip (on the robot) does not move during this operation - gun sag compensation and fixed
tip wear compensation are NOT performed.
• You can set thickness value up as current gun open distance by pressing F4”RECORD”.
• You can measure thickness by pressing Shift + F5“MEAS THK”. Pressing shift + F5“MEAS THK”,
movable tip automatically closes and measures thickness. Please refer to 4.5 ‘Thickness measurement’
for detail.

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B-83264EN/03 4.MANUAL OPERATIONS

4.4 GUN JOG OPERATION

Servogun movable tip can be move to any position via jogging. For example, jogging is used to fine tune the
zero position, before zero-position mastering. Servogun axis can be jogged when gun group is selected
(procedure 1) or robot group is selected (procedure2).

Procedure1 – jogging when gun group is selected

1. Confirm the motion group number.

This value is the current motion group

number. If the servo gun is in motion
group 2, the group number must be G2.

TEST1 LINE 1 T2 ABORTED G1 JOINT 30%

TEST1
1/6

Change the group number if needed.

Change group by toggle style
i. Press the FCTN key, and select “CHANGE GROUP”.
The value G# changes each time CHANGE GROUP is selected such as G1, G2, G3, …, G1.
ii. Press group key
The value G# changes each time group key is selected such as G1, G1S, G2, G2S, G3, …, G1. In this
regard, if selected group has sub group, current selected group changes to sub group when group key is
pressed.
Change group directly
iii. Type in group number in “GROUP” on the jog menu.
The value G# changes to typed value.
iv. Press number key with pressing group key.
The value G# changes to pressed number.

2. Decrease the override value for safety.

OR ＋

3. Use the keys shown below to jog the movable tip.

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4.MANUAL OPERATIONS B-83264EN/03

＋ ： Jog the tip in the positive direction.

＋ ： Jog the tip in the negative direction.

Note: gun close direction is defined on servogun setup screen. If gun close direction is positive, then + x
closes the gun, otherwise–x closes the gun.

Procedure2 – jogging when robot group is selected

Teach pendant has keys to jog 8 axes. Most robots only have 6 axes, so axis 7 jog key is typically unused.
Therefore, j7 key is automatically assigned to servogun axis, for convenience. I.E. jogging of robot and gun
can be performed while robot group is selected, so robot and gun can be jogged, without changing group. J7
(and J8 axis) is available for gun jogging, when jog group selection is any of the following:

G1 JOINT
G1 JGFRM
G1 WORLD
G1 TOOL
G1 USER

1. Confirm that motion group number corresponds to robot. Change group if needed. The procedure to
confirm and change is same with procedure1.
2. Decrease the override value for safety. This procedure is same with precedure1.
3. Use the keys shown below to jog the movable tip.

Keys to jog the robot axes

＋ ： Jog the tip in the positive direction.

＋ ： Jog the tip in the negative direction.

If servogun axis has been mapped to J7, position status screen displays the gun# assigned to J7 jog key , as
shown below.

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B-83264EN/03 4.MANUAL OPERATIONS

POSITION
Joint Tool: 1

J1: -54.731 J2: -6.871 J3: -26.857

J4: 72.283 J5: 58.989 J6: -58.195
Servo gun axis is assigned.
J2/J3 Interaction: -33.728

(J7) G2 / J1 -20.000

[TYPE] JNT USER WORLD

Assignment of servogun axis to J7/J8 key

In the case where servogun option is ordered, J7/J8 jog key is preferentially assigned as servogun axis.
In the case where servogun axis is only one, J7 key is assigned as servogun axis. In the case where servogun
axes which can move at same time are two such as dual gun, J7 and J8 key are assigned as servogun axes
automatically.
If you want to disable automatic assignment and change assignment, perform the following procedure.

1. Set $SGSYSCFG.$MAPKY78_2SG = FALSE..

2. When the cursor is moved to the item “J7, J8 jog key Setup” in the system configuration menu. and the
ENTER key is pressed in the system configuration menu, the following screen is displayed.

System/Config
J7 J8 Jog keys 1/6
Group: 1 R-2000iB/165F

1 J7 Group: 2 SVGUN system

2 J7 Axis: 1
3 J7 Label: Gun:1
4 J8 Group: 1 R-2000iB/165F
5 J8 Axis: 0
6 J8 Label:

GROUP

Item Description
Group The group number and the robot name that setting is done currently is displayed.
In order to setup in another group, press F3 GROUP to change the group.
Note: In default setting(automatic assignment is enabled), J7/J8 key for servo gun
group is assigned to servo gun axis.
J7 Group This is the group number and the robot name of the axis that is jogged by pressing
J7 key. The group number can be changed.
J7 Axis This is the axis number that is jogged by pressing J7 key. The axis number can be
changed. If this item is set to 0, J7 key is disabled.
J7 Label This is the label name that is displayed beside “J7” in the current position screen.
The label name can be changed within 15 characters. When this item is not set, or
the null character is specified to this item, the group number and the axis number
are displayed in the current position screen. (Example: G1 /J7 ).
J8 Group This is the group number and the robot name of the axis that is jogged by pressing
J8 key. The group number can be changed.
J8 Axis This is the axis number that is jogged by pressing J8 key. The axis number can be
changed. If this item is set to 0, J8 key is disabled.
J8 Label This is the label name that is displayed beside “J8” in the current position screen.
The label name can be changed within 15 characters. When this item is not set, or
the null character is specified to this item, the group number and the axis number
are displayed in the current position screen. (Example: G2 /J1 ).

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4.MANUAL OPERATIONS B-83264EN/03

3. Change assignment setting you need.

Also, the setting of J7 and J8 keys can be confirmed in any screen. When J7 key or J8 key is pressed
without pressing the shift key, the pop up window is displayed at the upper right corner of the screen as
follows. The name displayed in the pop up window can be changed by setting “J7 Label” or “J8 Label”
in J7, J8 Jog Key Setup screen.

JOINT 30%
Without pressing
shift key G1 / J7

Pop up window

J7 key or
J8 key

For example, robot: 6 axes (group1) + rail (extend axis of group1) + servogun (group2) , in such case if you
want to assign J7 key to servogun and J8 key to rail to jog, assign as following.

Robot motion group

System/Config
J7 J8 Jog keys 1/6
Group: 1 R-2000iB/165F

1 J7 Group: 2 SVGUN system

2 J7 Axis: 1
3 J7 Label: Gun:1
4 J8 Group: 1 R-2000iB/165F
5 J8 Axis: 7
6 J8 Label: Rail

GROUP

Servo gun motion group

System/Config
J7 J8 Jog keys 1/6
Group: 2 SVGUN system

1 J7 Group: 2 SVGUN system

2 J7 Axis: 1
3 J7 Label: Gun:1
4 J8 Group: 1 R-2000iB/165F
5 J8 Axis: 7
6 J8 Label: Rail

GROUP

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B-83264EN/03 4.MANUAL OPERATIONS

WARING
When system has multi motion groups, switch motion group with F3key, confirm
appreciate assignment for all motion groups.
It is recommended to set common assignment of j7/j8 key for all motion groups in
order to not change assignment when any jog group is selected..

4.5 THICKNESS MEASUREMENT

Thickness value is needed as an input on several screens, and in spot instruction. Thickness measurement
function can be used to determine the value automatically. There are two options for thickness
measurement:
a. One-sided thickness measurement: caliper type measurement of panel thickness.
b. Two-sided thickness measurement: detection of both panel surfaces + caliper type measurement.
Type of measurement used is specified when measure thickness key is pressed.

4.5.1 Initial Setting

Execute the items in the order listed below, prior to initial thickness measurement.
• Autotuning
• Pressure calibration
• Setting the tool coordinate system
• Tip wear standard
• Tip wear detection

NOTE
Master position of the gun axis must be accurate to use thickness measurement.
Execute tip wear detection to ensure that wear amount and mastering are correct.
Execute thickness check calibration to ensure that deflection calibration is
accurate.

NOTE
To measure thickness accurately, execute thickness check calibration again after
pressure calibration.

4.5.2 Thickness Measurement from Editor

Number of gun that will
measure thickness

SAMPLE Measure Thickness - Gun:1

1/2
1:L P[1] 2000mm/sec CNT50 Two measurement modes are available
: SPOT[SD=1,P=1,t=2.0,S=1,ED=1] 1.Close gun tip: FixedTip ON panel
[END] 2.Close both tip: FixedTip NOT ON panel

WARNING: robot moves during mode 2 !

Select mode 2, if panel is fixtured
And fixed tip is not on panel.
Select mode 1, otherwise.

Is Fixed tip on panel?

POINT SPOT TOUCHUP > CANCEL YES NO

[INST] MEAS THK [EDCMD] >

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4.MANUAL OPERATIONS B-83264EN/03

Action at MEAS THK keypress

“Is Fixed tip on panel?”
If Answer = CANCEL: Thickness measurement is aborted.
If Answer = YES: Execute measure thickness mode1. (Gun tip is closed.)
If Answer = NO: prompt “Close both tips and measure thickness?”
If Answer = YES: Execute measure thickness mode2. (Both tips are closed.)
If Answer = NO: prompt “Thickness measurement declined.”

Thickness measurement status info

The following screens are displayed as while thickness is measured.
Confirm measured thickness and press F4 YES to update thickness. If measured thickness is wrong, press F5 NO to NOT update
thickness.

Measurement Thickness – Gun:1 Measurement Thickness – Gun:1 _

Measurement mode: Close GunTip Measurement mode: Close Both Tips

Original thickness(mm): 1.5 Original thickness(mm): 2.5
Measured thickness(mm): 2.0 Measured thickness(mm): 2.0
Measurement pressure(kgf): 0 Measurement pressure(kgf): 0
Measurement deflection(mm): -.0 Measurement deflection(mm): -.0
Gun tip StartPos(mm): -50.0 Gun tip StartPos(mm): -50.0
Gun tip EndPos(mm): -2.0 Gun tip EndPos(mm): -2.0
Fixed tip offset(mm): 24.8

Change thickness from:1.5mm to 2.0mm ? Change thickness from:2.5mm to 2.0mm ?

YES NO YES NO

1. Close GunTip 2. Close Both Tips

Item Description
Measurement Mode Selected mode is displayed.
• Close Gun Tip: Fixed tip ON panel.
• Close Both Tips: Fixed tip NOT ON panel.
Robot moves during Close Both Gun Tips.
Original thickness Set thickness before thickness measurement.
Measured thickness Result of thickness measurement.
Measurement pressure Pressure for thickness measurement.
Measurement deflection Deflection of fixed tip during thickness measurement.
Gun tip StartPos Gun tip open distance at start of thickness measurement.
Gun tip EndPos Gun tip open distance at end of thickness measurement.
Fixed tip offset Move distance of fixed tip at thickness measurement mode2.

NOTE
Parameters EndPos, Measured and Fixed tip offset display as *****, when process starts.
Actual value for each parameter is written, when it is determined.

4.5.3 Thickness Measurement from MANUAL Screen

Thickness measurement is available on following screens: manual weld, thickness table, pressure
calibration. Thickness measurement is initiated via F5 on these screens, instead of F9 in editor.
However, measurement process is operationally identical to editor-initiated measurement.

NOTE
1. Two-sided thickness measurement is disabled by default on manual screens.
2. “MANUAL” screens include thickness RECORD function (F4). F4 records thickness
based on current gun tip position (thickness = gun open distance).

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B-83264EN/03 4.MANUAL OPERATIONS

MANUAL FCTNS SERVO GUN DATA

1/6 THICKNESS TABLE / EQ:1 Gun:1 1/10
Manual Weld (Last Weld) No. Thickness(mm) Comment
1 Equipment number: 1 1 1.0 [ ]
2 Start distance sched: ( 0) 1 2 2.0 [ ]
3 Pressure schedule: ( 0) 1 3 ****** [ ]
4 Weld sched: ( 0) 1 4 ****** [ ]
5 End distance sched: ( 0) 1 5 ****** [ ]
6 Thickness: ( 0.0) 0.0 6 ****** [ ]
Weld duration(ms): 0 7 ****** [ ]

[TYPE] EXEC RECD THK MEAS THK [TYPE] EQUIP GUN RECORD MEAS THK

Manual weld
Thickness table

SETUP Servogun
PERSSURE CALIB PARAM / EQ:1 Gun:1
1 Calibration status:
3/14
INCOMP
Thickness functions are provided
2 Pressuring Time(sec): 0.0 on F4, F5 for pressure calibration
3 Thickness of Gauge(mm): 10.0 screen. However, unlike manual
4 Gun Open Value(mm): 150.0
Torque(%) Speed(mm/sec) Press(nwt) weld screen and thickness table,
5 10.0 % 50 mm/sec 1500.0 nwt
6 20.0 % 50 mm/sec 3000.0 nwt
F4, F5 change based on cursor
7 0.0 % 50 mm/sec 0.0 nwt position - F4, F5 display REC
THK MEAS THK only if cursor is
[TYPE] CANCEL PRESSURE REC THK MEAS THK
on “Thickness of gauge”.
Pressure calibration

4.5.4 Dual Gun

Gun number is specified by value identified in gun index, for that equipment.
In dual gun case, gun index is specified per table below:

Screen Selection criteria

Editor Instruction parameter
GunA:
SPOT[S=(1,0)], SPOT[S=(1,1)], SPOT[S=(0,0)]
PRESS_MOTN[SEL=1,0],PRESS_MOTN[SEL=1,1]
GunB:
SPOT[S=0,1]
PRESS_MOTN[SEL=0,1]
Thickness measurement is executed by a gun that is set weld schedule or SEL. When
both guns are set or not, Gun A has a priority.
Thickness table Gun# selected on screen.
Pressure calibration Gun# selected on screen.
Manual weld Weld schedule specified on screen
GunA: S=1,1, S=1,0, S=0,0
GunB: S=0,1
Thickness measurement is executed by a gun that is set weld schedule. When both guns
are set or not, Gun A has a priority.

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5.PROGRAMMING B-83264EN/03

5 PROGRAMMING
This section describes programming operation related to spot weld of servo gun.

5.1 SPOT WELDING INSTRUCTIONS

Instructions used in a program to specify servo gun operation are generically called spot welding
instructions. Processes (such as closing, pressing, welding, and opening) specified using a spot welding
instruction are called a spot welding sequence.
Spot welding instructions perform tip wear compensation and arm deflection compensation as well as the
following welding sequences.

5.1.1 SPOT Instruction Format

The following is SPOT instruction format for servo gun.

SPOT [SD=m, P=n, t=i, S=j, ED=m]

m : Distance schedule numbers (1-$sgsyscfg.$dst_elm (default=99))

n : Pressure schedule number (1 to $sgsyscfg.$sch_elm(default=99))
When "*" is specified, the pressure schedule specified by a Servo Gun Pressure Schedule
instruction (GUN1 P[n]) previously will be used.
i : Part thickness (0.0 - 999.9)
j : Welding schedule number (0 to 255)

This instruction specifies Start distance (SD), pressure schedule (P), part thickness (t), weld schedule (S),
and End Distance (ED) directly.

xStart Distance: The specified Start Distance (SD) openings are passed through on the way to the
taught spot location
xPressurization: Pressurization (clamping, squeezing) is performed according to the specified
pressure schedule number (P).
xThickness: Pressurization (clamping, squeezing) is performed according to the specified
thickness value (t).
xWelding: The specified weld schedule number (S) is sent to the weld controller when the
pressure reaches the specified value.
xEnd Distance : The gun is opened in response to the welding completion signal. The gun opens
through the specified End Distance (ED).

Set each schedule for SPOT instruction in DATA screen.

1. Press DATA key, display DATA screen
2. Press F1[TYPE]

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B-83264EN/03 5.PROGRAMMING

DATA Registers
SPOT [SD=m, P=n, t=i, S=j, ED=m] 1/200
R[ 1: ]=0
R[ 2: ]=0
R[ 3: ]=0
R[ 4: TYPR 1 ]=0
1 Registers
R[ 5: ]=0
2 Position
R[ 6: Reg ]=0
3 String
R[ Reg
7: ]=0
4 KAREL
R[ Vars
8: ]=0
5 KAREL
R[ Posns
9: ]=0
6 Pressure
R[ 10: ]=0
7 Distance
R[ 11: ]=0
8 Manual Bkup
9 Manual Thickness

[TYPE] >

This number is indicated to weld controller as weld schedule.

Pressure Schedule Setting

To program a spot instruction, it is necessary to specify the pressure schedule number that determines the
weld pressure.

1: L P[1] 2000mm/sec CNT100

: SPOT [SD=m, P=n, t=i, S=j, BU=m]

1. Press the DATA key to display the DATA screen.

2. Press F1“[TYPE]” to display the pull-up menu.
Select “Pressure”.
3. The servo gun Pressure Schedule list setting screen appears.

F4 DETAIL Displays the detail setting of the Pressure schedule for edition.
F5 COPY Pressing this key with the cursor on the schedule of a copy source displays a prompt for the
schedule number for a copy destination.

SERVO GUN DATA _

PRESSURE / EQ:1 Gun:1 1/99
No. Press(kgf) Manual Comment
1 350.0 FALSE [spot 1-10 ]
2 200.0 FALSE [spot 11-15]
3 0.0 FALSE [ ]
4 0.0 FALSE [ ]
5 150.0 FALSE [tip dress ]
6 0.0 FALSE [ ]
7 200.0 TRUE [gage check]
8 0.0 FALSE [ ]
9 0.0 FALSE [ ]

[ TYPE ] EQUIP GUN DETAIL COPY >

4 Pressing F4“DETAIL”. The servo gun Pressure Schedule detail screen appears. Pressing F4“LIST”
brings you back to the Pressure Schedule list screen.
SERVO GUN DATA _
PRESSURE / EQ:1 Gun:1 No:1 1/3
1 Comment: [spot 1-10 ]
2 Weld Pressure(kgf): 350.0
3 Gun Sag Comp Value(mm): 0.0

[ TYPE ] EQUIP GUN LIST

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5.PROGRAMMING B-83264EN/03

Descriptions of items to be set up

Comment A comment can be added to each Pressure Schedule.
Weld Pressure (Kgf) Weld Pressure specifies the pressure to be applied when a spot welding instruction is
Minimum: 0.0 executed.
Maximum: 9999.9
Part Thickness (mm) Part Thickness specifies the thickness of the workpiece to be welded.
Minimum: 0.0
Maximum: 1000.0
Gun Sag Comp Value Gun Sag Comp Value specifies a compensation amount if “Gun Sag Comp Value” has
(mm) been set to ENABLE on the General Setup screen.
Minimum: -1000.0
Maximum: 1000.0
Weight compensation type This item is displayed by setting gun type to Weight Compensation in detail of Pressure
Compensation setup in UTILITIES Gun setup screen.
Select gun axis weight compensation type.
Please refer to Section 18 about gun axis weight compensation function.
Adjusted (%) This item is displayed by $SGSYSCFG.$SHO_PRS_SPD_=TRUE.
Default: 100% The following screen is displayed. This item can adjust contact speed at pressure. The
speed rate can be change based on speed which is calibrated in pressure calibration.
Contact speed can be increased/decreased by maximum / minimum joint speed

SERVO GUN DATA _

PRESSURE / EQ:1 Gun:1 No:1 1/5
1 Comment: [spot 1-10 ]
2 Weld Pressure(kgf): 3500.0
3 Gun Sag Comp Value(mm): 0.0
Contact speed:
Calibrated(mm/sec): 100.0
4 Adjusted: ( 60.0mm/sec) 60.0%
5 Weight compensation type: DISABLE

[ TYPE ] EQUIP GUN LIST

NOTE
System file of pressure schedule: SYSPRESS.SV can be load from another robot
controller to copy schedule. (Note: R-30iA System file cannot be load.)

Distance Schedule Setting

To program a spot instruction, it is necessary to specify the Distance schedules used for both Start Distance
(SD) and End Distance (ED). Start Distance specifies the clearance trajectory for both tips of the servo gun
when closing to the spot weld and End Distance specifies the clearance when opening after the spot weld.
1. Press the DATA key to display the DATA screen.
2. Press F1“[TYPE]” to display the pull-up menu.
Select “Distance”.
3. The servo gun Distance table appears.
4. Edit the tip clearance distances here. Press F4 – Detail to see the detail screen.

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B-83264EN/03 5.PROGRAMMING
SERVO GUN DATA _
DISTANCE / EQ:1 Gun:1 1/99
No. Gun(mm) Robot(mm) Comment
1 10.0 10.0 [ ]
2 10.0 10.0 [ ]
3 10.0 10.0 [ ]
4 10.0 10.0 [ ]
5 10.0 10.0 [ ]
6 10.0 10.0 [ ]
7 10.0 10.0 [ ]
8 10.0 10.0 [ ]
9 10.0 10.0 [ ]
10 10.0 10.0 [ ]

[ TYPE ] EQUIP GUN DETAIL COPY >

5. Edit the attributes to define how the selected distance schedule will perform when used
End distance (ED) attributes – defines the attributes used when the schedule is used as an End
distance
SPOT [SD=m, P=n, S=i, ED=m]

SERVO GUN DATA _

DISTANCE DTL / EQ:1 Gun:1 No:1 1/5

1 Distance gun(mm): 10.0

2 Distance robot(mm): 10.0 Start distance (SD) attributes – defines the
End distance (ED) attributes attributes used only when the schedule is used in a
3 Termination Type: CNT 100
stand alone instruction or a manual operation.
4 ACC instruction: ACC100

Start distance (SD) attributes

5 <*DETAIL*>

[ TYPE ] EQUIP GUN END

SERVO GUN DATA _

DISTANCE DTL / EQ:1 Gun:1 No:1 1/3

Manual/StandAlone(start dst attrib)

1 Termination Type: CNT 100
2 ACC instruction ACC100
3 Speed(%): 100

[ TYPE ] EQUIP GUN [CHOICE]

NOTE
System file of distance schedule: SYSDIST.SV can be load from another robot
controller to copy schedule. (Note: R-30iA System file cannot be load.)

Servo Gun SPOT Trajectory with Distance Schedule

The following positions are created from the taught position and the specified Start and End Distance
schedule.

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5.PROGRAMMING B-83264EN/03

Taught Playback
Position Sequence

Start These positions are End

Distance Automatically generated Distance

Synchronized Pressing
Contact pos pos
GUN
side
Panel
ROBOT
side
Time

(Start/End Distance
Setting)
Gun [mm] Specify the approach position of the Start and End Distance
Min.: 0.0 movable side tip as a distance from the
Max.: 1000.0 part Gun
Robot [mm] Specify the approach position of the fixed Gun(mm)
Min.: 0.0 side tip as a distance from the part. Thick(mm)
Max.: 1000.0 Robot(mm)
mm
Robot

Closing and Opening Trajectory according to SPOT termination type

When executing a motion option SPOT, both tips of the servo gun arrive at the metal surface for the
specified spot location at the same time.
The trajectory of the tips will vary according to the specified Start/End Distance and termination type

Specifying term type

FINE/CNT0 : tips will pause momentarily at the specified start/end distances
CNT1-100 : tips will round the corner through the start/end distance with less deceleration. CNT100
specifies the minimum deceleration to and from the spot.

Term type for starting pressure motion and ending pressure motion is decided individually. Refer to
following explanation.

Term type for starting pressure motion (Start Distance motion)

If SPOT instruction is added to motion instruction, robot tip trajectory is decided by specified term type of
the motion instruction.

SAMPLE1 _
P[2]
1/3
START 1: L P[1] 1000mm/sec CNT100
DISTANCE 2: L P[2] 1000mm/sec CNT50
: SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
Increasing CNT 3: L P[3] 1000mm/sec FINE

P[1] POINT SPOT TOUCHUP >

The term type of motion instruction is applied.

In case of standalone SPOT or PRES_MOTN instruction, the term tyep can be specified in
“Start distance (SD) attributes”

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B-83264EN/03 5.PROGRAMMING
Term type for ending pressure motion (End Distance motion)
robot tip trajectory after pressure is decided term type that is specified with “End distance (ED) attributes”
in distance schedule screen.

SERVO GUN DATA _

DISTANCE DTL / EQ:1 Gun:1 No:1 1/5
P[2]
1 Distance gun(mm): 10.0
END 2 Distance robot(mm): 10.0
Distance End distance (ED) attributes
3 Termination Type: CNT 80
Increasi ng CNT 4 ACC instruction: ACC100

Start distance (SD) attributes

P[3] 5 <*DETAIL*>

[ TYPE ] EQUIP GUN END

NOTE
If there is gap between actual panel position and taught position, gun tip would
early-contact panel without synchronization, or robot tip would drag panel surface.
In this case, decrease CNT of SD motion and ED motion. It could prevent form
early-contact and dragging.

Part thickness
To program a spot instruction, it is necessary to specify the part thickness that determines the thickness of
the workpiece to be weld.

1: L P[1] 2000mm/sec CNT100

: SPOT [SD=m, P=n, t=i, S=j, BU=m]

“**” is displayed to a part thickness right after add a spot instruction. This means the parts thickness is not
initialized. Set the part thickness to appropriate value

NOTE
When a spot instruction is performed at uninitialized thickness, the WARNING
message “SVGN-372 Uninitialized thickness: t=** ” appears.

NOTE
When spot instructions are loaded from a program made by an old-type controller,
part thicknesses are set to uninitialized thickness. After load, set the part thicknesses
of all spot instructions to appropriate values.

5.1.2 Welding Sequence

This section describes a welding spot instruction-based welding sequence.

1: L P[1] 2000mm/sec CNT100

: SPOT[SD=1,P=3,S=5,ED=2]

･ A welding sequence is executed when the specified pressure is reached.

･ The welding sequence outputs welding schedule signals between the robot controller and welding
machine timer, and waits for the Weld completion signal.
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5.PROGRAMMING B-83264EN/03

･ The welding sequence is specified using the same screens (SETTING menu and “Spot welding”) as for
the air gun except integral weld timer.
Pressure
Specified pressure

*1 Weld start delay

Output signals

Welding schedule (i, j)

Welding strobe
Welding command *2

Input signal

Welding completion

Pressurization Welding sequence Opening

*1) When the tip is moving to the pressurization position, if the specified pressure is reached, all signals
from the additional signal to the welding permission signal are output sequentially.
If the specified pressure is not reached, the WARNING message “SVGN-020Pressure shortage ”
appears, resulting in program execution being discontinued.
Weld start delay can be set in SETUP/Spot Equip screen.

*2) When the Weld completion signal is input, it turns off all output signals, and triggers an opening
sequence. When the opening sequence ends, the next instruction is executed

NOTE
During pressure, gun position on current position screen does not indicate actual gun
position.

5.1.3 Teaching Position

x When a spot welding instruction is taught, the stationary (robot) tip should be touching the panel.
(2) The movable tip can be in any position. It would be wise to
Movable tip keep it opened to an appropriate position, though.

Panel

Stationary tip

(1) Jog the stationary tip until it touches the panel.

(3) While holding down the SHIFT key, press F2”SPOT”.

x To teach a position, it is best to use a new tip.

NOTE
Even if new tip is installed, wear amount would not be 0 completely. Because there
are new tip settlement error and/or deformed shank.
Therefore when new tip is installed, it is better to measure tip wear amount. And teach
position with enabled tip wear compensation.

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B-83264EN/03 5.PROGRAMMING
x If tip wear compensation is enabled, the last measured wear amount is automatically considered during
teaching and touchup.
x Use the Cartesian representation of position data. If spot welding instruction is attached to the Joint
angles representation of position data, an alarm is issued when the instruction is executed. (Usually,
the Cartesian representation of position data is taught.)
Position[1] Position[1]
X W J1 J4
Y P J2 J5
Z R J3 J6

5.1.4 Hold
x When an alarm or pause occur during execution of the SPOT instruction (during the spot sequence),
both the robot axis and the gun axis decelerate and come to a stop.
x When execution of the program is paused during pressure control, program execution is stopped. The
following system variable can be used to set the specification to be used when the hold input signal is
input during pressurization:

$SGSYSCFG. $REL_PRESS
= 0: Maintains the pressure.
= 1: Releases the pressure.

NOTE
When releasing pressure at HOLD is enabled, the following variable can specify
delay time until pressure is released since HOLD is received.
$SGSYSCFG.$REL_PRS_DRY (DEFAULT 2000ms)
However, too long delay time would cause OVC alarm.

x When program execution is paused, the weld signal and weld condition signal turn OFF.
x A restart resumes program execution from the spot sequence.
When program execution is paused between start of pressuring and end of welding, a restart executes
pressuring again (initial pressure), and welding is carried out after the specified pressure is reached.

5.1.5 E-Stop
x If servomotor does not have brake, when an emergency stop or power down occurs during pressure
control, the pressure is not maintained.
x If servomotor has brake, when an emergency stop or power down occurs during pressure control, the
pressure position is maintained. However it dose not guarantee the pressure accuracy.
x When an emergency stop or power down occurs, the weld signal and weld condition signal turn OFF.
x A restart resumes program execution from the spot sequence. When an emergency stop or power down
occurs between start of pressuring and end of welding, a restart executes pressuring again (initial
pressure), and welding is carried out after the specified pressure is reached. (In the case of a power
interruption, power fail recovery must be enabled.

5.1.6 Single-Step
When an operation instruction with the SPOT option is executed in the single-step mode, the machine first
passes through the approach position and stops at the taught position.

Then, it restarts the spot welding sequence from the approach position and completes the sequence
(including pressurization) by the 2nd single step execution.

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Current L P [1] 2000mm/sec CNT100 SPOT [P=1,S=1,BU=0]

position

Step forward Step forward

(1st) (2nd)

Stops at the taught position. Executes pressurization

and opens the gun.

NOTE
The taught position is reproduced only in step and backward execution mode. In
the continuous execution mode, taught position is not passed through.

Changing the taught position reproduction mode

The following system variable can be used to specify whether to pass through the taught position when the
spot welding instruction is executed in the single-step mode:

$SGSYSCFG.$STEP_TCHPT=TRUE(Enabled)/FALSE(Disabled)
TRUE: Stops at the taught position. (default setting)
FALSE: Does not stop at the taught position.

Stop positions during execution of step forward (details)

Start Opening
Taught Start
Distance position
position Distance
Gun tip
Pressuri-
zation
Taught position position
show mode Gun
($SGSYSCFG.$S Stroke
TEP_TCHPT

Robot tip

Pass→ Stop <1> Pass→ Pass→ Stop <2>

Enabled
Enabled CNT0 CNT 0 (pressurization)
(TRUE) Pass→ Stop <1> --- --- Stop <2>
Disabled
CNT0
Stop <1> --- --- Pass→ Stop <2>
Enabled
Disabled (pressurization)
(FALSE) Stop <1> --- --- --- Stop <2>
Disabled

Pass→: Position at which the machine does not stop and passes through
Stop : Position is which playback stops until FWD is pressed again
--- : Position at which the machine neither stops nor passes through

Servo gun motion setting in single step mode

Servo gun motion in single step can be specified via SPOT WELD screen. SPOT WELD screen can be
displayed with the following procedure.
x Press Menu key, select 2.TEST CYCLE, then press F1[TYPE] and select [2 SPOT WELD]
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B-83264EN/03 5.PROGRAMMING
SPOT WELD
1/10
1 Gun operation: STROKE
2 Weld controller mode: NOWELD
3 Tryout mode: DISABLED
4 Weld IO sim: ENABLED
5 Weld Duration (ms): 500 ms
6 Inform output to PLC DO[ 0]
7 Force process complete: DISABLED

Servo Gun Motion in Single Step

8 Press Motion: ENABLED
9 Stop @ Taught Pos: ENABLED

Servo Gun Motion in Backward

10 STOP @ Taught Pos: ENABELD

[ TYPE ] STROKE NOSTROKE

Servo gun motion in single step Description

Pressure motion ENABLE(DEFAULT) :
When SPOT instruction in program is executed with single step, gun closes.
DISABLE:
When SPOT instruction in program is executed with single step, gun does not
closes.
Note: Pressure utility (Manual pressure, manual weld etc) executed gun
closing even if this is disabled.
Stop @ Taught Pos ENABLE(DEFAULT) :
When SPOT instruction in program is executed with single step, robot and
gun pauses at taught position.
This is same as $SGSYSCFG.$STEP_TCHPT=TRUE
DISABLE(DEFAULT) :
When SPOT instruction in program is executed with single step, robot and
gun does not pause at taught position.
This is same as $SGSYSCFG.$STEP_TCHPT=FALSE

5.1.7 Backward
Servo gun motion in backward has two modes.

Taught position unreproduction mode

When motion option with spot instruction is executed in the backward mode, the robot moves to large
position either of end distance(ED) or start distance(SD) and pauses. Even if next backward execution is
done, the robot doesn't move to taught position.
L P [1] 2000mm/sec CNT100 SPOT [SD=1, P=1, t=2.0, S=1, ED=1]

Curre nt po sition Pause at large positio n eithe r

e nd distance or start dista nce

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Taught position reproduction mode

When motion option with spot instruction is executed in the backward mode, robot first pauses at end
distance(ED). By next backward execution, robot moves to taught position and pauses. By next backward
execution, robot moves to start distance(SD) and pauses.

L P [1] 2000mm/sec CNT100 SPOT [SD=1, P=1, t=2.0, S=1, ED=1]

Curre nt po sition P ause at e nd Pa use at ta ught Pa use at start

distance po siti on distance

NOTE
The taught position is reproduced only in step and backward execution mode. In
the continuous execution mode, taught position is not passed through.

Switching taught position reproduction mode

Taught position reproduction mode can be switched on SPOT WELD screen. SPOT WELD screen can be
displayed with the following procedure.
x Press Menu key, select [2.TEST CYCLE], then press F1[TYPE] and select [2 SPOT WELD]

SPOT WELD
1/10
1 Gun operation: STROKE
2 Weld controller mode: WELD
3 Tryout mode: DISABLED
4 Weld IO sim: ENABLED
5 Weld Duration (ms): 500 ms
6 Inform output to plc DO[ 0]
7 Force process complete: DISABLED

Servo Gun Motion in Single Step

8 Pressure Motion: ENABLED
9 Stop @ Taught Pos: ENABLED

Servo Gun Motion in Backward

10 Stop @ Taught Pos: DISABLED

[TYPE] ENABLED DISABLED

Servo gun motion in backward Description

Stop @ Taught Pos DISABLED(DEFAULT) :
When SPOT instruction in program is executed with backward,
robot and gun does not pause at taught position.
This is the taught position unreproduction mode.
ENABLE :
When SPOT instruction in program is executed with backward,
robot and gun pauses at taught position.
This is the taught position reproduction mode.

Touchup in backward execution

In taught position unreproduction mode, robot restarts from either largeness of start distance(SD) or end
distance(ED) at next backward execution when manual touchup or Guntouchup are occurs during while
backward is executing.
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B-83264EN/03 5.PROGRAMMING
In taught position reproduction mode, robot restarts from the start distance(SD) at next backward execution
when manual touchup or Guntouchup are occurs during while backward is executing.

NOTE
In taught position unreproduction mode, robot restarts from either largeness of
start distance(SD) or end distance(ED) at next backward execution when
Guntouchup is canceled during while backward is executing.
In taught position reproduction mode, robot restarts from the end distance(ED) at
next backward execution when Guntouchup is canceled during while backward is
executing.

5.1.8 Tips to Using SPOT Instruction

Offset taught position of SPOT with Offset instruction
If you want to offset taught position of SPOT, refer to the following.

OK: L P[1] 2000mm/s CNT100 Offset SPOT[SD=1,P=1,S=1,ED=1]

NG: L P[1] 2000mm/s CNT100 SPOT[SD=1,P=1,S=1,ED=1] Offset

Add offset instruction just behind motion instruction like OK format to offset taught position of SPOT.
SPOT instruction needs offset position data beforehand to generate the path.
With NG format, SPOT instruction can not generate the path via offset position.

Synchronization between robot and gun axis.

Robot tip and gun tip are controlled synchronously so that these contact panel surface simultaneously. It
prevents robot tip from dragging, or gun tip from early-contacting.
The synchronize control is effective to robot axis and gun axis. Extend axis is not controlled synchronously.
For example, there is robot or stationary gun on slide rail in system. In the system, rail motion is not
controlled synchronously with SPOT instruction. When gun approaches with slide rail, the tip would drag
panel surface.
The workaround are;
• Do not make slide rail approach with separating slide rail motion from SPOT instruction.
• Decrease CNT of motion instruction includes SPOT instruction. It separate pressure motion from
approach motion.

5.2 OTHER INSTRUCTIONS

This section describes other instructions for servo gun function except SPOT instruction.

5.2.1 Press Motion Instruction

The Press Motion instruction is intended to perform pressurization of the servo gun without performing
welding. This instruction is commonly used for tip dressing/grinding operations.

The Press Motion instruction does not open the gun or perform welding after pressurization is completed.

Like spot welding instructions, the Press motion instruction carries out tip wear compensation and arm
deflection compensation when it is used as a motion option.

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Instruction format
Stand Alone format:
1: PRESS_MOTN [SD=l, P=m, t=n]
Motion Option format:
1: L P[1] 2000mm/sec FINE Press_motn [SD=1, P=1, t=2.0]

x Pressurization is performed according to the Start distance and pressure schedule numbers specified.
x “**” is displayed to a part thickness right after add a press motion instruction. This means the parts
thickness is not initialized. Set the part thickness to appropriate value.
x The pressurization instruction can be used as both motion option and standalone instructions.
- Motion option instruction
The additional-operation instruction controls both movable and stationary tips during a
pressurization sequence. It also performs tip wear compensation and gun deflection
compensation.
x The pressurization instruction performs only pressurization it does not open the gun. So, it is
necessary to teach Pressuring time and gun opening separately. (See the sample program.)

Sample Program
1:L P[1] 100mm/sec FINE Line 1: Closes to pressure at taught position
: Press_motn [SD=1, P=2] Line 2: Pressuring time
2: WAIT 2.00sec Line 3: Gun Opening
3:L P[2] 100mm/sec FINE

NOTE
When a press motion instruction is performed at uninitialized thickness, the
WARNING message “SVGN-372 Uninitialized thickness: t=** ” appears.

NOTE
When press motion instructions are loaded from a program made by an old-type
controller, part thicknesses are set to uninitialized thickness. After load, set the part
thicknesses of all press motion instructions to appropriate values.

5.2.2 Pressure Instruction

The pressure instruction is intended to limit the maximum torque of the servo gun to the specified pressure
when ordinary motion statements rather than spot welding and pressurization instructions are used to
control gun motion. It can be used when load becomes too heavy if the maximum torque is applied to the
servo gun axis, for example, to press the servo gun against the workpiece for a purpose other than spot
welding. It cannot be used to control the pressure used in a spot welding or pressurization instruction.

Instruction format
Pressure specification instruction
Pressure[tl]kgf
Pressure condition number (1 to 9999) gun 1

NOTE
Maximum Pressure is limited by "Max Pressure(Kgf)" in General Setup in SETUP
SPOT Weld screen at executing the instruction.
Pressure standard instruction
Pressure standard gun 1

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B-83264EN/03 5.PROGRAMMING
x The pressure standard instruction changes the motor torque limit for the movable tip by calculating it
by multiplying the specified pressure by a conversion factor (pressure-torque).
It also modifies the excessive-error threshold value in order to prevent excessive error at
pressurization.
x The pressure standard instruction cancels changes made by the pressure specification instruction to the
torque limit value and excessive-error threshold value, and resumes their previous values. If the current
pressure has been modified using the pressure specification instruction, resume its previous value,
using the pressure standard instruction. Otherwise, the operation continues with a low torque, resulting
in a decreased cycle time.

NOTE
If the pressure specification instruction is used to lower the pressure applied to
grasp the workpiece, keep the newly specified pressure until the workpiece is
conveyed and released. If the previous pressure is resumed when the workpiece
is held on the gun, the torque limit is lifted, causing the maximum torque to be
generated, which is likely to lead to an excessive load to be laid on the workpiece

Sample program
1: Pressure[100]Kgf Line 1: Pressure change
2: L P[1] 100mm/sec CNT50 Line 2: grasp workpiece
3: L P[2] 100mm/sec CNT50 Line 3: Move to a point
4: L P[3] 100mm/sec FINE Line 4: Release workpiece
5: Pressure standard gun1 Line 5: Resume to the previous value

x If a spot welding instruction (or pressurization instruction) is used along with a pressure instruction
used to limit the gun axis motor torque, the pressure specified in the spot welding instruction (or
pressurization instruction) overrides the pressure specified in the spot welding instruction. If the
pressure instruction specifies 100 kgf, for example, when a spot welding instruction is executed with a
Pressure Condition of 200 kgf, a pressure of 200 kgf is generated

5.2.3 Gun Zero Master Instruction

This subsection explains other instructions. Currently, the gun zero mastering instruction is available.
The gun zero mastering instruction performs zero-point mastering for the gun axis at the current position.
Instruction format

Gun Zero Master［#］

#: Gun number (1 to 6)
Sample program
1:L P[1] 100mm/sec FINE Line 1: 0 kgf must be specified for pressure condition
: Press_motn [SD=1, P=98] P=[98].
2: WAIT 0.5 sec Line 2: waits to let the position settle
3. Gun Zero Master [1] Line 3: sets the mastering for gun 1.
4: L P[2] 100mm.sec FINE Line 4: opens the gun

NOTE
The above sample program cannot perform zero-point mastering for a gun of
which the mastering position is completely shifted or that for which mastering is
not complete.

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5.2.4 TIPDRESS Instruction

TIPDRESS is a instruction that allows you to close, pressurize and open a servo gun without welding. It can
be used in coordination with a tip dressing operation on a tip dresser.

Instruction format
Stand Alone format:
1: TIPDRESS [SD=m, P=n, t=i, TD=j, ED=m]

m: Distance schedule numbers (1-99)

n: Pressure schedule number (1-99)
i: Thickness of dresser (mm)(0.0 - 999.9)
j: Tip dress schedule number* (0-2)
*Tip dress schedule can be set on the Tip dress setup menu.
Motion Option format:
1: L P[1] 2000mm/sec FINE TIPDRESS [SD=m, P=n, t=i, TD=j, ED=m]

x Close the gun using the specified start distance in the (SD=) field.
x Turn on the blowoff valve identified in the TIPDRESS SETUP menu
x Close the gun at the pressure specified in the Pressure (P=) and Thickness (t=) field.
x “**” is displayed to a thickness of dresser right after add a TIPDRESS instruction. This means the
thickness of dresser is not initialized. Set the thickness of dresser to appropriate value
x Once pressure is achieved, hold pressure for the time specified in the schedule assigned in the Tip Dress
(TD=) field.
x Once the Tip Dress time has expired, open the gun to the end distance specified in the (ED=) field, and
turn off the blowoff valve.
x Increment the guns tip dress count, and increment the tip dressers cutter count.

NOTE
When a TIPDRESS instruction is performed at uninitialized thickness, the
WARNING message “SVGN-372 Uninitialized thickness: t=** ” appears.

NOTE
When TIPDRESS instructions are loaded from a program made by an old-type
controller, thicknesses of dresser are set to uninitialized thickness. After load, set the
thicknesses of dresser of all TIPDRESS instructions to appropriate values.

Tip Dress Setup menu

Display the TIPDRESS SETUP menu, using the procedure below:
1. Press the MENU key. Select “6 SETUP”.
2. Press F1“[TYPE]” to display the pull-up menu.
Select “9 Tip Dress”.
3. TIPDRESS SETUP menu appears.

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B-83264EN/03 5.PROGRAMMING
TIP DRESS
1/16
- Dresser #:1
Current # of cuts: 0
Max # of cuts: 0
Max Cuts alarm Sev: FAULT
Blow Off Valve: DO[ 0]
Fault oupput: DO[ 0]
Alert output: DO[ 0]
Fault/Alert Reset: DI[ 0]

- Gun #:1
Dresser number for gun: 1
Current # of dresses: 0
Max # of dresses: 0
Max dress alarm Sev: FAULT

- Sched #:1
Step #1:
Duration (ms): 0
Comment:

[ TYPE ]

The SETUP menu is broken up into 3 sections.

x Dresser info
ITEM DESCRIPTION
Dresser # You can enter the dresser number you want to configure here. There is only 1 dresser
configured by default. To increase the number of dressers, set $sgtdcfg.$num_dresrs,
and then perform a CTRL start, then FCTN START COLD.
Current number of cuts This item is incremented automatically after each successful dress. If you move cursor to
the item then set it to 0, or programmatically by setting
$sgtdset[Dresser_num].$cut_count, you can reset this count on this screen
Max # of cuts This is the maximum cuts for the cutter blade to perform before it requires
to be changed. When current cuts is greater than max cuts, then the
system will post a Fault or Warning depending on the Max cuts alarm sev.
Setting.
Max Cuts Alarm Sev. This is the severity of the alarm which occurs when the max number of
dresses on the specified dresser is exceeded. It can be a Fault or
Warning.
Blow off Valve This is the index of the DOUT to control the blowoff valve when a dress is
being performed.
Fault output This is the index of the DOUT that will turn on when there is a TIPDRESS
error, and the severity has been configured as a FAULT. The user is
responsible to reset this output.
Alert output This is the index of the DOUT that will turn on when there is a TIPDRESS
error, and the severity has been configured as an Warning. The user is
responsible to reset this output.
Fault/Alert Reset The reset input can turn off Fault output and Alert output

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5.PROGRAMMING B-83264EN/03

x Gun info
ITEM DESCRIPTION
Gun # A servo gun is mapped to a dresser, so when a servo gun is used, the system knows
which dresser to control. Here you can enter the gun number to configure.
Dresser number for gun This maps the gun to a specific dresser so that when this gun executes a
TIPDRESS instruction, the correct dresser can be controlled.
Current # of dresses This item is incremented automatically after each successful dress. If you
move cursor to the item then set it to 0, or programmatically by setting
$sggun#.$setup.$dress_cnt, you can reset this count on this screen.
Max number of dresses This is the maximum dresses for this gun’s tips to perform before they
require to be changed. When current dresses is greater than max
dresses, then the system will post a Fault or Warning depending on the
Max dress alarm severity setting
Max Dress Alarm Sev This is the severity of the alarm which occurs when the max number of
dresses is exceeded. It can be a Fault or Warning.

x Schedule info
ITEM DESCRIPTION
Sched # You can enter the tip dress schedule number you want to configure here.
There are 2 schedules by default. To increase the number of schedules,
set $sgtdcfg.$num_sched, and then perform a CTRL start, then FCTN
START COLD. The maximum number of schedules is 10.
Duration (ms) This is the duration in ms for the dress. This time begins once pressure is
achieved with the servo gun tips.
Comment Allows you to associate a comment with this tip dress schedule.

NOTE
When TIPDRESS is executed with low override, the pressurizing time might become
longer than the specified duration. Change the push depth to 5mm when you want to
evade this. The push depth can be changed by the system variable $sgsch#[pressure
schedule number].$pushing_depth. A default value of the push depth is 10mm.

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B-83264EN/03 6.TIP WEAR DOWN COMPENSATION

6 TIP WEAR DOWN COMPENSATION

6.1 OVERVIEW
Tip Wear Compensation is used to compensate for changes at the servo gun tips. These changes include
wear resulting: from welding, dressing, etc. and growth resulting from tip change, electrode change, etc.
Tip Wear Compensation adjusts the final position of both weld tips when executing the SPOT or
PRESS_MOTN instruction.
It is necessary to measure the amount of tip wear down in order to use this function. The tip wear
compensation function works by using Teach Pendant programs and macros that are included with the
Servo Gun software option.

Two standard methods of tip wear measurement are available that do not require external sensors. They are
called TWO STEP and ONE-STEP. Only one method can be used for each robot. Two-Step is default choice
and more accurate.

TWO-STEP (i.e. fixture-based, fixture-touch)

First, the gun is closed and re-mastering is done. Next, the gun is brought to a rigid plate/fixture in the cell
-often mounted on the tip dresser- and the moving tip closes to the fixture (fixture-touch) while the gun
opening is measured. The unique wear amount on each tip is determined accurately using this method.

1st Step (Re-Master/Calibrate) 2nd Step (fixture-touch)

Position #1 Position #2

The two-step method is the most accurate, since the unique wear of each tip is determined. This is the
default method.

ONE-STEP (i.e. fixture-less, tip-to-tip)

The gun is closed and re-mastered. The fixture-touch step is skipped so, only the combined wear of both
tips is determined. Each tip’s unique wear amount is then estimated by applying the user-defined “wear
ratio”.
TIP WEAR TASKS
With both methods, there are two main tasks for using tip wear compensation:
INITIAL SETUP – do this once, to initialize tip wear reference data*
UPDATE– do this after initial setup, every time a new tip wear measurement is needed.

When tip wear compensation is enabled, wear amount is always considered on all SPOT taught position.
Update wear amount before SPOT taught position is taught up with worn tip.

NOTE
After soon initial setup, it is not necessary to execute update wear down
continuously.

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6.TIP WEAR DOWN COMPENSATION B-83264EN/03

* Initial Setup must be run again if BZAL (Battery Zero Alarm) occurs, change in gun geometry or change in gun friction when
using Two-Step method. Read the Recovery from Loss of Mastering Data section for more detail on running the initialization after
BZAL.

6.2 STANDARD TIP WEAR PROGRAM LIST

The following TP programs are included in the TP program list when the Servo Gun option is installed. Use
these programs to perform the tip wear initial setup and update tasks, as well as a few other common functions if
needed.

The TP programs are setup to perform a specific tip wear function on gun #1. These programs can be
copied or re-named by the user for special cases such as:
Multi-gun systems
To support a customer specified TP program naming convention
To support indirect argument assignments
Etc.
The MACRO programs should generally not be re-named or deleted since they are used as sub-routines of
the main tip wear programs.

Default TP Main Macro That is Function

program name Run
The following programs are always loaded
TW_SET01 TW_SETUP Initialize tip wear data for the 2-step method on gun 1. Must specify the gun
number in the macro program call.
TW_UPD01 TW_UPDAT Measure the tip wear using the 2-step method for gun 1. Must specify the gun
number and the tip condition (new or used) in the macro program call.
TW_MV2PT N/A Move the robot to the positions required for each step in the 2-step method.
This is a sub-routine called by TW_SETUP and TW_UPDAT that is used to
specify positions and should not be re-named!
If $SGSYSCFG. $LOAD_TWD＝11 the following programs are loaded
WR_SET01 WR_SETUP Initialize tip wear data for the 1-step method on gun 1. Must specify the gun
number in the macro program call.
WR_UPD01 WR_UPDAT Measure the tip wear using the 1-step method for gun 1. Must specify the gun
number and tip condition (new or used) in the macro program call.
If $SGSYSCFG. $LOAD_TWD＝12, the following programs are loaded
TW_PRS01 TW_PRSRT Press new tips onto the gun tip holder by opening and closing the gun with
pressure several times. Please refer to Appendix .F about more details.

The purpose of this document is to describe how to use the TP & macro programs and Tip Wear UIF screens
to properly measure and compensate for tip wear.

NOTE
Some program loaded by setting $SGSYSCFG.$LOAD_TWD>0 is KAREL
program and then these KAREL program is not saved to backup files. Therefore
even if all backup files is restored after initial start, please set
$SGSYSCFG.$LOAD_TWD again to load KAREL program.

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B-83264EN/03 6.TIP WEAR DOWN COMPENSATION

6.3 PREPARATIONS FOR TIP WEAR DOWN COMPENSATION

6.3.1 Preparations
• Complete servo gun autotune and pressure calibration
• Set Tip Wear Comp ’to ENABLE in Servo gun general setup screen
• Perform Gun zero mastering with new tip before measurement setup.
• Confirm if gun stroke limit is correct.

NOTE
Robot and gun positions will change slightly from the originally taught position at
execution of the SPOT and Press Motion with tip wear compensation. Be sure robot
arm and gun arms do not interfere with tooling and fixtures when tip wear amount is
large.

6.3.2 Preparation of TWO-STEP

Prepare a fixture for detecting the moving tip position in the fixture-touch step of the measurement If the
fixture deflects while the tip presses against it, the measurement error may increase. Please prepare a fixture
as rigid as you can. (As a standard, movable tip will press the fixture with 100-200 kgf of pressure.).
Movable tip
fixture

6.3.3 Confirmation of Register & Position Register Number

The macro programs for tip wear down measurement use R[10] and PR[20],PR[21] as the default registers.
Don’t use these registers for another purpose. These registers can be changed in the macros, however it is
generally not necessary to change.
If you change these register and position register numbers, edit them in the macro programs, directly. See
following table and details about the macro programs. The numbers used by tip wear down measurement
are used arguments of CALL instructions. They are rimmed black box in details. See comments in the
macro programs for details of the arguments.

NOTE
Change all register and position register numbers used by all macro programs at
same time when you change them.

Macro Name Used Register Used Position Register

TW_SETUP R[10] PR [21]
TW_UPDAT R[10] PR [21]
WR_SETUP R[10] PR [20], PR [21]
WR_UPDAT R[10] PR [20], PR [21]

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6.TIP WEAR DOWN COMPENSATION B-83264EN/03

TW_SETUP TW_SETUP

1/64 34/64
1: !Program description ; 34: !Move to posn away from fixture ;
2: ! Setup fixture-based wear measm ; 35: ! parm1: gun number ;
3: ; 36: ! parm2: posn number ;
4: !Input parameter(s) ; 37: ! parm3: data register ;
5: ! AR[1]: Gun number ; 38: CALL TW_MV2PT(AR[1],1,10) ;
6: ; 39: ;
7: !Data register(s) used ; 40: !Calibrate 0 with master tips ;
8: ! R[10] ; 41: ! parm1: gun number ;
9: ; 42: ! parm2: data register1 ;
10: !Position register(s) used ; 43: ! parm3: position register ;
11: ! PR[21] ; 44: CALL TWKZRCLB(AR[1],10,21) ;
12: ; 45: ;
13: !Version info / revisions ; 46: !Move to fixture position ;
14: !v6.22: multi-gun support ; 47: ! parm1: gun number ;
15: !v6.31: parameter reduction ; 48: ! parm2: posn number ;
16: ; 49: ! parm3: data register ;
17: !Initialize gun data ; 50: CALL TW_MV2PT(AR[1],1,10) ;
18: !parm1:gun number ; 51: CALL TW_MV2PT(AR[1],2,10) ;
19: CALL TWKINIT(AR[1]) ; 52: ;
20: ; 53: !Measure open distance ;
21: !Move to posn away from fixture ; 54: ! parm1: gun number ;
22: ! parm1: gun number ; 55: ! parm2: data register1 ;
23: ! parm2: posn number ; 56: ! parm3: position register1 ;
24: ! parm3: data register ; 57: CALL TWKFXTCH(AR[1],10,21) ;
25: CALL TW_MV2PT(AR[1],1,10) ; 58: ;
26: ; 59: !Move to posn away from fixture ;
27: !Set force threshold ; 60: ! parm1: gun number ;
28: !NOTE:Gun is opened via TWTTHOLD ; 61: ! parm2: posn number ;
29: ! parm1: gun number ; 62: ! parm3: data register ;
30: ! parm2: data register ; 63: CALL TW_MV2PT(AR[1],2,10) ;
31: ! parm3: position register ; 64: CALL TW_MV2PT(AR[1],1,10) ;
32: CALL TWKTHOLD(AR[1],10,21) ; [END]
33: ;

[ INST ] [EDCMD] [ INST ] [EDCMD]

TW_UPDAT TW_UPDAT

1/48 23/48
1: !Program description ; 23: !Calibrate 0 with worn tips ;
2: ! Update fixture-based wear meas ; 24: ! parm1: gun number ;
3: ; 25: ! parm2: data register1 ;
4: !Input parameter(s) ; 26: ! parm3: position register ;
5: ! AR[1]: Gun number ; 27: CALL TWKZRCLB(AR[1],10,21) ;
6: ; 28: ;
7: !Data register(s) used ; 29: !Move to fixture position ;
8: ! R[10] ; 30: ! parm1: gun number ;
9: ; 31: ! parm2: posn number ;
10: !Position register(s) used ; 32: ! parm3: data register ;
11: ! PR[21] ; 33: CALL TW_MV2PT(AR[1],1,10) ;
12: ; 34: CALL TW_MV2PT(AR[1],2,10) ;
13: !Version info / revisions ; 35: ;
14: !v6.22: multi-gun support ; 36: !Measure open distance ;
15: !v6.31: parameter reduction ; 37: ! parm1: gun number ;
16: ; 38: ! parm2: data register1 ;
17: !Move to posn away from fixture ; 39: ! parm3: position register1 ;
18: ! parm1: gun number ; 40: ! parm4: new-1/worn-0 ;
19: ! parm2: posn number ; 41: CALL TWKFXTCH(AR[1],10,21,AR[2]) ;
20: ! parm3: data register ; 42: ;
21: CALL TW_MV2PT(AR[1],1,10) ; 43: !Move to zero calibration posn ;
22: ; 44: ! parm1: gun number ;
45: ! parm2: posn number ;
46: ! parm3: data register ;
47: CALL TW_MV2PT(AR[1],2,10) ;
48: CALL TW_MV2PT(AR[1],1,10) ;
[END]

[ INST ] [EDCMD] [ INST ] [EDCMD]

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B-83264EN/03 6.TIP WEAR DOWN COMPENSATION
WR_SETUP WR_SETUP

1/64 32/64
1: !Program description ; 32: !Write open distance to PR ;
2: ! Setup fixtureless wear measmt ; 33: ! Parm1: Gun # ;
3: ! Version:6.40 ; 34: ! Parm2: Position register index ;
4: ; 35: ! Parm3: Typ(1=opndist,2=curpos) ;
5: !Input parameters ; 36: ! Parm4: Magnitude of open dist ;
6: ! AR[1]: Gun number ; 37: CALL TWKWRTPR(AR[1],21,1,25) ;
7: ; 38: ;
8: !Data registers R[] used ; 39: !Move gun to PR ;
9: ! R[10]: Work register ; 40: ! Parm1: Velocity label ;
10: ! R[11]: Work register ; 41: ! Parm2: Position register index ;
11: ; 42: CALL TW_MVGUN(1,21) ;
12: !Position registers used ; 43: ;
13: ! PR[20]: Position at wr start ; 44: !Skip threshold measurement ;
14: ! PR[21]: Work position register ; 45: !Increment phase(step) ;
15: ; 46: ! Parm1:gun number ;
16: ; 47: CALL TWKINCPH(AR[1]) ;
17: !Initialize gun data ; 48: ;
18: ! Parm1:gun number ; 49: !Calibrate 0 with master tips ;
19: CALL TWKINIT(AR[1]) ; 50: ! parm1: gun number ;
20: ; 51: ! parm2: data register1 ;
21: !Update grp mask for motn prog ; 52: ! parm3: position register ;
22: ! Parm1: gun number ; 53: ! parm4: data register2 (<v6.31) ;
23: ! Parm2: program name ; 54: CALL TWKZRCLB(AR[1],10,21) ;
24: CALL TWKGPMSK(AR[1],'TW_MVGUN') ; 55: ;
25: ; 56: !Skip fixture measurement ;
26: ! Write present posn to PR ; 57: !Increment phase(step) ;
27: ! Parm1: Gun # ; 58: ! Parm1:gun number ;
28: ! Parm2: Position register index ; 59: CALL TWKINCPH(AR[1]) ;
29: ! Parm3: Typ(1=opndist,2=curpos) ; 60: ;
30: CALL TWKWRTPR(AR[1],20,2) ; 61: !Move gun to PR ;
31: ; 62: ! Parm1: Velocity label ;
63: ! Parm2: Position register index ;
64: CALL TW_MVGUN(1,20) ;
[END]

[ INST ] [EDCMD] [ INST ] [EDCMD]

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6.TIP WEAR DOWN COMPENSATION B-83264EN/03

WR_UPDAT WR_UPDAT

1/65 35/65
1: !Program description ; 35: !Move gun to PR ;
2: ! Update fixtureless wear measmt ; 36: ! Parm1: Velocity label ;
3: ! Version:6.40 ; 37: ! Parm2: Position register index ;
4: ; 38: CALL TW_MVGUN(1,21) ;
5: !Input parameters ; 39: ;
6: ! AR[1]: Gun number ; 40: !Calibrate 0 with worn tips ;
7: ! AR[2]: New tip ( reset wr ) ; 41: ! parm1: gun number ;
8: ; 42: ! parm2: data register1 ;
9: !Data registers R[] used ; 43: ! parm3: position register ;
10: ! R[10]: Work register ; 44: ! parm4: data register2 ;
11: ! R[11]: Work register ; 45: CALL TWKZRCLB(AR[1],10,21) ;
12: ; 46: WAIT 0.00(sec) ;
13: !Position registers used ; 47: ;
14: ! PR[20]: Position at wr start ; 48: !Reset ref to 0 before checking ;
15: ! PR[21]: Work position register ; 49: !for wear error, if new tip ;
16: ; 50: R[10] = AR[2] ;
17: !Update grp mask for motn prog ; 51: IF R[10] <> 1,JMP LBL[1] ;
18: ! Parm1: gun number ; 52: CALL TWKRSWDN ;
19: ! Parm2: program name ; 53: LBL[1] ;
20: CALL TWKGPMSK(AR[1],'TW_MVGUN') ; 54: ;
21: ; 55: !Update wear amounts ;
22: !Write present position to PR ; 56: !Parm1: 0<=Robot wear ratio<=1.0 ;
23: ! Parm1: Gun # ; 57: !RbtTipWear = ( rbtwr_ratio * ;
24: ! Parm2: Position register index ; 58: ! total wear ) ;
25: ! Parm3: Typ(1=opndist,2=curpos) ; 59: !Parm2: New tip installed ;
26: CALL TWKWRTPR(AR[1],20,2) ; 60: CALL TWKCALC2(0.5,AR[2]) ;
27: ; 61: ;
28: !Write open distance to PR ; 62: !Move gun to PR ;
29: ! Parm1: Gun # ; 63: ! Parm1: Velocity label ;
30: ! Parm2: Position register index ; 64: ! Parm2: Position register index ;
31: ! Parm3: Typ(1=opndist,2=curpos) ; 65: CALL TW_MVGUN(1,20) ;
32: ! Parm4: Magnitude of open dist ; [END]
33: CALL TWKWRTPR(AR[1],21,1,25) ;
34: ;
[ INST ] [EDCMD] [ INST ] [EDCMD]

6.4 TWO-STEP MEASUREMENT METHOD

Procedures for TWO-STEP Measurement (ex. Gun =1)
The Two-Step measurement uses the macro programs TW_SETUP and TW_UPDAT to perform the initial
setup and update tasks respectively.

6.4.1 Teaching Position

1. Teach two positions in TW_MV2PT
Label of gun number & teaching position
TW_MV2PT
1/99
31: LBL[11:P1/Tips_tch.Gun1 ] Shift + F5
32: L P[1] 250mm/sec FINE
33: END
34: LBL[21:P2/Fix_tch.Gun1]
35: L P[2] 250mm/sec FINE
36: END P1 - Approach position for fixture (Tips_tch)
37:

POINT SPOT TOUCHUP > Shift + F5

>5mm

P2 - Fixture touch position (Fix_tch)

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B-83264EN/03 6.TIP WEAR DOWN COMPENSATION

NOTE
Notice the following for teaching positions.
1. TW_MV2PT is pre-installed in controller.
2. Confirm/Set robot group and gun group is match to group mask of TW_MV2PT.
3. Refer to the label comment of TW_MV2PT for gun number & teaching position.
4. 2 position index are provided for per gun. Teach position with correct index for the
gun.
5. Place robot tip away fixture with about 5 -10 mm when teaching 2nd position.
6. Do not place gun tip on fixture when teaching 2nd position.
7. The positions should be taught such that movement from Posn[1] to
Posn[2] or vice-versa does not cause any collision
8. These are the same points the robot will move to for the measurement of tip wear
during production. Be sure to consider this when calling the tip wear update
program in production.

6.4.2 Initial Setup

1. Copy program TW_SET01、to a new program (name) if necessary, and modify the instructions.
Ex) TW_SET02.TP : for setup gun 2

TW SET01
10/11
5: ; Set correct gun number
6: !Use the following call for ;
7: !fixture-based wear measurement ;
8: !Parm1: gun number ;
9: !CALL TW_SETUP( 1 ) ;
10: CALL TW_SETUP(1) ;

POINT SPOT TOUCHUP >

2. Execute user program that was copied from TW_SET01.TP for each gun. Check teaching positions
and gun axis speed, then execute it finally with override 100% (AUTO mode or T2 mode).

Position[1]:Tips touch position Position[2]:Fix touch position

Threshold value measurement Reference zero position calibration Reference open position measurement

Robot positions in TW_MV2PT

WARNING
If motor is replaced, or gun hardware is overhauled in maintenance, gun character is
changed. In this case, perform gun autotune, pressure calibration, and setup
program of tip wear measurement again.
If shank or gun arm are replaced, TCP is changed. In this case, correct TCP, and
then perform setup program of tip wear measurement again

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6.TIP WEAR DOWN COMPENSATION B-83264EN/03

NOTE
When setup program of tip wear measurement is performed, the following
WARNING is posted.
SVGN-178 Open/CloseLim = XXX mm/ YYY mm
This indicates standard stroke limit that is compensated according to wear down.
If this stroke limit is not correct, gun could not press correctly.
About compensated stroke limit, refer to 6.10 for more detail

6.4.3 Update Tip Wear Amount

1. Copy program TW_UPD01、to a new program (name) if necessary, and modify the instructions.
Ex)TWUPD02 for update gun 2
Set correct gun number
TW UPD01
20/21
15: !Use the following call for ;
16: !fixture-based wear measurement ;
17: !Parm1: gun number ;
17: !Parm2: new tips ; Normally set ‘0’ for worn tip.
19: !CALL TW_UPDAT( 1, 0 ) ;
20: CALL TW_UPDAT(1,0) ; Set ‘1’ after installing new tip.

POINT SPOT TOUCHUP >

2. Set the arguments correctly for the wear measurement that is required. The arguments may be
specified indirectly by using data register.
3. Run the TW_UPDAT macro any time an updated measurement is needed:
-After tip change (set new tips parameter)
-After tip dress
-After pre-determined number of welds or parts
-Whenever an updated wear measurement is desired
Position[1]:Tips touch position Position[2]:Fix touch position

Reference zero position calibration Wear down amount measurement

Robot move to positions of TW_MV2PNT

WARNING
During performing setup/update, TWTHOLD2.TP TWZRCLB2.TP TWFXTCH2.TP ,
which are internal program for tip wear measurement, is visible status.
Do not edit or delete these

NOTE
Perform setup/update for per gun. Confirm gun number is correct.

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B-83264EN/03 6.TIP WEAR DOWN COMPENSATION

NOTE
If wear update program is executed with new tip and init setup program is executed
again with the new tip, then SVGN-187 occurs. Because once wear update program
is executed, the tip is regarded as worn tip. Before init setup program is executed,
perform gun zero mastering or reset wear down amount.

The following is a sample for this function.

6.4.4 Example of Tip Wear Down Measurement

1. TP program ”SAMPLE.TP” executes motion instruction and SPOT instruction, then calls tip wear
down measurement program “TW_UPD01”.
2. When tip is replaced to new tip, new tip measurement is executed by turning on DI[10].

SAMPLE _ TW_UPD01
1/9
3: L P[1] 250mm/sec FINE 20/20
SPOT[SD=1,P=1,t=2.0,S=1,ED=1] 15: !Use the following call for ;
4: L P[2] 250mm/sec FINE 16: !fixture-based wear measurement ;
SPOT[SD=1,P=1,t=2.0,S=1,ED=1] 17: !Parm1: gun number ;
5: L P[3] 250mm/sec FINE 18: !Parm2: new tips ;
SPOT[SD=1,P=1,t=2.0,S=1,ED=1] 19: !CALL TW_UPDAT( 1, 0 ) ;
6: IF DI[10]=ON, R[1]=1 20: CALL TW_UPDAT(1,R[1]) ;
7: IF DI[10]=OFF,R[1]=0 [END]
8: CALL TW_UPD01
9: WAIT DI[10]=OFF
10: J P[5] 250mm/sec CNT100
[END]
POINT SPOT TOUCHUP > POINT SPOT TOUCHUP >

User Program Tip wear down measurement program

6.5 ONE-STEP MEASUREMENT METHOD

Procedures for ONE-STEP Measurement (ex. Gun =1)
The One-Step measurement uses the macro programs WR_SETUP and WR_UPDAT to perform the initial
setup and update tasks respectively.

6.5.1 Initial Setup

1. Copy WR_SET01、to a new program (name) if necessary, and modify the instructions.
Ex) WR_SET02.TP : for setup gun 2

WR SET01 Set correct gun number

10/11
7: !fixture-based wear measurement ;
8: !Parm1: gun number ;
9: !CALL WR_SETUP( 1 ) ;
10: CALL WR_SETUP(1) ;

POINT SPOT TOUCHUP >

2. Execute the newly created program. Only the gun should move. Check gun axis speed, and then
execute it finally with override 100% (AUTO mode or T2 mode).

NOTE
If WR_SET01 is not found on program list, set $SGSYSCFG.$LOAD_TWD＝11, and
then repower controller.
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6.TIP WEAR DOWN COMPENSATION B-83264EN/03

WARNING
If motor is replaced, or gun hardware is overhauled in maintenance, gun character is
changed. In this case, perform gun autotune, pressure calibration, and setup
program of tip wear measurement again.
If shank or gun arm are replaced, TCP is changed. In this case, correct TCP, and
then perform setup program of tip wear measurement again.

NOTE
When setup program of tip wear measurement is performed, the following
WARNING is posted.
SVGN-178 Open/CloseLim = XXX mm/ YYY mm
This indicates standard stroke limit that is compensated according to wear down.
If this stroke limit is not correct, gun could not press correctly.
About compensated stroke limit, refer to 6.10 for more detail

6.5.2 Update Amount of Wear Down

1. Set wear ratio (This step is not necessary if default wear ratio (=0.5) is used.).The wear ratio is defined
as the fraction of total wear that is assigned to the robot tip
a. Open the program WR_UPDAT
b. Find the line that calls twkcal2, as shown (highlighted) below
c. Set the 1st argument to the wear ratio you desire. (Default = 0.5, equal wear on each tip)

WR_UPDAT
60/66
53: LBL[1] ;
54: ;
55: !Update wear amounts ;
56: !Param1: 0<=Robot wear ratio<>1.0 ;
57: !RbtTipWear = ( rbtwr_ratio * ;
58: ! total wear ) ;
59: !Parm2: New tip installed ; 0: all wear is assigned to the moving tip
60: CALL TWKCALC2(0.5,AR[2]) ; 1: all wear is assigned to the robot tip
61: ;
62: !Move gun to PR ; 0<Wear ratio<1: wear is assigned to both
63: ! Parm1: Velocity label ; tips
64: ! Parm2: Position register index ;
65: CALL TW_MVGUN(1,20) ;

[INST] [EDCMD] >

2. Copy WR_UPD01、to a new program (name) if necessary, and modify the instructions.
Ex) WR_UPD02.TP : for update gun 2

WR UPD01
20/20
16: !fixtureless wear measurement ;
Normally set ‘0’ for worn tip.
17: !Parm1: gun number ; Set ‘1’ after installing new tip.
18: !Parm2: new tips ;
19: ! CALL WR_UPDAT( 1, 0)
20: CALL WR_UPDAT(1,0) ;

POINT SPOT TOUCHUP >

Set correct gun number

3. Set the arguments correctly for the wear measurement that is required. The arguments may be
specified indirectly by using data register.
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4. Run the WR_UPDAT macro any time an updated measurement is needed.:
-After tip change (set new tips flag)
-After tip dress
-After pre-determined number of welds or parts
-Whenever an updated wear measurement is desired

WARNING
During performing setup/update, TWZRCLB2.TP which are internal program for tip
wear measurement, is visible status.
Do not edit or delete these

NOTE
Perform setup/update for per gun. Confirm gun number is correct.

WARNING
In case of 1 step measurement method, replace both tip at installing new tip, and
then update wear down. If only one side tip is replaced, wear down is not match to
actual wear down.

NOTE
If wear update program is executed with new tip and init setup program is executed
again with the new tip, then SVGN-187 occurs. Because once wear update program
is executed, the tip is regarded as worn tip. Before init setup program is executed,
perform gun zero mastering or reset wear down amount.

6.5.3 ONE-STEP Measurement with Multi Task

During 1step measurement method, only gun axis moves. Using multi task, 1step measurement method can
be executed together robot motion. For example, during robot returns to home position after tip dress, 1step
measurement method can be executed. Please refer to the following sample.

Main program
PSN0001
7/10
:
4: ;
5: CALL SPOT_WELD ;
6: CALL TIP_DRESS ;
7: RUN WR_UPD01 ;
8: CALL MOV_TO_HOME ;
9: ;
:
[END]

POINT SPOT TOUCHUP >

Return to HOME Update wear down

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MOV_TO_HOME _ TW_UPD01
1/5
1: L P[1] 1500mm/s ｲﾁｷﾞﾒ ; 20/21
2: L P[2] 1500mm/s ﾅﾒﾗｶ 100 ; 18: !Parm2: new tips ;
3: L P[3] 1500mm/s ﾅﾒﾗｶ 100 ; 19: ! CALL WR_UPDAT( 1, 0)
4: L PR[1:HOME] 1500mm/s ﾅﾒﾗｶ 100 ; 20: CALL WR_UPDAT(1,R[1]) ;
5: WAIT R[2:UPDT COMP]= 1 21: R[2:UPDT COMP]=1 ;
[END] [END]

POINT SPOT TOUCHUP > POINT SPOT TOUCHUP >

Both of returning to home position and updating wear down is performed at same time. In
this sample, robot wait for updating wear down.

NOTE
In case using multi task, do not specify group mask of gun to robot motion program
that is MOV_TO_HOM.TP in the above sample.

WARNING
During updating wear down with 1 step measurement method, do not change
servo gun posture largely with robot motion. Large changing posture would cause
mis-mastering or mis-detection.
There are another instance that stationary gun updates wear down during robot handles/replaces
panel.

6.6 COMBINATION 2 STEP METHOD AND 1 STEP METHOD

6.6.1 Overall
Combination 2 step method and 1 step method bring in the following benefit.
- Decrease cycle time by decreasing time to perform 2 step method.
- Improve accuracy of 1 step method.

NOTE
Please refer to section 6.7 about auto updating wear ratio.

6.6.2 Procedure to Use

Procedure

1. Specify initial wear ratio via tip wear standard screen if you want to change the value.
See section 6.6.4.

NOTE
Definition of wear ratio for 1 step method is decided by initial setup.
If initial set up of 1 step method (WR_SETUP) is executed, wear ratio is defined on
WR_UPDAT macro.
If initial set up of 2 step method (TW_SETUP) is executed, wear ratio is defined on
tip wear standard screen.

2. Perform initial setup with 2 step method. Execute TW_SETUP macro program.
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The procedure and notice of execution is same as normal 2 step method.

NOTE
After initial setup of 2 step method complete, this function can switch auto updating
wear ratio to enable/disable in any time.
Please refer to section 6.7 about auto updating wear ratio.

3. After tip dress, it is allowed to update wear down amount with 1 step method. Execute WR_UPDAT
macro program. The procedure and notice of execution is same as normal 1 step method.

4. When tip has been dressed with several times (wear down amount is increased), perform 2step method to
update wear ratio. In the case to update wear ratio, execute TW_UPDAT macro program without
new tip flag. Measurement of wear down and calculation of wear down are complete successfully, and
then wear ratio is updated automatically.

6.7 OPERATIONAL SETTING AND ALARM PROCESSING

6.7.1 Tip Wear Detect Setup Screen

In this screen, user can setup about measurement and Alarm process

SETUP Servogun _ SETUP Servogun

GENERAL / EQ:1 Gun:1 8/13 TIP WEAR DETECT / EQ:1 Gun:1 8/15
1 Tip Wear Comp DISABLE
2 Gun Sag compensation DISABLE 1 Common setup: <*DETAIL*>
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1 [+Z ] 2 Detection type: LOAD
5 Max Motor Torque(%): 140.0 3 Margin of load(nwt): 294
6 Max Pressure (nwt): 4903.3 4 Tip speed(mm/sec): 20
Max Gun Torque(%): 45.0 5 Mis-detect toler.(mm): 5.00
7 Tip stick detect distance(mm): 5
8 Tip Wear Detection: <*DETAIL*> Maximum wear check(Gun)
9 Pressure Cal: COMP <*DETAIL*> 6 Max wear value(mm): 0.00
10 Tip Wear Standard: INCOMP <*DETAIL*> 7 Inform signal: DO[ 0]
11 Thickness check: <*DETAIL*> 8 Increased error(mm): 0.00
12 Gun Stroke limit: <*DETAIL*> Maximum wear check(Robot)
13 OverTorque protection: <*DETAIL*> 9 Max wear value(mm): 0.00
10 Inform signal: DO[ 0]
11 Increased error(mm): 0.00
Auto update wear down ratio
12 Update Enb/Dsb: DISABLE
Update status: INACTIVE
13 Max Wear ratio limit: 0.70
14 Min Wear ratio limit: 0.30
15 Severity for limit over: WARN

[TYPE] EQUIP GUN > [TYPE] EQUIP GUN END >

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6.7.1.1 Setup for tip wear down measurement

These are items that are used in measurement. Basically, it is not necessary to change it. It is necessary to
re-execute SETUP, if these items are change.

Setup Items Description

Common Pressure Schedule Number of the pressure schedule to use for the re-master step of tip wear
setup (Default = 98) measurement. Do not use this schedule for other tasks or for welding
Start distance Number of the start distance schedule to use for the re-master step of tip
Schedule wear measurement. Do not use this schedule for other tasks or for welding
(Default = 98)
Open Gun at Restart ENABLE/DISABLE, specifies whether the gun is opened to the start
(Default = ENABLE) distance before retry after a mis-detection.
Retry times no. of times the re-master step is re-tried when a mis-detection is observed.
Detection Type LOAD or DO is available. All the programs described in this document
( Default : LOAD) assumes the LOAD technique is used. DO (Digital Output) requires an
external visual sensor to measure wear instead of a fixture-touch.
Margin of Load This is the amount of force(load) in addition to the gun friction (measured
(Default = 30 kgf) during tip wear setup/initialization) that will be applied to detect the fixture
touch. This value is set automatically by the software based on the servo
gun max pressure, but the user can override this value.
Tip Speed(mm/sec) set by default to 30mm/sec, this is the maximum speed the tip will close to
(Default = 30 mm/sec) the fixture at during the fixture-touch step of a two-step measurement. The
user can increase this value experimentally if needed. This value must be
set before running the TW_SETUP program, so that TW_SETUP uses the
same fixture touch speed that TW_UPDAT uses. Using the same tip speed
for each measurement is critical for accurate results.
Mis-detect toler(mm) set by default to 5mm. This is how much tip growth is acceptable between
(Default = 5 mm ) the “reference tips” and the present tips (“reference tips” are the tips that
were used during initialization). If a tip growth in excess of this amount is
observed it will be deemed a mis-detection and the measurement will be
re-tried by the number of times listed in the “Common Setup” before posting
a “Tip Wear Down misdetection’ fault.

6.7.1.2 Setup for tip wear down alarm process

These are items that are used in alarm process for each tip.

Setup Items Description

Maximum Wear Down Value The user specifies the maximum wear that can be measured on either the gun
tip or the robot tip before the Maximum Wear Exceeded WARNING and Inform
Signal [DO] is activated. Typical values are between 4-7mm
The error messages that occur when max wear down value is exceeded are:
SVGN-118 Max wear exceeded (Gun Tip).
SVGN-119 Max wear exceeded (Rbt Tip).
Inform Signal this is the digital output that is turned on when the measured wear exceeds the
specified Maximum Wear Down Value.
Increased error this is the maximum tip growth that can be observed (compared to the previous
tip wear measurement) before the Tip Increased Error fault is asserted. The
only case where a longer tip would be expected is at tip change. Setting the
new tip flag to 1in the TW_UPDAT or WR_UPDAT program, prevents the
Increased error from being checked so that no alarm is posted when tips are
changed. Typical settings for this item are 1-2mm.

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NOTE:
The Tip Increased error informs the user that the tip wear program observed the tips
touching each other or the fixture before it did on the previous wear measurement (by
an amount >= tip increased error(mm) setting). When this happens consider the
following possible causes:
• A piece of metal from tip dressing operation remained on the tip making it longer.
Remove the excess metal.
• New tips were placed on the gun, but the new tips flag was not set in the update
program or the tips were not properly seated. Properly seat the tips, then set the
new tips flag and run the update program again.
• The fixture-touch tip speed was slower than it was during the previous wear
measurement. Keep the fixture-touch tip speed consistent.
• The fixture-touch or re-master position was mis-detected (sensed too soon). This
can happen if the fixture position has shifted relative to the robot, the gun friction
has changed or the Margin of Load is set too small. When using the two-step
measurement, increase the Margin of Load if the fixture does not bend. If this
does not work re-execute the Initialization Procedure and determine why the gun
friction has changed.

WARNING
When tip increase error occurs, measured wear down amount that shows increase
error is reset automatically, then recover last wear amount temporary. As son as
eliminate cause of tip increase error, update wear down again.
NOTE
In the latest software version, when tip increase error occurs, the following massage
is posted as cause code.
SVGN-186 Wdn: Old: xx.x mm->New: yy.y mm
“Old: xx.x mm” indicates the last wear down amount before updating. “New: yy.y
mm” indicates updated wear down amount that shows increase error. Difference
of both ( = Old – New ) means increase error amount.

NOTE
Inform signal(DO) can be output when tip increase error occurs. Specify index of the
inform signal to the following variable.
$SGGUN#.SETUP.$TIPINCIOIDX(# is gun number): This variable is signal index
for gun tip increase error.
$SGGUN#.SETUP.$RBTINCIOIDX(# is gun number) : This variable is signal index
for robot tip increase error.

6.7.1.3 Setting of calculation and updating wear ratio

It set up basic item about calculation and updating wear ration in tip wear detection screen.

Setup Items Description

Update Enb/Dsb Enable: Wear ratio is calculated and updated automatically.
Default: DISABLE Disable: Wear ratio is not calculated and updated.
Prompt massages are posted at changing item. Follow the prompt
massage.

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Setup Items Description

Update status ACTIVE: 2 step method can update wear ratio.
Default: INACTIVE INACTIVE: 2 step method does not update wear ratio.
This item is changed by Update Enb/Dsb and init setup status. Operator
can not change this directly.
Max Wear ratio limit This specifies maximum limit value to update wear ratio. If calculated wear
Default: 0.7 ratio is larger than this value, wear ratio is not updated.
Min Wear ratio limit This specifies minimum limit value to update wear ratio. If calculated wear
Default: 0.3 ratio is smaller than this value, wear ratio is not updated.
Severity for limit over This specifies severity of alarm that occurs if calculated wear ratio is out of
Default: WARN tolerance.
WARN: Severity is WARNING. Program does not pause if alarm occurs.
FAULT: Severity is FAULT. Program pauses if alarm occurs.

6.7.1.4 Confirmation of wear ratio

It confirms wear ratio in tip wear standard screen.
See section 6.7.2.

6.7.2 Tip Wear Standard Screen

User can see and check some data about tip wear down compensation in this screen.

Fixture-based Measurement(Two-step)
SETUP Servogun _ SETUP Servogun
GENERAL / EQ:1 Gun:1 8/13 TIP WEAR STANDARD / EQ:1 Gun:1 1/3
1 Tip Wear Comp DISABLE
2 Gun Sag compensation DISABLE 1 Tip Wear value(Gun)(mm) 0.00
3 Close Direction(Gun): PLUS 2 Tip Wear value(Robot)(mm) 0.00
4 Close Direction(Robot): UT: 1 [+Z ] 3 Wear ratio for 1 step: *******
5 Max Motor Torque(%): 140.0
6 Max Pressure (nwt): 4903.3 Detect load(nwt):COMPLETE 294
Max Gun Torque(%): 45.0 Standard tip
7 Tip stick detect distance(mm): 5 Master count: COMPLETE 34886729
8 Tip Wear Detection: <*DETAIL*> Opening(mm): COMPLETE 13.7
9 Pressure Cal: COMP <*DETAIL*>
10 Tip Wear Standard: INCOMP <*DETAIL*>
11 Thickness check: <*DETAIL*>
12 Gun Stroke limit: <*DETAIL*>
13 OverTorque protection: <*DETAIL*>

[TYPE] EQUIP GUN > [TYPE] EQUIP GUN END >

Fixture-less Measurement(One-step)
SETUP Servogun
COMP: tip wear setup is complete TIP WEAR STANDARD / EQ:1 Gun:1 1/2

INCOMP: tip wear setup is incomplete 1 Tip Wear value(Gun)(mm) 0.00

2 Tip Wear value(Robot)(mm) 0.00

Standard tip
Master count: COMP 34886729

[TYPE] EQUIP GUN END >

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Setup Items Description

Tip Wear Value displays the present wear amount of each tip (WARNING: It is recommended to not
manually change these values)
Wear Ratio This indicates current wear ratio. This value is updated when wear ratio is calculated
Default: 0.5 correctly. If you want to specify initial wear ratio, change this value before initial setup.
Also, if auto updating wear ratio is disabled, *** is appeared.
Detect Load displays COMP if the fixture-touch setup/initialization has been executed and displays the
load measured during initialization to accurately detect the fixture
Master Count Displays COMP if the tip wear reference master has been executed and displays the
Pulsecoder count of that reference position
Opening (mm) displays COMP if the fixture-touch reference open position is valid and displays the opening
that was recorded as the reference open position during initialization.

WARNING
If incorrect wear ratio is specified, wear down amount will be incorrect, then wear
down compensation does not work correctly.
Note that manual changing wear ratio.

6.8 AUTO UPDATING WEAR RATIO

6.8.1 Overall
This function can calculate wear down automatically with actual dress amount. Actual dress amount is
measured by 2 step method, and then wear down is calculated and updated during production. 1 step
method can used the updated wear ratio. To measure dress amount and updating regularly can obtain
appropriate wear down according to dress trend in the time.

6.8.2 Procedure to Use

Procedure
1. Enable automatic updating wear down via tip wear detection screen.
See section 6.6.3.

NOTE
This setting can be change in any time after initial setup of 2 step method complete.

2. Specify initial wear ratio via tip wear standard screen if you want to change the value.
See section 6.6.4.
3. Perform initial setup with 2 step method. Execute TW_SETUP macro program.
The procedure and notice of execution is same as normal 2 step method.

NOTE
It is unnecessary to perform initial setup of 1 step method

4. After tip dress, it is allowed to update wear down amount with 1 step method. Execute WR_UPDAT
macro program. The procedure and notice of execution is same as normal 1 step method.
5. When tip has been dressed with several times (wear down amount is increased), perform 2step method to
update wear ratio. In the case to update wear ratio, execute TW_UPDAT macro program without
new tip flag. Measurement of wear down and calculation of wear down are complete successfully, and
then wear ratio is updated automatically.

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NOTE
If tip hardly is worn, wear ratio can not be calculated accuracy.
It recommends performing 2 step method to update wear ratio when total wear
down amount is changed by 2,3mm.

NOTE
When wear ratio is updated correctly, the following warning massage is posted.
(Value are example )
SVGN -282 Wear ratio updated:0.5->0.65
The above massage example shows wear ratio is changed from 0.5 to 0.65.

NOTE
When wear ratio is calculated, if the ratio is larger than 1.0 or smaller than 0.0, the
following warning massage is posted. (Value are example )
SVGN -283 Wear ratio(-0.5) Not updated
Together SVGN-285, either following massage is posted as cause code.
SVGN-284 Gun: 6.0 => 3.0,Rbt: 3.0=>4.0
SVGN-284 shows the wear down that is measured by the last 2 step method and
wear down that is measured by current 2step method. The above massage example
shows, wear down amount of gun tip changes from 6.0mm to 3.0mm.
Even if these warning are posted, measured wear down amount is updated and
applied to compensation. However only wear ratio is NOT updated.

NOTE
When wear ratio is calculated, if the ratio is larger than maximum limit or smaller
than minimum limit, the following warning massage is posted. (Value are example )
SVGN -285 Wear ratio Out of Tolerance
Together SVGN-285, either following massage is posted as cause code.
SVGN-286 Wear ratio:0.81 > Max:0.7
SVGN-287 Wear ratio:0.7 < Min:0.81
Even if these warning are posted, measured wear down amount is updated and
applied to compensation. However only wear ratio is NOT updated.

NOTE
SVGN-283 or SVGN-285 occurs when wear down is grown from wear down that is
measured by the last 2 step method.
The main cause ;
- When cap is replaced, 2 step method (TW_UPDAT macro) is performed without
new tip flag.
- Twice 2 step method are performed continually if wear down hardly changes.

6. It necessary to perform 2 step method when cap tip is replaced. Perform TW_UPDATE macro
program with new tip flag.

WARNING
If 2 step method is performed without new tip flag when cap tip is replaced, incorrect
wear ratio is updated. After that, wear down can NOT be measured correctly.

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NOTE
2 step method of when cap tip is replaced does not calculate and update wear ratio.

NOTE
When updating wear ratio is enabled, it is allowed to replace each cap tip.

NOTE
When perform 1 step method with new tip flag, the following warning occurs.
SVGN-374 Wear ratio update Locked.
SVGN-288 New tip! Use 2step TWD
If this warning occurs, next 2 step method does not update wear ratio. And until
next 2 setup method is performed, wear down of robot tip by 1 step method is
assigned with wear ratio of all wear down. This value is same as original wear
down by 1 step method. As possible as, perform 2 step method.

NOTE
When 2 step method is performed after1 step method with new tip flag, the
following warning occurs.
SVGN-374 Wear ratio update Locked.
SVGN-375 Next 2step TWD updates wear ratio
If this warning occurs, this 2 step method does not update wear ratio. Next 2 step
method update wear ratio. About this warning, it does not need any remedy.

6.8.3 Sample for Introduction

The following flowchart shows a sample to introduce and manage this function for reference.
Apply management according to actual user’s production system with this sample specification.

This sample flowchart is created by the following specification.

- R[1]~R[3] store the last wear down amount.
- R[4]~R[6] store wear down amount of the last 2step method.
- After tip dress, compare the last wear down amount to wear down amount of the last 2step method.
- If the difference is larger than 2.0mm, it seems that wear down amount increases since the last 2step
method.
Then, it performs 2 step method, and update to new wear ratio. New wear ratio is used by the next 1step. In
this time, R[4]~R[6] is updated, these values is reference to check the next updating wear ratio.
- If the difference is smaller than 2.0mm, it does not seem that wear down amount increases much. In this
case, it performs 1 step method with current wear ratio.
- Therefore, in this specification, wear ratio is updated by 2.0mm of wear down increasing.
- If measured wear down amount is larger than maximum wear down amount, new cap tip is installed. Then,
it performs 2 step method. In this time, R[4]~R[6] is updated. These values is reference to check the next
updating wear ratio. However, wear ratio is not updated when new cap tip is installed.
- After measurement wear down amount, R[1]-R[3] are always updated. These values is reference to check
the next updating wear ratio.

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Auto updated wear ratio is enabled

Specified initial wear ratio

CALL TW_SETUP(1)

R[1:Gun wear] = 0
R[2:Robot wear] = 0
R[3:Total wear] = 0
R[4:Gun wear2] = 0
R[5:Robot wear2] = 0
R[6:Total wear2] = 0

Production

R[1:Gun wear] = $SGGUN1.$SETUP. $WRDWN_TIP

R[2:Robot wear] = $SGGUN1.$SETUP. $WRDWN_RBT
Tip Dress R[3:Total wear] = R[1:Gun wear] + R[2:Robot wear]

NO
R[3:Total wear]-R[6:Total wear2] ] > 2.0

YES

CALL TW_UPDAT(1,0) CALL WR_UPDAT(1,0)

R[4:Gun wear2] = $SGGUN1.$SETUP. $WRDWN_TIP

R[5:Robot wear2] = $SGGUN1.$SETUP. $WRDWN_RBT
R[6:Total wear2] = R[1:Gun wear] + R[2:Robot wear]

NO
Max wear down over ?

YES

Install new cap tip

CALL TW_UPDAT(1,1)

R[4:Gun wear2] = $SGGUN1.$SETUP. $WRDWN_TIP

R[5:Robot wear2] = $SGGUN1.$SETUP. $WRDWN_RBT
R[6:Total wear2] = R[1:Gun wear] + R[2:Robot wear]

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6.9 DATA RECOVERY

6.9.1 Recovery Mastering Data

When mastering data is lost for the servo gun, the tip wear reference data gathered during the initial setup is
invalidated and must be recovered too. Mastering data is lost when the BZAL occurs, typically caused
when the pulse cable is disconnected or damaged.

Recovery by Gun Zero Master Utility

1. Gun zero master utility can recover mastering data. Please refer to Appendix C for using Gun zero
master utility.
2. Re-run the tip wear Update program.(TW_UPD01 if the two-step method is used.)
3. Confirm the robot tip locations. Touch-up position if it is requested

6.9.2 Recovery from Lost of Tip

When tip is lost or damaged, the tip will have to be changed on the spot. If user would like to continue
welding without update wear down amount in this case, please run reset macro program for replaced tip.
Beforehand, user have to create macro program. The created macro program also can be assigned to DI.
This assignment can reset wear down amount during program pausing.
There is sample macro programs for gun 1 in the next page. Please refer for your system.
Gun tip is broken ! Replace new tip Reset wear down amount of gun tip

Broken tip cannot Continue

continue welding.

NOTE
Please update wear down amount after the welding cycle.

NOTE
Please execute wear amount reset macro program when robot and servo gun are
not moving. If macro program is called in TP program, specified FINE to motion
instruction just before calling or specified WAIT instruction.

Reset macro requests one register. It is no problem that the register is same as one of other tip wear macro
programs

Ex）
Reset target : Gun 1
・Register number : R[10]

Reset macro program for movable tip of gun 1: TWRSMV1.TP （Group mask[*,*,*,*,*]）
CALL TWKRSMOV( 1, 10 ) Reset wear down amount of movable tip
!arg1:Always 0.
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CALL TWKSTROK( 0 ) Change stroke limit. Set 0 as argument

CALL TWKRSCLB( 10 ) Recovery mastering
Reset macro program for fixed tip of gun 1: TWRSFX1.TP （Group mask[*,*,*,*,*]）
CALL TWKRSFIX( 1, 10 ) Reset wear down amount of fixed tip
!arg1:Always 0.
CALL TWKSTROK( 0 ) Change stroke limit. Set 0 as argument
CALL TWKRSCLB( 10 ) Recovery mastering
NOTE
In case of using 1 step measurement (WR_SET01 and WR_UPD01), replace both
tips at the same time even if one of tips is normal. Then run both of reset macro
program for movable /fixed tip.
It is no problem about the order of running.

6.10 ACTIVE STROKE LIMIT PROTECTION

Tip Wear Compensation determines the servo gun stroke limits automatically. Please notice the following
about the stroke limit protection:

1. The close stroke limit is the distance past the reference zero position that the gun axis can advance (not
the present zero position)
2. If either robot tip or gun tip is worn, a tip opening distance larger than the open stroke limit is not
allowed.
3. When mastering data is lost, the gun stroke limits are invalided and one of the procedures from the
“Recovery from loss of mastering” section must be used to recover the proper stroke limits
4. Standard stroke limit is set by setup program of tip wear measurement. “SVGN-178 Open/CloseLim =
XXXmm/YYYmm” indicate it.
5. When the setup program is performed again with worn tip, compensated stroke limit is applied to
standard stroke limit. Perform gun zero mastering with new tip before performing the setup program.

See the visual example below:

Open Stroke
Limit (60mm)
New Master Tips 10mm Worn Tips
60mm 60mm from Servo Gun
from new worn tips PLUS (+)
zero
tips zero direction
REFERENCE
ZERO LINE
20mm from Worn tips 10mm from reference zero
new tips zero Zero Line 10mm from worn
Close Stroke tips zero
Limit (20mm)

Summary of Stroke Limit behavior:

Wear value Stroke Limit value
Close Stroke Limit Open Stroke limit
Total Wear > 0 Original Close Stroke Limit MINUS total tip Original Open Stroke Limit (does not
wear increase with tip wear)
Total Wear < 0 (growth<= Original Close Stroke Limit (does not Original Open Stroke Limit (does not
tipchgtol) increase with tip growth) decrease with tip growth)
Total Wear < 0 (growth> Original Open Stroke Limit MINUS
tipchgtol) $sggun#.$sgtwd.$tipchgtol

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Due to the active stroke limit protection that Tip Wear Compensation provides, the following procedure
should be followed to completely disable the active stroke limit control when tip wear compensation is no
longer required, after it was already initialized:

Procedure to disable Tip Wear Compensation and its active stroke limit control:
1. Perform gun zero mastering with New Tips.
2. Confirm/Set the Gun Stroke Limits to the proper value if they are not already
3. Set Tip Wear Comp to DISABLE on Servo Gun General Setup Page
4. Set the sysvar $SGGUN#.$SGTWD.$PHASE = 0 (where # is the gun number)
5. Re-power controller.

NOTE
Perform the setup program again if you want to enable tip wear compensation. Stroke
limit is compensated after performing the setup program.

WARNING
Do not change $SGGUN#.$SGTWD.$PHASE in except the above case. Because
this is status variable. If it was changed, tip wear compensation would work wrong.

6.11 COMPATIBILITY OF TIP WEAR MEASUREMNET

PROGRAMS
The following descript about compatibility of tip wear measurement programs before R-30iA

Tip wear measurement programs that are used on R-J3iB

These programs can not be supported on R-30iB. According to later description, modify user programs.

Tip wear measurement programs that are used on R-30iA

i. Case of using KAREL programs that are provided since R-30iA
These programs can be supported on R-30iB without user program’s modification.
Also, TW_SETUP,TW_UPDAT,WR_SETUP,WR_UPDAT macro programs can be supported, too.

ii. Case of using TP programs that have been provided at R-J3iB

These programs cannot be supported on R-30iB. According to later description, modify user programs.

NOTE
When tip wear measurement programs provided at R-J3iB is executed, SVGN-392
“This TW**.TP is not supported” occurs. According to later explanation, modify user
Programs.

Modification user programs

Please rename subroutine TP program of R-J3iB to subroutine KAREL program of R-30iB in user
programs for using R-J3iB user program. Please refer to the following table for renaming.

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No CALLING R-J3iB TP PROGRAM CALLING R-30iB KAREL PROGRAM

1 CALL TW0THOLD( #1, #2, #3 ) CALL TWKTHOLD( #1, #2, #3 )

2 CALL TW1MTCLB( #1, #2, #3 ) CALL TWKZRCLB( #1, #2, #3 )

3 CALL TW1MTFIX( #1, #2, #3 ) CALL TWKFXTCH( #1, #2, #3 )

4 CALL TW2WDCLB( #1, #2, #3 ) CALL TWKZRCLB( #1, #2, #3 )

5 CALL TW2WDFIX( #1, #2, #3 ) CALL TWKFXTCH( #1,#2,#3,#4)

6 CALL TW3RSCLB( #2 ) CALL TWKRSCLB( #2 )

#1:Gun number
#2:Register number
#3:Position register number
#4:New tip flag
New tip : 1
Worntip : 0

NOTE
• The order of argument is same as R-J3iB.except No.5.Please set the same
number.
• About No.2,No.4 and No.3,No.5, use common KAREL program.
• About No.3, user not have to add new argument.

SAMPLE
R-J3iB User Program R-30iB User program
TIP MST TIP_MST

： ：
3: L P[1:PRESS] 250mm/sec FINE 3: L P[1:PRESS] 250mm/sec FINE
4: CALL TW0THOLD(1,10,20) 4: CALL TWKTHOLD(1,10,20)
5: CALL TW1MTCLB(1,10,20) 5: CALL TWKZRCLB(1,10,20)
6: L P[2:FIXTUE] 250mm/sec FINE 6: L P[2:FIXTUE] 250mm/sec FINE
7: CALL TW1MTFIX(1,10,20) 7: CALL TWKFXTCH(1,10,20)
： ：

POINT SPOT TOUCHUP > POINT SPOT TOUCHUP >

About New tip flag

Please add argument at renaming of No.5.
Added argument judges either new tips measurement or worn tip measurement.

New tip measurement : CALL TWKFXTCH(1,10,20, 1 )

Worn tip measurement :CALL TWKFXTCH(1,10,20, 0 )

Please refer to the following examples

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B-83264EN/03 6.TIP WEAR DOWN COMPENSATION
Ex1: Using register for new tip flag ( For example R[99] )
R-J3iB User Program R-30iB User program
TI MEAS TI MEAS

： ：
3: L P[2:FIXTUE] 250mm/sec FINE 3: L P[2:FIXTUE] 250mm/sec FINE
4: CALL TW1MTFIX(1,10,20) 4: CALL TWKFXTCH(1,10,20,R[99])
： ：

POINT SPOT TOUCHUP > POINT SPOT TOUCHUP >

R[99]=1 : New tip measurement

R[99]=0 : Worn tip measurement

Ex2: Using register for new tip flag ( For example DI[1] )
R-J3iB User Program R-30iB User program
TI_MEAS TI MEAS

： ：
3: L P[2:FIXTUE] 250mm/sec FINE 3: L P[2:FIXTUE] 250mm/sec FINE
4: CALL TW1MTFIX(1,10,20) 4: IF DI[1]<>ON JUMP LABEL[100]
： 5: CALL TWKFXTCH(1,10,20,1)
6: JUMP LABEL[200]
7: LABEL[100]
8: CALL TWKFXTCH(1,10,20,0)
7: LABEL[200]
：
POINT SPOT TOUCHUP > POINT SPOT TOUCHUP >

DI[1]=ON : New tip measurement

DI[1]=OFF : Worn tip measurement

6.12 TIP WEAR DOWN COMPENSATION FOR

MULTI-EQUIPMENT

6.12.1 Standard Tip Wear Program List for Multi-Equipment

The following TP programs for multi-equipment are included in the TP program list when the Servo Gun
option is installed. Use these TP programs to perform the tip wear initial setup and update tasks from eq2 to
eq5.

TP program are not prepared at each equipment. Copy and use these TP programs.

NOTE
Tip wear down compensation for multi-equipment has been supported since software
version 7DC2P02.

Default TP Function
program name
If $SGSYSCFG. $LOAD_TWD＝15 the following programs are loaded
TW_SET0X This initializes tip wear data for the 2-step method. This program cannot be executed at the same time with
two or more equipments.
Copy and use this TP program.
Ex.) Eq2: TW_SET0X → COPY → TW_SET02
TW_UPD0X This measures the tip wear using the 2-step method. This program can be executed at the same time with
two or more equipments.
Copy and use this TP program.
Ex.) Eq2: TW_UPD0X → COPY → TW_UPD02

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6.TIP WEAR DOWN COMPENSATION B-83264EN/03

Default TP Function
program name
WR_SET0X This initializes tip wear data for the 1-step method. This program cannot be executed at the same time with
two or more equipments.
Copy and use this TP program.
Ex.) Eq2: WR_SET0X → COPY → WR_SET02
WR_UPD0X This measures the tip wear using the 1-step method. This program can be executed at the same time with
two or more equipments.
Copy and use this TP program.
Ex.) Eq2: WR_UPD0X → COPY → WR_UPD02

6.12.2 Initial Setup of 2-step method for Multi-Equipment

1. Set $SGSYSCFG.$LOAD_TWD＝15, and then repower controller. TW_SET0X will be loaded.
2. Copy TW_SET0X to another name. (After this, TW_SET02 is used to explain as an example.)
Ex.) Eq2: TW_SET0X → COPY → TW_SET02
3. Confirm robot group and gun group is match to group mask of TW_SET02.
4. Teach two positions in TW_SET02.

TW_SET02

1: !Initialize gun data ;

2: !parm1:gun number ;
3: CALL TWKINIT(...) ;
4: ;
5: !Move to posn away from fixture ;
6: !P1/Approach position for fixture ;
7: L P[...] 250mm/sec FINE ;
8: ;
9: !Set force threshold ;
10: !NOTE:Gun is opened via TWTTHOLD ;
11: ! parm1: gun number ;
12: ! parm2: data register ; Shift + F5
13: ! parm3: position register ;
14: CALL TWKTHOLD(... ... ...) ;
15: ;
16: !P1/Approach position for fixture ;
17:L P[...] 250mm/sec FINE ; Approach position for fixture (Ti ps tch )
18: ;
19: !Calibrate 0 with master tips ;
20: ! parm1: gun number ;
21: ! parm2: data register1 ;
22: ! parm3: position register ;
23: CALL TWKZRCLB(... ... ...) ;
24: ;
25: !P1/Approach position for fixture ;
26:L P[...] 250mm/sec FINE ;
Gun
27: ;
28: !Move to fixture position ; Shift + F5
29: !P2/Fixture touch position ;
30:L P[...] 250mm/sec FINE ; Robot
31: ;
32: !Measure open distance ;
33: ! parm1: gun number ;
34: ! parm2: data register1 ; Fixture touch position(Fix tch)
35: ! parm3: position register1 ;
36: CALL TWKFXTCH(... ... ...) ;
37: ;
38: !P2/Fixture touch position ;
39:L P[...] 250mm/sec FINE ;
40: ;
41: !Move to posn away from fixture ;
42: !P1/Approach position for fixture ;
43:L P[...] 250mm/sec FINE ;
44: ;
POINT SPOT TOUCHUP

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B-83264EN/03 6.TIP WEAR DOWN COMPENSATION

NOTE
• Confirm/Set robot group and gun group is match to group mask of TW_SET02.
• Specify same position ID to all approach position.
• Specify same position ID to all fixture touch position.
• Place robot tip away fixture with about 5 -10 mm when teaching 2 position.
nd

• Do not place gun tip on fixture when teaching 2 position.

nd

• The positions should be taught such that movement from Posn[1] to Posn[2] or
vice-versa does not cause any collision.
• These are the same points the robot will move to for the measurement of tip wear
during production. Be sure to consider this when calling the tip wear update
program in production.

5. Specify gun number, register number, and position register number. Don’t use these registers for
another purpose.

TW_SET02

1: !Initialize gun data ;

2: !parm1:gun number ;
3: CALL TWKINIT(...) ; TWKINIT(Gun number)
4: ;
5: !Move to posn away from fixture ;
6: !P1/Approach position for fixture ;
7:L P[...] 250mm/sec FINE ;
8: ;
9: !Set force threshold ;
10: !NOTE:Gun is opened via TWTTHOLD ;
11: ! parm1: gun number ;
12: ! parm2: data register ;
13: ! parm3: position register ;
14: CALL TWKTHOLD(... ... ...) ; TWKTHOLD(Gun number,
15: ; Register number,
16: !P1/Approach position for fixture ;
17:L P[...] 250mm/sec FINE ; Position register number)
18: ;
19: !Calibrate 0 with master tips ;
20: ! parm1: gun number ;
21: ! parm2: data register1 ;
22: ! parm3: position register ;
23: CALL TWKZRCLB(... ... ...) ; TWKZRCLB(Gun number,
24: ; Register number,
25: !P1/Approach position for fixture ;
26:L P[...] 250mm/sec FINE ; Position register number)
27: ;
28: !Move to fixture position ;
29: !P2/Fixture touch position ;
30:L P[...] 250mm/sec FINE ;
31: ;
32: !Measure open distance ;
33: ! parm1: gun number ;
34: ! parm2: data register1 ;
35: ! parm3: position register1 ;
36: CALL TWKFXTCH(... ... ...) ; TWKFXTCH(Gun number,
37: ; Register number,
38: !P2/Fixture touch position ;
39:L P[...] 250mm/sec FINE ;
Position register number)
40: ;
41: !Move to posn away from fixture ;
42: !P1/Approach position for fixture ;
43:L P[...] 250mm/sec FINE ;
44: ;
POINT SPOT TOUCHUP

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6.TIP WEAR DOWN COMPENSATION B-83264EN/03

NOTE
• Specify the same number to all gun number in TW_SET02.
• Specify the same number to all register number in TW_SET02.
• Specify the same number to all position register number in TW_SET02.
Ex.)
CALL TWKINIT(2) ;
CALL TWKTHOLD(2, 30, 31) ;
CALL TWKZRCLB(2, 30, 31) ;
CALL TWKFXTCH(2, 30, 31) ;

6. Execute TW_SET02. Check teaching positions and gun axis speed, then execute it finally with
override 100% (AUTO mode or T2 mode).

WARNING
TW_SET02 cannot be executed at the same time with two or more equipments.

6.12.3 Update Tip Wear Amount of 2-step method for

Multi-Equipment
1. Set $SGSYSCFG.$LOAD_TWD＝15, and then repower controller. TW_UPD0X will be loaded.
2. Copy TW_UPD0X to another name. (After this, TW_UPD02 is used to explain as an example.)
Ex.) Eq2: TW_UPD0X → COPY → TW_UPD02
3. Confirm robot group and gun group is match to group mask of TW_UPD02.
4. Teach two positions in TW_UPD02.

TW_UPD02

1: !Move to posn away from fixture ;

2: !P1/Approach position for fixture ;
3: L P[...] 250mm/sec FINE ;
4: ;
5: !Calibrate 0 with worn tips ;
6: ! parm1: gun number ;
7: ! parm2: data register1 ; Shift + F5
8: ! parm3: position register ;
9: CALL TWKZRCLB(... ... ...) ;
10: ;
11: !P1/Approach position for fixture ;
12:L P[...] 250mm/sec FINE ; Approach position for fixture (Ti ps tch )
13: ;
14: !Move to fixture position ;
15: !P2/Fixture touch position ;
16:L P[...] 250mm/sec FINE ;
17: ;
18: !Measure open distance ;
19: ! parm1: gun number ;
20: ! parm2: data register1 ;
21: ! parm3: position register1 ;
22: ! parm4: new-1/worn-0 ; Gun
Shift + F5
23: CALL TWKFXTCH(... ... ...,0) ;
24: ;
25: !P2/Fixture touch position ; Robot
26:L P[...] 250mm/sec FINE ;
27: ;
28: !Move to zero calibration posn ;
29: !P1/Approach position for fixture ; Fixture touch position(Fix tch)
30:L P[...] 250mm/sec FINE ;
31: ;

POINT SPOT TOUCHUP

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B-83264EN/03 6.TIP WEAR DOWN COMPENSATION

NOTE
• Confirm/Set robot group and gun group is match to group mask of TW_UPD02.
• Specify same position ID to all approach position.
• Specify same position ID to all fixture touch position.
• Approach position of TW_UPD02 should be the same as approach position of
TW_SET02.
• Fixture touch position of TW_UPD02 should be the same as fixture touch position
of TW_SET02.

5. Specify gun number, register number, and position register number. Don’t use these registers for
another purpose.

TW_UPD02

1: !Move to posn away from fixture ;

2: !P1/Approach position for fixture ;
3:L P[...] 250mm/sec FINE ;
4: ;
5: !Calibrate 0 with worn tips ;
6: ! parm1: gun number ;
7: ! parm2: data register1 ;
8: ! parm3: position register ;
9: CALL TWKZRCLB(... ... ...) ; TWKZRCLB(Gun number,
10: ;
11: !P1/Approach position for fixture ;
Register number,
12:L P[...] 250mm/sec FINE ; Position register number)
13: ;
14: !Move to fixture position ;
15: !P2/Fixture touch position ;
16:L P[...] 250mm/sec FINE ;
17: ;
18: !Measure open distance ;
19: ! parm1: gun number ;
20: ! parm2: data register1 ;
21: ! parm3: position register1 ;
22: ! parm4: new-1/worn-0 ;
23: CALL TWKFXTCH(... ... ...,0) ; TWKFXTCH(Gun number,
24: ; Register number,
25: !P2/Fixture touch position ;
26:L P[...] 250mm/sec FINE ; Position register number,
27: ; New tips parameter)
28: !Move to zero calibration posn ;
29: !P1/Approach position for fixture ; New tips parameter
30:L P[...] 250mm/sec FINE ;
31: ; 0: Worn tip (Normal)
1: New tip
POINT SPOT TOUCHUP

NOTE
• Gun number in TW_UPD02 should be the same as gun number in TW_SET02.
• Register number in TW_UPD02 should be the same as register number in
TW_SET02.
• Position register number in TW_UPD02 should be the same as position register
number in TW_SET02.

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6.TIP WEAR DOWN COMPENSATION B-83264EN/03

NOTE
• Specify the same number to all gun number in TW_UPD02.
• Specify the same number to all register number in TW_UPD02.
• Specify the same number to all position register number in TW_UPD02.
Ex.)
CALL TWKZRCLB(2, 30, 31) ;
CALL TWKFXTCH(2, 30, 31, 0) ;

6. Execute TW_UPD02.

WARNING
During performing setup/update, TWTHOLD2.TP, TWZRCLB*.TP, TWFXTCH*.TP,
which are internal program for tip wear measurement, is visible status.
Do not edit or delete these.

6.12.4 Initial Setup of 1-step method for Multi-Equipment

1. Set $SGSYSCFG.$LOAD_TWD＝15, and then repower controller. WR_SET0X will be loaded.
2. Copy WR_SET0X to another name. (After this, WR_SET02 is used to explain as an example.)
Ex.) Eq2: WR_SET0X → COPY → WR_SET02
3. Confirm gun group is match to group mask of WR_SET02.
4. Teach measurement start position and measurement end position in WR_SET02.

WR_SET02

1: !Initialize gun data ;

2: ! Parm1:gun number ;
3: CALL TWKINIT(...) ;
4: ;
5: !Move to 1STEP start position ;
6: !P1/1STEP start position for gun ;
7: L P[...] 250mm/sec FINE ;
8: ;
9: !Skip threshold measurement ;
10: !Increment phase(step) ;
11: ! Parm1:gun number ;
12: CALL TWKINCPH(...) ; Shift + F5
13: ;
14: !Calibrate 0 with master tips ; Open 20mm or more
15: ! parm1: gun number ;
16: ! parm2: data register1 ;
17: ! parm3: position register ;
18: CALL TWKZRCLB(... ... ...) ; Measurement sta rt po sition, Measurement end position
19: ;
20: !Skip fixture measurement ;
21: !Increment phase(step) ;
22: ! Parm1:gun number ;
23: CALL TWKINCPH(...) ;
24: ;
25: !Move to 1STEP start position ;
26: !P1/1STEP start position for gun ;
27:L P[...] 250mm/sec FINE ;
28: ;

POINT SPOT TOUCHUP

NOTE
Confirm/Set gun group is match to group mask of WR_SET02.

5. Specify gun number, register number, and position register number. Don’t use these registers for
another purpose.
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B-83264EN/03 6.TIP WEAR DOWN COMPENSATION

WR_SET02

1: !Initialize gun data ;

2: ! Parm1:gun number ;
3: CALL TWKINIT(...) ; TWKINIT(Gun number)
4: ;
5: !Move to 1STEP start position ;
6: !P1/1STEP start position for gun ;
7:L P[...] 250mm/sec FINE ;
8: ;
9: !Skip threshold measurement ;
10: !Increment phase(step) ;
11: ! Parm1:gun number ;
12: CALL TWKINCPH(...) ; TWKINCPH(Gun number)
13: ;
14: !Calibrate 0 with master tips ;
15: ! parm1: gun number ;
16: ! parm2: data register1 ;
17: ! parm3: position register ;
18: CALL TWKZRCLB(... ... ...) ; TWKZRCLB(Gun number,
19: ; Register number,
20: !Skip fixture measurement ;
21: !Increment phase(step) ; Position register number)
22: ! Parm1:gun number ;
23: CALL TWKINCPH(...) ; TWKINCPH(Gun number)
24: ;
25: !Move to 1STEP start position ;
26: !P1/1STEP start position for gun ;
27:L P[...] 250mm/sec FINE ;
28: ;

POINT SPOT TOUCHUP

NOTE
• Specify the same number to all gun number in WR_SET02.
• Specify the same number to all register number in WR_SET02.
• Specify the same number to all position register number in WR_SET02.
Ex.)
CALL TWKINIT(2) ;
CALL TWKINCPH(2) ;
CALL TWKZRCLB(2, 30, 31) ;

6. Execute WR_SET02. Check teaching positions and gun axis speed, then execute it finally with
override 100% (AUTO mode or T2 mode).

WARNING
WR_SET02 cannot be executed at the same time with two or more equipments.

6.12.5 Update Tip Wear Amount of 1-step method for

Multi-Equipment
1. Set $SGSYSCFG.$LOAD_TWD＝15, and then repower controller. WR_UPD0X will be loaded.
2. Copy WR_UPD0X to another name. (After this, WR_UPD02 is used to explain as an example.)
Ex.) Eq2: WR_UPD0X → COPY → WR_UPD02
3. Confirm gun group is match to group mask of WR_UPD02.
4. Teach measurement start position and measurement end position in WR_UPD02.

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6.TIP WEAR DOWN COMPENSATION B-83264EN/03

WR_UPD02

1: !Move to 1STEP start position ;

2: !P1/1STEP start position for gun ;
3: L P[...] 250mm/sec FINE ;
4: ;
5: !Calibrate 0 with worn tips ;
6: ! parm1: gun number ;
7: ! parm2: data register1 ;
8: ! parm3: position register ;
9: CALL TWKZRCLB(... ... ...) ;
10: WAIT 0.00(sec) ;
11: ;
12: !Reset ref to 0 before checking ; Shift + F5
13: !for wear error, if new tip ;
14: R[...]=... ; Open 20mm or more
15: IF R[...]<>1,JMP LBL[1] ;
16: CALL TWKRSWDN ;
17: LBL[1] ;
18: ; Measurement sta rt po sition, Measurement end position
19: !Update wear amounts ;
20: !Parm1: 0<=Robot wear ratio<=1.0 ;
21: !RbtTipWear = ( rbtwr_ratio * ;
22: ! total wear ) ;
23: !Parm2: New tip installed ;
24: CALL TWKCALC2(.5 ...) ;
25: ;
26: !Move to 1STEP start position ;
27: !P1/1STEP start position for gun ;
28:L P[...] 250mm/sec FINE ;
29: ;
POINT SPOT TOUCHUP

NOTE
Confirm/Set gun group is match to group mask of WR_UPD02.

5. Specify gun number, register number, and position register number. Don’t use these registers for
another purpose.

WR_UPD02

1: !Move to 1STEP start position ;

2: !P1/1STEP start position for gun ;
3:L P[...] 250mm/sec FINE ;
4: ;
5: !Calibrate 0 with worn tips ;
6: ! parm1: gun number ;
7: ! parm2: data register1 ;
8: ! parm3: position register ; TWKZRCLB(Gun number,
9: CALL TWKZRCLB(... ... ...) ;
10: WAIT 0.00(sec) ;
Register number,
11: ; Position register number)
12: !Reset ref to 0 before checking ;
13: !for wear error, if new tip ; 0: Worn tip (Normal)
14: R[...]=... ;
15: IF R[...]<>1,JMP LBL[1] ;
1: New tip
16: CALL TWKRSWDN ;
17: LBL[1] ;
18: ; Register number (14th line and 15th line are
19: !Update wear amounts ; same register numbers.)
20: !Parm1: 0<=Robot wear ratio<=1.0 ;
21: !RbtTipWear = ( rbtwr_ratio * ;
22: ! total wear ) ;
23: !Parm2: New tip installed ;
24: CALL TWKCALC2( .5 ...) ; 0: All wear is assigned to the moving tip
25: ; 1: All wear is assigned to the robot tip
26: !Move to 1STEP start position ;
27: !P1/1STEP start position for gun ; 0<Wear ratio<1: Wear is assigned to both tips
28:L P[...] 250mm/sec FINE ;
29: ;
ﾎﾟｲﾝﾄ ｽﾎﾟｯﾄ ｲﾁ修正

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B-83264EN/03 6.TIP WEAR DOWN COMPENSATION

NOTE
• Gun number in WR_UPD02 should be the same as gun number in WR_SET02.
• Register number in WR_UPD02 should be the same as register number in
WR_SET02.
• Position register number in WR_UPD02 should be the same as position register
number in WR_SET02.

6. Execute WR_UPD02.

WARNING
During performing setup/update, TWZRCLB*.TP which are internal program for tip
wear measurement, is visible status.
Do not edit or delete these.

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7.GUN SAG COMPENSATION B-83264EN/02

7 GUN SAG COMPENSATION

Compensating for gun sag (deflection) that may occur at pressurization will enable a spot welding sequence
to always be performed at an optimum position.

The gun sag compensation amount required is the deflection that occurs in the robot tip during
pressurization.

State with no gun deflection compensation State with gun deflection compensation

Gun deflection
compensation amount h ｈ

Compensation method
Gun deflection is compensated for by setting up the gun sag comp value in the Pressure Schedule and
pushing up the robot tip by the gun sag comp amount as pressure is applied.

Gun Sag Compensation amount setting method:

1. Press the DATA key to display the DATA screen
2. Press F1“[TYPE]” to display the pull-up menu.
3. Select “Pressure”. The servo gun Pressure Schedule list screen appears.
4. Press F4"DETAIL". The servo gun Pressure Schedule detail setting screen appears.
5. Input the gun deflection amount to the item " Gun Sag Comp Value (mm)" in the screen.

SERVO GUN DATA

PRESSURE / EQ:1 GUN:1 1/99
No. Press(Nwt) Manual Comment
1 3500.0 TRUE [ ]
2 1800.0 TRUE [ ]
3 0.0 FALSE [ ]
4 0.0 FALSE [ ]

[ TYPE ] EQUIP GUN DETAIL COPY >

SERVO GUN DATA

PRESSURE / EQ:1 GUN:1 1/4
1 Comment: [ ]
2 Standard Pressure(nwt): 3500.0
3 Gun Sag Comp Value(mm): 1.2
4 Weight compensation type: DISABLE

[ TYPE ] EQUIP GUN LIST

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B-83264EN/03 8.EXT. TIP STICK SIGNAL DETECTION

8 EXT. TIP STICK SIGNAL DETECTION

An external sensor can be supplied to detect continuity or stuck tips. This sensor can be mapped to an input
specified by the tip stick detect input. The state of this input will be checked after the weld complete signal
is received and the gun actuator reaches the position specified by the tip stick detect distance. The robot will
stop if the tips stick detect signal is still on at this specified opening.

NOTE
The user is required to prepare the equipment for detecting stuck tips and the tip
stick detection input signal.

Tip Stick Detect Input is the input from the external device that indicates the tips are stuck. This input must
be OFF when the gun opens past the tip stick detect distance, otherwise the robot will stop and issue the
following alarm:
“SVGN-030 SVAL1 Tip Stick Detection”

Tip Stick Detect signal setting method

Display the I/O screen by executing the following procedure
1. Press the MENU key to bring up the screen menu.
2. Select “I/O”.
3. Press F1“[TYPE]” to display the pull-up menu.
4. Select “Spot Equip”. The Spot I/O screen appears.
5. Specify the index of the “Tip stick detect” input on Spot Input screen.

I/O Weld In
10/10
NAME OUT PT SIM STATUS
1 Weld in process: DI[ 0] U ***
2 Weld complete: DI[ 0] U ***
3 WELD/NOWELD status: DI[ 0] U ***
4 Major alarm: DI[ 0] U ***
5 Minor Alarm: DI[ 0] U ***
6 Iso contactor on: DI[ 0] U ***
7 Cap change request: DI[ 0] U ***
8 Appr Cap change: DI[ 0] U ***
9 Tip dress request: DI[ 0] U ***
10 Tip stick detect: DI[ 0] U ***

[ TYPE ] IN/OUT >

Tip Stick Detect Distance is the tip opening at which the tip stick detect input will be checked to determine
if the tips are stuck. 1-5mm are typical values for this item.

Tip Stick Detect Distance setting method

Display the General Setup screen by executing the following procedure
1. Press the MENU key to bring up the screen menu.
2. Select “SETUP”.
3. Press F1“[TYPE]” to display the pull-up menu.
4. Select “Servo Gun”.
5. Select "General Setup". (Move the cursor on <*DETAIL*> and press ENTER key.) General Setup
screen for Servo Gun setup appears.
6. Specify "Tip stick detect distance(mm)"

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8.EXT. TIP STICK SIGNAL DETECTION B-83264EN/03

SETUP Servogun
GENERAL / EQ:1 GUN:1 7/13
1 Tip Wear Comp: DISABLE
2 Gun Sag Compensation: DISABLE
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1 [+Z]
5 Max Motor Torque(%): 100.0
6 Max Pressure(nwt): 4900.0
Max Gun Torque(%): 10.5
7 Tip stick detect distance(mm): 5
8 Tip Wear Detection: <*DETAIL*>
9 Pressure Cal: COMP <*DETAIL*>
10 Tip Wear Standrd: INCOMP <*DETAIL*>
11 Thickness check: <*DETAIL*>
12 Gun Stroke limit: <*DETAIL*>
13 OverTorque protection <*DETAIL*>

[ TYPE ] EQUIP GUN

Tip Stick Timing Output can be used to inform the PLC when the tip stick check was performed. Each time
the gun opens from the weld spot, the tip stick timing output is turned on when the gun reaches the opening
specified by the Tip Stick Detect Distance. This output turns on regardless of whether the tips are stuck or
not.

I/O Weld Out

12/12
NAME OUT PT SIM STATUS
1 Weld schedule: GO[ 0] U **********
Extended schedule: 0
2 Weld ID: GO[ 0] U **********
3 Weld parity: DO[ 0] U ***
4 Schedule strobe: DO[ 0] U ***
5 Weld Initiate: DO[ 0] U ***
6 Enable weld: DO[ 0] U ***
7 Reset stepper: DO[ 0] U ***
8 Reset welder: DO[ 0] U ***
9 Iso contactor: DO[ 0] U ***
10 Cap change comp: DO[ 0] U ***
11 Enbl cont. savr: DO[ 0] U ***
12 Tip stck timing: DO[ 0] U ***

[ TYPE ] IN/OUT >

Tip Stick Timing Output setting method

Display the I/O screen by executing the following procedure
1. Press the MENU key to bring up the screen menu.
2. Select “I/O”.
3. Press F1“[TYPE]” to display the pull-up menu.
4. Select “Spot Equip”. The I/O Spot Input/Output screen appears.
5. Specify the index of the “Tip stick Timing” output on Spot Output screen.

The duration of the Tip Stick Timing output pulse is specified by the following system variable (the time is
specified in ms):
$Spotweldio[eq#].$stkdo_dwltm = 500 (default)

TIP STICK DETECTION DETAIL

Tip Stick Detect Distance is defined as the separation between the tips and the part when the tip stick detect
input shall be checked, see the flow chart:

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B-83264EN/03 8.EXT. TIP STICK SIGNAL DETECTION

Tip stick detect distance = a + b

Thickness d

So, the servo gun position (d) at the time of tip stick check equals:
d = Tip Stick Detect Distance + Part Thickness

Since the gun is moving when the tip stick check is initiated, the position when the servo gun stops with a tip
stick detection may be larger than the position at which the check is initiated.

NOTE
In the case that the tips are stuck, the gun actuator will move in the open direction,
but the tips will remain in contact with the part, causing deflection in the gun
mechanism. Be sure that the tip stick detect distance is set to a value less than the
maximum allowed deflection for the gun mechanism.
Gun Tries to
Gun Closed open – tips
– weld done stick

Opening the Gun after a Tip Stick

When a tip stick occurs the gun can be opened by pressing the Shift+RESET key together, then still holding
down the Shift key jog the gun open with the +/- jog key (X for gun 1, Y for gun 2) or use the BACKUP (BU
1/2) key.

NOTE
Take great caution when using this jog method to release the tip stick. The
Shift+RESET key sequence will override the Overtorque Protection limit and
jogging the gun may place a large mechanical load on the servo gun and a large
thermal load on the servo motor. The Collision Guard function of the robot will also
be temporarily disabled. Release the Shift key to exit the Shift+RESET mode.

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8.EXT. TIP STICK SIGNAL DETECTION B-83264EN/03

Weld complete

Gun Opening

YES
End distance

NO

Detect distance

NO Gun opening is larger than

Detect distance + Thickness

YES

NO Detect signal is ON

YES

SVGN-030 Tip Stick Detection Next line

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B-83264EN/03 9.SERVO GUN MONITORING

9 SERVO GUN MONITORING

The state of the spot welding instruction being executed is displayed on the servo gun monitoring screen at
real-time on the teach pendant. However, the refresh rate of the teach pendant may be such that the
information is only updated every few seconds.

Display the servo gun monitoring (status) screen by executing the following procedure.

Procedure
1. Press the MENU key to bring up the screen menu.
2. Select “0 -- NEXT --“ and “4 STATUS”.
3. Press F1“[TYPE]” to display the pull-up menu.
4. Select “Servo Gun”. The SERVO GUN Monitoring screen appears.

STATUS Servogun
SERVO GUN / EQ:1 Gun:1 1/13
1 Pressure schedule: 0
2 Start distance schedule: 0
3 End distance schedule: 0
4 Tip Wear value(Gun)(mm): 0.00
5 Tip Wear value(Robot)(mm): 0.00
6 Pressure value(nwt): 0.00
7 Current position(Gun)(mm): 0.00
8 Thickness check:
9 Program name:
***************************************
10 Program line: *****
11 Specified thickness(mm): ******
12 Observed thickness(mm): ******
13 Weight compen status: <*DETAIL*>

[ TYPE ] EQUIP GUN

Display items and Descriptions

Pressure schedule Indicates the pressure schedule number specified for the spot welding
instruction being executed. If no spot welding instruction is being executed,
the Pressure schedule for the most recently executed spot welding instruction
is indicated.
Pressure schedule number is specified by the P=#, in the spot instruction.
The pressure schedule contains all data for the pressure position: weld force,
thickness, gun sag compensation value, etc.
Start distance schedule Indicates the start distance schedule number for the spot welding instruction
being executed. This index defines an open distance for the movable tip and
stationary tip, enroute to the spot weld location.
End distance schedule Indicates the end distance schedule number for the spot welding instruction
being executed. This index defines an open distance for the movable tip and
stationary tip when opening from the spot weld location. However, there is no
end distance schedule for a press_motion instruction: end distance
schedule= 0 for press_motion.
Tip Wear value (Gun) (mm) Indicates the wear amount of the movable tip.
Tip Wear value (Robot) Indicates the wear amount of the stationary tip.
(mm)

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9.SERVO GUN MONITORING B-83264EN/03

Pressure value (kgf) Indicates the pressure applied during the execution of a spot welding
instruction. The indicated pressure is obtained by subtracting a dynamic
friction portion from the specified torque (corresponding to a disturbance
torque) and multiplying the difference by a pressure conversion coefficient.
The indicated value is therefore, a rough estimate of the pressure actually
applied between the tips.
Current position (Gun) Indicates the current gun position on the gun axis.
(mm)
Thickness check: The following parameters provide thickness check status data. Thickness
status data is set at check (after force is achieved).
Thickness status data is cleared at:
Gun close
Task end
****** is displayed after thickness check data is cleared.
Prog, line: Program name and line number of spot/pressuring motion where thickness
check is being performed.
Specified thickness(mm) The expected (target) part thickness specified via pressure schedule or local
condition.
Observed thickness(mm) The measured (estimated) part thickness.
Weight compensation Compensation status by gun axis weight compensation function.
status Please refer to Section 18

NOTE
The above displayed items are depended on software version and/or software
option configuration.

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B-83264EN/03 10.TEST CYCLE

10 TEST CYCLE
This chapter describes the settings for the test cycle to confirm the correct operation of robot or gun before
automatic operation executed in the conditions of production. In particular, this chapter focuses on how to
set the servo gun specific application items related to running a test cycle. Please refer to Spot Welding
OPERATOR’S MANUAL (B-83284EN-4) for more details on how to use the Test Cycle.

Spot Weld Test Cycle screen

1. Press the MENU key to bring up the screen menu.
2. Select "2 TEST CYCLE".
3. Press F1 “TYPE” then select 2 Spot Weld.

SPOT WELD
1/10
1 Gun operation: STROKE
2 Weld controller mode: WELD
3 Tryout mode: DISABLED
4 Weld IO sim: ENABLED
5 Weld Duration (ms): 500 ms
6 Inform output to plc DO[ 0]
7 Force process complete: DISABLED

Servo Gun Motion in Single Step

8 Pressure Motion: ENABLED
9 Stop @ Taught Pos: ENABLED

Servo Gun Motion in Backward

10 Stop @ Taught Pos: ENABLED

[TYPE] ENABLED DISABLED

Setup for Spot Weld Test Cycle

Specify the requirement for test cycle of a program in Spot Weld Test Cycle screen.

Gun Operation ¾ Stroke – the gun will close and open at each weld spot. Passing of weld current
depends on the setting of the weld controller mode
(cannot be changed if a ¾ No Stroke – the gun stops closing for each weld spot at the specified Start Distance.
program is running) The pressurization motion is not executed. The gun then opens to the specified End
Distance. The weld controller mode must be set to NOWELD
Weld controller ¾ WELD – when the gun closes the weld controller executes the appropriate schedule
mode: and passes current through the gun
¾ NOWELD - no current passes through the gun when the weld controller executes the
(cannot be changed if a weld sequence.
program is running)
Tryout Mode: ¾ ENABLED – Thickness on SPOT instruction need not be changed, and pressure
shortage error is not generated even if there is no panel.
Assign tryout signal of cell interface so that tryout mode is ENBLE.
DISABLED – pressure motion is normally executed with thickness for pressure on
SPOT instruction.
When Tryout signal of cell interface is not assigned, tryout mode is always DISABLE..
Weld IO sim ¾ ENABLED –Welding can be executed without setting weld schedule. Disable weld
controller mode for sim weld.
¾ DISABLED – sim weld is disabled.
Weld Duration Specify sim weld time on this item.
NOTE: Sometimes sim weld time is not specified value.
Default : 500ms
Maximum: 32767ms
Minimum : 0ms

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10.TEST CYCLE B-83264EN/03

Inform out out to plc This signal inform to PLC that sim weld is ENABLE
Force Process ¾ ENABLED - Process Complete is turned on immediately. Process Complete will be
Complete: cleared at the start of the next style. The Process Alert signal is turned on whenever
Force Process Complete is enabled, and a WARNING error is displayed on the
ALARMS screen to indicate that this abnormal operation was performed.
¾ DISABLED - Process Complete is turned off.
Servo gun motion in single step
Pressure motion ¾ ENABLED(DEFAULT) : When SPOT instruction in program is executed with single
step, gun closes.
¾ DISABLED: When SPOT instruction in program is executed with single step, gun
does not closes.
Note: Pressure utility (Manual pressure, manual weld etc) executed gun closing even
if this is disabled.

Refer to subsection 5.1.6 for more detail.

Stop @ Taught Pos ¾ ENABLED(DEFAULT) : When SPOT instruction in program is executed with single
step, robot and gun pauses at taught position.
This is same as $SGSYSCFG.$STEP_TCHPT=TRUE
¾ DISABLED : When SPOT instruction in program is executed with single step, robot
and gun does not pause at taught position. This is same as
$SGSYSCFG.$STEP_TCHPT=FALSE.

Refer to subsection 5.1.6 for more detail.

Servo Gun Motion in Backward
Stop @ Taught Pos ¾ ENABLED : When SPOT instruction in program is executed with backward, robot and
gun pauses at taught position.
¾ DISABLED(DEFAULT) : When SPOT instruction in program is executed with
backward, robot and gun does not pause at taught position.

Refer to subsection 5.1.7 for more detail.

NOTE
If weld duration is specified extremely short or override is low, pressuring time
might become longer than specified weld duration.

NOTE
Even if tryout mode is enabled, open distance and trajectory of tips and timing of
deceleration is same as case that there is panel (tryout mode is disabled). Even if
there is no panel, gun motion is decelerated before panel position. So cycle time of
tryout mode is difference from cycle time of case that there is panel (tryout mode is
disabled).

NOTE
Turn off rightmost bits of system variable $SGCFG[equipment
number].$TRYOUT_MSK if you would like to use "PRESSURE ENABLE
SIGNAL", "NEXT STEP ENABLE" or "NEXT STEP ENABLE FROM WELD
CONTROLLER" with tryout mode enabled. To turn off rightmost bits, set value
obtained by subtracting 1 from $TRYOUT_MSK if $TRYOUT_MSK is an odd
number. For example, change to $TRYOUT_MSK = 6 in case of $TRYOUT_MSK
= 7 (ODD). "PRESSURE ENABLE SIGNAL", "NEXT STEP ENABLE" or "NEXT
STEP ENABLE FROM WELD CONTROLLER" can already be used if
$TRYOUT_MSK is an even number.

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B-83264EN/03 11.PRESSURE RELATED I/O SIGNALS

11 PRESSURE RELATED I/O SIGNALS

Special signals can be set in the servo gun software to read and activate I/O related to the pressuring
operation of the servo gun. The use and setup of these signal is optional. In the normal case, these signals
do not need to be used.

Equalize Signal (output)

When a pneumatic equalizer is used, the timing for activation and the value of the Group Output associated
with the equalizer can be controlled.

Pressure Enable Signal (input)

Set to enable the closing of the servo gun to pressure

Next Step Enable Signal (input)

Set to enable execution of the next step in the teach pendant program following the completion of a spot
welding instruction

Pressure Notification Signal (output)

Set to inform that pressuring is active on the servo gun

11.1 EQUALIZE SIGNAL

Initial Setup
To enable the function with servo gun, do the following:
1. Set the following items on the Spot Config screen
• Equalization Pressure : ENABLE
• Number of Pressures: 4 or higher
Example: If 5 I/O points will be used with the group output, the number of pressure should be set to 31. If
there is only 1 I/O point, then set to 4
SPOT CONFIG
8/34
1 F Number: F00000>
2 Load Spottool Macros: DISABLED
3 Number of equipments: 1
4 Number of weld controllers: 1
5 Current equipment, gun: 1, 1
6 Weld interface: INTEGRAL
7 Number of guns: SINGLE
8 Equalization Pressure: ENABLED
9 number of pressures: 4
10 Rst water saver time-out: 500 ms
11 pulse length: 500 ms

[ TYPE ] ENABLED DISABLED

2. Select the Group Output to assign to the Pneumatic Equalizer on the Spot Equipment I/O screen.
I/O Equip Out
3/3
NAME OUT PT SIM STATUS
1 Reset water saver: DO[ 0] U ***
2 Gun pressure: DO[ 0] U ***
3 Eqlztn pressure: GO[ 1] U ***

[ TYPE ] IN/OUT >

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11.PRESSURE RELATED I/O SIGNALS B-83264EN/03

3. Configure the Group output in the Group output config screen.

I/O Group Out
1/100
GO # RACK SLOT START PT NUM PTS
1 0 1 21 1
2 0 0 0 0
3 0 0 0 0
4 0 0 0 0
5 0 0 0 0

[ TYPE ] MONITOR IN/OUT HELP >

4. Cycle Power for the I/O changes to take effect.

Equalization Trigger Control

The settings to control the equalizing function are available on the Spot Equipment Setup Screen.
SETUP Spot Equip
5/10
Equalizer: before pressure state
5 Trigger type: EVENT
6 Trigger event: NEAR_SD
7 Control type: Param***
Equalizer: after pressure state
8 Trigger type: DISTANCE
9 Trigger event: 5.0
10 Control type: Param***

[ TYPE ] [CHOICE]

You must set 3 items to specify the operation of the equalizer for before and after the weld. Refer to
following table for descriptions for each item.

Table. Equalizer function setup

ITEM DESCRIPTION
Equalizer: before pressure state - These items specify the operation for the equalizing cylinder control as the gun is
closing to the spot weld.
Trigger Type You can specify trigger type before pressure.
EVENT:
when this is selected, you will have a list of “events” which will trigger the equalizing
cylinder group output to change to the before pressure value as the gun is closing
to the spot weld.
TIME:
when this is selected, you will be able to specify the time (ms) before the tips arrive
at the spot weld for the equalizing cylinder to be triggered.
Trigger Event EVENT Choices:
START_SD:
trigger occurs as soon as the gun tips begin moving to the start distance. The
timing will vary with start distance value and with term type used on the spot
instruction, typically this event will occur early in the robot transfer to the spot.
NEAR_SD:
trigger occurs near the programmed start distance. The timing will vary with start
distance value and with term type used on the spot instruction, typically this event
will occur near the actual start distance position, after the robot transfer is nearly
done
NEAR_PS:
trigger occurs as the gun tips are closing to the spot, typically after the robot
transfer is complete.

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B-83264EN/03 11.PRESSURE RELATED I/O SIGNALS

ITEM DESCRIPTION
Trigger time If you select TIME as trigger type, you can specify the time (ms) before the tips
arrive at the spot weld for the equalizing cylinder to be triggered.
Control type PARAM:
you will set the group output value via the EP parameter of each spot instruction.
The group output will change to this value when the before pressure state trigger
occurs.
ex） SPOT[SD=1, EQ=#, P=1, t=1.0, S=1, ED=1]
CONST ＃:
the group output value will be set to the number specified here for every spot.
There will be no parameter in the spot instruction.
Equalizer: after pressure state - These items specify the operation for the equalizing cylinder control as the gun is
opening from the spot weld
Trigger Type You can specify trigger type after pressure.
DISTANCE:
when this is selected, the user will specify the tip clearance – with respect to the
part surface - when the equalizer should change to the after pressure value.
TIME:
when this is selected, you will be able to specify the time after motion start when
the equalizer should change to the after pressure value.
Trigger Distance If you select DISTACE as trigger type, you can specify trigger distance after
pressure. This clearance is 5mm by default.
Trriger time If you select TIME as trigger type, you can specify trigger time after pressure. This
clearance is 5mm by default.
Control type PARAM:
you will set the group output value via the EP parameter of each spot instruction.
The group output will change to this value when the before pressure state trigger
occurs.
ex） SPOT[SD=1, P=1, t=1.0, S=1, EQ=#, ED=1]
CONST ＃:
the group output value will be set to the number specified here for every spot.
There will be no parameter in the spot instruction.

11.2 PRESSURE ENABLE SIGNAL

When a spot welding instruction is issued, the robot checks the state of the Pressure enable signal before
starting pressurization. If the signal is on, pressurization is started

Movem to approach position

OFF/ time-out
Wait for Pressure enable signal
turn ON

ON
Pressurization Time-out alarm

SETTING
The user must specify both the Digital Input index and the time-out value to activate this function.

• The Digital Input index is specified by setting the following system variable:

$SPOTEQIO[eq#].$DI_PEN_I

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11.PRESSURE RELATED I/O SIGNALS B-83264EN/03

$SPOTEQIO[eq#].$DI_PEN_I = 62, would inform the software verify that DI[62]is ON before
pressurizing the gun in the next spot weld instruction

• The time-out value is defaulted to 5 seconds. To change the value, update the following system
variable (msec).

$SPOTEQSETUP[eq#].$PEN_TMOUT = 5000 (Change to desired value)

Others
This function does not work with:
x Pressurization instruction
x Manual pressurization
x Manual welding

If a time-out condition occurs, the following alarm message appears, causing the program to pause.

"SVGN-035 Pressure enable time out”

NOTE
Turn off rightmost bits of system variable $SGCFG[equipment
number].$TRYOUT_MSK if you would like to use "PRESSURE ENABLE SIGNAL"
with tryout mode enabled. To turn off rightmost bits, set value obtained by
subtracting 1 from $TRYOUT_MSK if $TRYOUT_MSK is an odd number. For
example, change to $TRYOUT_MSK = 6 in case of $TRYOUT_MSK = 7 (ODD).
"PRESSURE ENABLE SIGNAL" can already be used if $TRYOUT_MSK is an
even number.

11.3 NEXT STEP ENABLE

When a spot welding instruction is issued, the robot checks the state of the Weld completion signal between
gun opening and the execution of the next instruction. If the signal is on, the next instruction is started.

Gun opening position

OFF/ time-out
Wait for Next Step Enable signal to
turn ON

ON
Next instruction Time-out alarm

SETTING
The user must specify both the Digital Input index and the time-out value to activate this function.

• The Digital Input index is specified by setting the following system variable:

$SPOTEQIO[eq#].$DI_NSE_I

$SPOTEQIO[eq#].$DI_NSE_I = 63, would inform the software verify that DI[63]is ON before
execution of the next instruction

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B-83264EN/03 11.PRESSURE RELATED I/O SIGNALS

• The time-out value is defaulted to 5 seconds. To change the value, update the following system
variable (msec).

$SPOTEQSETUP[1].$NSE_TMOUT = 5000 (Change to desired value)

Others
This function does not work with:
x Pressurization instruction
x Manual pressurization
x Manual welding
If a time-out condition occurs, the following alarm message appears, causing the program to pause.
"SVGN-036 Comp confirmation time out”

NOTE
Turn off rightmost bits of system variable $SGCFG[equipment
number].$TRYOUT_MSK if you would like to use "NEXT STEP ENABLE" with
tryout mode enabled. To turn off rightmost bits, set value obtained by subtracting 1
from $TRYOUT_MSK if $TRYOUT_MSK is an odd number. For example, change
to $TRYOUT_MSK = 6 in case of $TRYOUT_MSK = 7 (ODD). "NEXT STEP
ENABLE" can already be used if $TRYOUT_MSK is an even number.

11.4 PRESSURIZATION NOTIFICATION SIGNAL

On the spot equip I/O screen, set the "gun pressurization notification" signal.
This signal is output to external devices as the pressurization signal.

I/O Equip Out

2/3
NAME OUT PT SIM STATUS
1 Reset water saver: DO[ 0] U ***
2 Gun pressure: DO[ 0] U ***
3 Eqlztn pressure: GO[ 1] U ***

[ TYPE ] IN/OUT DO RO >

The pressurization signal is turned on or off as follows:

On: After the machine reaches the pressurization start position (this position actually varies depending on
the setting of the positioning mode for the pressurization start position.)

Off: When welding is complete or after the machine reaches the pressurization completion position (this
position actually varies depending on the setting of the positioning mode for the pressurization completion
position.)

When the program starts, restarts, pauses, or is forcibly terminated, this signal is forcibly turned off.
The following system variable can be used to change the specification to be used when the hold input signal
is input during pressurization:

$SGSYSCFG.$PRES_SIGNAL
= 0 (default setting): Turns the signal off when welding is complete. (A) in the following figure.
= 1: Turns the signal off after the machine reaches the pressurization completion position. (B) in the
following figure.

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11.PRESSURE RELATED I/O SIGNALS B-83264EN/03

Start distance
Pressurization End distance

t
Pressure

(A) Pressurization notification

signal (OUT)

(B) Pressurization notification

signal (OUT)

Welding command (OUT)

Welding condition (OUT)

Welding completion (IN)

For the pressurization instructions (Press_motion), the pressurization signal is not output.

11.5 NEXT STEP ENABLE FROM WELD CONTROLLER

When a spot welding instruction is issued, the robot checks the state of the “next step enable signal from
weld controller” between weld completion signal receiving and the execution of the next instruction. If the
signal is on, the next instruction is started.

SETTING
SPOT instruc tion running

Weld completion signal receiving

Is Next Step Enable OFF

Robot is moving to ED signal turning on?
while opening gun.
ON
Has the robot NO
reached ED?

YES

Robot passes ED. Robot waits on ED.

(This is usual motion.)

Is Next Step Enable OFF

signal turning on?

ON

NO
Time-out?

YES

Next instruction Time-out alarm

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B-83264EN/03 11.PRESSURE RELATED I/O SIGNALS

• Make “next step enable signal from weld controller” effective via the following system variables.

$SGSYSCFG.$NSE_MODE = 1 ENABLED
$SGSYSCFG.$NSE_MODE = 0 DISABLED (Default)

NOTE
When this function is made effective, section 11.3 NEXT STEP ENABLE cannot
be used.

• The digital input index is specified by setting the following system variable:

$SPOTWELDIO[#].$DI_WCS_T= 1(DI)
$SPOTWELDIO[#].$DI_WCS_I = Port number
# : Weld controller number

Specify 63 to $SPOTWELDIO[#].$DI_WCS_I if you want to use DI[63] for this signal.

• The time-out value is defaulted to 5 seconds. To change the value, change the following system
variable (msec).

$SPOTWELDIO[#].$WCS_TMOUT = 5000
# : Weld controller number

NOTE
Make the timeout period the same when you connect a separate weld controller
with gun A and gun B in dual gun system.

• When the robot pauses while being waiting to turn on “next step enable signal from weld controller”,
after robot moves to SD by next start, the robot executes spot instruction again.

• If a time-out condition occurs, the following alarm message appears, causing the program to pause.

"SVGN-036 Comp confirmation time out”

Others
This function does not work with:
x When weld IO sim is enabled
x Pressurization instruction
x Tip dress instruction
x Manual pressurization

NOTE
Turn off rightmost bits of system variable $SGCFG[equipment
number].$TRYOUT_MSK if you would like to use "NEXT STEP ENABLE FROM
WELD CONTROLLER" with tryout mode enabled. To turn off rightmost bits, set
value obtained by subtracting 1 from $TRYOUT_MSK if $TRYOUT_MSK is an
odd number. For example, change to $TRYOUT_MSK = 6 in case of
$TRYOUT_MSK = 7 (ODD). "NEXT STEP ENABLE FROM WELD
CONTROLLER" can already be used if $TRYOUT_MSK is an even number.

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12.PRESSURE PROFILE CONTROL FUNCTION B-83264EN/03

12 PRESSURE PROFILE CONTROL

FUNCTION
12.1 OVERVIEW
It is possible to control pressure value with multi-step in servo gun spot welding. This function can increase
a welding quality. This function is an optional.
x Maximum 4 steps pressure can be specified for each step (Before welding, In welding, After welding).
x Pressure profile can be specified for each pressure condition.

Enable pressure profile control

Pressure Before welding In welding After welding

Weld Start signal Weld complete signal

Process by weld timer

Disable pressure profile control (Standard)

Pressure Before welding In welding After welding

Weld Start signal Weld complete signal

Process by weld timer

NOTE
If this option is added after completing auto tune, additional tuning is required.
Please perform “Auto Tune” or “Profile Auto Tune” in servo gun autotuning utility.

12.2 PROFILE DATA

12.2.1 Operation
1. Select DATA menu. And select pressure condition menu.

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B-83264EN/03 12.PRESSURE PROFILE CONTROL FUNCTION
SERVO GUN DATA
PRESSURE / EQ:1 Gun:1 3/99
No. Press(Nwt) Manual Comment
1 2500.0 FALSE [WORK A ]
2 3000.0 FALSE [WORK A ]
3 2850.0 FALSE [WORK A ]

[ TYPE ] EQUIP GUN DETAIL COPY >

F4 “DETAIL”
SERVO GUN DATA
PRESSURE / EQ:1 Gun:1 No:1 3/4
1 Comment: [WORK A ]
2 Standard Pressure(nwt): 2500.0
3 Pressure Profile: ENABLE<*DETAIL*>
4 Gun Sag Comp Value(mm): 0.0

[ TYPE ] EQUIP GUN LIST

2. Move cursor to "3 Pressure Profile", and push ENTER key.

Please refer to the next page for the meaning of each items.

SERVO GUN DATA

PROFILE / EQ:1 Gun:1 No:1 1/7
1 Pressure Profile Control: ENABLE
2 Manual Compensation: DISABLE
3 Standard Pressure(nwt): 2500.0
4 Init Press: 2500.0[nwt] (100.0[%])
(Pressure Control Start)
5 0[msec] 2000.0[nwt] ( 80.0[%])
(Weld Start)
6 0[msec] 2500.0[nwt] (100.0[%])
(Weld Complete)
7 0[msec] 2000.0[nwt] ( 80.0[%])

[ TYPE ] EQUIP GUN ENABLE DISABLE

12.2.2 Meaning of Each Items

You can change a pressure value one time by one stage at each stage (Pressure control start, weld start and
weld complete) in standard.
Select ENABLE/DISABLE of profile control by each
pressure condition. Standard setting is DISABLE.

SERVO GUN DATA

PROFILE / EQ:1 Gun:1 No:1 1/7
1 Pressure Profile Control: ENABLE Select ENABLE/DISABLE of manual compensation.
2 Manual Compensation: DISABLE Please refer to the following figure for more information.
3 Standard Pressure(nwt): 2500.0
4 Init Press: 2500.0[nwt] (100.0[%])
(Pressure Control Start) Standard pressure value
5 0[msec] 2000.0[nwt] ( 80.0[%]) This is standard value is for the following pressure ratio(%).
(Weld Start)
6 0[msec] 2500.0[nwt] (100.0[%])
(Weld Complete)
7 0[msec] 2000.0[nwt] ( 80.0[%])
Specify target pressure value(P) and time(T). There are two
[ TYPE ] EQUIP GUN ENABLE DISABLE input types that specify the target pressure value(P) directly or
specify the pressure ratio(%) to the above standard pressure
value.

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12.PRESSURE PROFILE CONTROL FUNCTION B-83264EN/03

If “Manual Compensation” is enabled:

SERVO GUN DATA
PROFILE / EQ:1 Gun:1 No:1 1/10
1 Pressure Profile Control: ENABLE ENABLE : “Comp. factor” is displayed
2 Manual Compensation: ENABLE Convergence pressure can be adjust in each step.
3 Standard Pressure(nwt): 2500.0
4 Init Press: 2500.0[nwt] (100.0[%])
(Pressure Control Start)
5 0[msec] 2000.0[nwt] ( 80.0[%])
6 Comp. factor: 103.0
(Weld Start)
7 0[msec] 2500.0[nwt] (100.0[%])
If there is a gap between specified target pressure and
8 Comp. factor: 101.0
convergence pressure, please adjust this value. If the value
(Weld Complete)
is larger than 100, convergence pressure is larger. If the
9 0[msec] 2000.0[nwt] ( 80.0[%])
value is smaller than 100, convergence pressure is smaller.
10 Comp. factor: 103.0

[ TYPE ] EQUIP GUN ENABLE DISABLE

Relationship between target pressure value (P) and time (T):

Init Press Weld Start Weld Complete

Tf1 Tw1
Pressure Pf0
Pbase Pw1
Pe1
Pf1 Te1

Time
Weld start Weld complete signal
Welding

To change the target pressure value more than two times in each stage, a following system variable should
be changed.

$SGPPDCFG.$NUM_STEPS: Number of pressure change (Standard:1, Maximum:4)

($SGPPDCFG.$NUM_STEPS=4)
SERVO GUN DATA
PROFILE / EQ:1 Gun:1 No:1 1/16
1 Pressure Profile Control: ENABLE
2 Manual Compensation: DISABLE
3 Standard Pressure(nwt): Pbase
4 Init Press: Pf0[nwt] ( PRf0[%])
(Pressure Control Start)
5 Tf1[msec] Pf1[nwt] ( PRf1[%])
6 Tf2[msec] Pf2[nwt] ( PRf2[%])
7 Tf3[msec] Pf3[nwt] ( PRf3[%])
8 Tf4[msec] Pf4[nwt] ( PRf4[%])
(Weld Start)
9 Tw1[msec] Pw1[nwt] ( PRw1[%])
10 Tw2[msec] Pw2[nwt] ( PRw2[%])
11 Tw3[msec] Pw3[nwt] ( PRw3[%])
12 Tw4[msec] Pw4[nwt] ( PRw4[%])
(Weld Complete)
13 Te1[msec] Pe1[nwt] ( PRe1[%])
14 Te2[msec] Pe2[nwt] ( PRe2[%])
15 Te3[msec] Pe3[nwt] ( PRe3[%])
16 Te4[msec] Pe4[nwt] ( PRe4[%])

[ TYPE ] EQUIP GUN ENABLE DISABLE

When target pressure value is 0, process in a stage will be completed.

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SERVO GUN DATA
PROFILE / EQ:1 Gun:1 No:1 1/16
1 Pressure Profile Control: ENABLE
2 Manual Compensation: DISABLE
Pe1 Pe2
3 Standard Pressure(nwt): Pbase
4 Init Press: Pf0[nwt] ( PRf0[%])
Pf0 Pf1
(Pressure Control Start)
Pw3
5 Tf1[msec] Pf1[nwt] ( PRf1[%])
6 Tf2[msec] 0[nwt] ( 0[%])
7 Tf3[msec] 0[nwt] ( 0[%])
Pw1 Pw2
8 Tf4[msec] 0[nwt] ( 0[%])
(Weld Start)
9 Tw1[msec] Pw1[nwt] ( PRw1[%])
10 Tw2[msec] Pw2[nwt] ( PRw2[%])
11 Tw3[msec] Pw3[nwt] ( PRw3[%])
12 Tw4[msec] 0[nwt] ( 0[%])
Tf1 Tw1 Tw2 Tw3 Te1 Te2
(Weld Complete)
13 Te1[msec] Pe1[nwt] ( PRe1[%])
W/Start W/Complete
14 Te2[msec] Pe2[nwt] ( PRe2[%])
15 Te3[msec] 0[nwt] ( 0[%])
16 Te4[msec] 0[nwt] ( 0[%])

[ TYPE ] EQUIP GUN ENABLE DISABLE

When weld completion signal is received in welding (Twi), welding stage will move to processing of the
weld completion.

12.2.3 Example
Example1:
The following shows a setting example for increasing the pressure before and after welding.

switch by 30ms
3000N 3000N
100ms 100ms

2000N
Weld 300ms Weld
Start Complete

Weld Current

In this example, set $SGPPDCFG.$NUM_STEPS=2 for changing the target value two times in "Init Press"
and "Weld Complete" stages like the following figure.

Pf1, Tf1 Pf2, Tf2 Pe1, Te1 Pe2, Te2

Pf0

Pw1, Pw2

Init Press Weld Start Weld Complete

※ Do not have to set Tw1 and Tw2.

(Please set weld time by weld timer.)

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Set the values based on the above figure.

SERVO GUN DATA

PROFILE / EQ:1 Gun:1 No:1 1/10
1 Pressure Profile Control: ENABLE
2 Manual Compensation: DISABLE
3 Standard Pressure(nwt): 2000.0
4 Init Press: 3000.0[nwt] (150.0[%])
(Pressure Control Start)
5 100[msec] 3000.0[nwt] (150.0[%])
6 30[msec] 2000.0[nwt] (100.0[%])
(Weld Start)
7 0[msec] 2000.0[nwt] (100.0[%])
8 0[msec] 2000.0[nwt] (100.0[%])
(Weld Complete)
9 30[msec] 3000.0[nwt] (150.0[%])
10 100[msec] 3000.0[nwt] (150.0[%])

[ TYPE ] EQUIP GUN ENABLE DISABLE

Example2:
The following shows a setting example of 3 stage’s welding. (Please set weld current by weld timer.)

3000N
150ms

2000N 2000N
200ms 200ms
switch by 30m

Weld Weld
Start Complete

Weld
Current

In this example, set $SGPPDCFG.$NUM_STEPS=4 for changing the target value four times in "Weld
Start" stages like the following figure.

Pw3, Tw3
Pw2, Tw2 Pw4, Tw4

Pw1, Tw1
Pf0

Weld time set by weld timer

Weld Start Weld Complete

※Do not have to set Pf1～Pf4, Tf1～Tf4, Pe1～Pe4, Te1～Te4.

Set the values based on the above figure.

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SERVO GUN DATA
PROFILE / EQ:1 Gun:1 No:1 1/16
1 Pressure Profile Control: ENABLE
2 Manual Compensation: DISABLE
3 Standard Pressure(nwt): 2000.0
4 Init Press: 2000.0[nwt] (100.0[%])
(Pressure Control Start)
5 0[msec] 2000.0[nwt] (100.0[%])
6 0[msec] 2000.0[nwt] (100.0[%])
7 0[msec] 2000.0[nwt] (100.0[%])
8 0[msec] 2000.0[nwt] (100.0[%])
(Weld Start)
9 200[msec] 2000.0[nwt] (100.0[%])
10 30[msec] 3000.0[nwt] (150.0[%])
11 150[msec] 3000.0[nwt] (150.0[%])
12 30[msec] 2000.0[nwt] (100.0[%])
(Weld Complete)
13 0[msec] 2000.0[nwt] (100.0[%])
14 0[msec] 2000.0[nwt] (100.0[%])
15 0[msec] 2000.0[nwt] (100.0[%])
16 0[msec] 2000.0[nwt] (100.0[%])

[ TYPE ] EQUIP GUN ENABLE DISABLE

12.2.4 Limitations
Profile time
Please do not shorten a specified time in a profile data too much. (10Kgf/msec is a standard)

HOLD during profile pressure

When press motion paused during profile pressure with HOLD, pressure specification is decided accoding
to the following system variable.

$SYSCFG.$REL_PRESS
=0: Pressure is maintained at HOLD.
=1: Pressure is released at HOLD.

NOTE
$SCYSYSCFG.$REL_PRS_DLY can wait for pressure release time with
$SCYSYSCFG.$REL_PRESS = 1. However if pressure profile is enabled ,
$SCYSYSCFG.$REL_PRS_DLY does not work, then pressure is released as
soon as HOLD.

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13 GUN CHANGE FUNCTION

13.1 OUTLINE

13.1.1 Feature of Function

It is possible to switch more than two servo guns without power off.

13.1.2 Basic Specification

The total number of changeable gun 9 guns in one equipment. 10 guns in one system.
Only one gun can be controlled at the same
The period of gun detach(standard) 0.4 sec (Battery type) / 0.4 sec(Battery less type) *1)
The period of gun attach(standard) 0.8 sec(Battery type)/2.8 sec(Batteryless type) *1)
Backup battery Both battery type and batteryless type can be available.
(*1) The period includes the internal processing period, not include the period of robot motion for changing
the guns.

13.1.3 Restrictions
Restrictions matters
x The period of gun change of batteryless type gun is more than that of battery less type gun.
x The motor of the gun change must be controlled by the same amp.
x The gun change instruction can not used by multi task. (The gun change instruction can not be execute
by plural tasks at the same time)

Prohibition matters
x Do not force to detach the gun while the controller is off.
x The line tracking can not used with gun change function.
When the batteryless type is used, there are restrictions as follows:
x When the calibration motion type 1 or 2 is selected, calibration cannot be interrupted by a hold or
emergency stop. (Program execution must not be stopped during gun attach processing)
x When the calibration motion type 1 or 2 is selected, magnetic phase detection cannot be preformed.
x When the calibration motion type 3 or 4 is selected, the stroke limit must be expanded so that the gun
axis touches the open limit.
x When the calibration motion type 5 or 6 is selected, a switch such as a limit switch must be installed in
the gun.
x When the calibration motion type 7 or 8 is selected, calibration preformed during gun attachment is
disabled if the tip wear amount changed while the gun was detached. Therefore, tip replacement must
be performed for the attached gun.
For details of the calibration motion types, see Chapter 13.3,”GUN CHANGE SETUP”.

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B-83264EN/03 13.GUN CHANGE FUNCTION

NOTE
When a Pulsecoder alpha i AR128(A860-2010-T341) shipped until May of 2006 is
used, alarm SRVO-068(DTERR) occurs at turning power on and executing GUN
ATTACH instruction. Implement either of following countermeasures.
1. Replace Pulsecoder alpha i AR128 with one shipped after June of 2006.
2. Change system valuables as follows.
• $SHC_ITF[#].$WAITTM_PCHK = 270
• $SHC_ITF[#].$WAITTM_PWUP = 550
• $SHC_ITF[#].$SVON_DELAY = 230
• $SHC_ITF[#].$WAITTM_STRT = 650
# is group number of servo gun group using Gun Change Function.
When you implement 2nd countermeasure, gun attach process is extended by about
two seconds.

13.1.4 System Configuration

Servo gun change system is constructed as follows.
(Example : Servo gun is the 2nd group and the number of gun is four.)
Gun k
Detach/Attach

Gun 1 Gun 2 Gun 3 Gun 4

Robot = Motion group 1

J1 J2 J3 J4

（Max9）
EQ1
= Motion group 2
Robot
Controller

You can replace the servo gun with the air gun by switching on the controller.
Servo gun: (example: controller = 1)
• Driven by servo motor
(motion group = 2)
• Any open position can be set.

Air gun: (example: controller = 2)

• Driven by air ON/OFF
(no motion group)

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13.1.5 Outline of Installation

Select “Servo Gun” to the

Initial setup SETUP SERVO GUN
equipment type. 1/5
Enable the gun change. 1 Equip number: 1
Controlled Set gun number 2 Equip tyipe: [SERVO GUN]
3 Motion grop(Gun): 2
Start configuration 4 Motion group(Robot): 1
5 Gun Change: ENABLE

Set On to the battery type. [ TYPE ] EQUIP GUN_CFG

Execute gun attach
Provisional attach instruction. SETUP GUN CHANGE
1/10
Perform gun zero position
1 Comment: [ ]
mastering. 2 Attach signal: DI [ 0]
3 Identify signal: DI [ 0]
4 Battery: OFF
Select correct battery 5 Calibration motion type:[TYPE 7]
type. Calibration Motion Setup
Gun change setup
Select correct calibrate 6 Calibration Speed(%): 100
7 Acc Value: ACC100
motion type.
8 Position register index:PR[ 0]
9 Touch torque(%): (- ) 0.000
10 Detect speed(mm/s): 30

[ TYPE ] LIST

Perform reference position SYSTEM Master/Cal

setup. TORQUE = [ON ]
1 FIXTURE POSITION MASTER
Refpos setup 2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Check whether equipment
number is correct or not. [ TYPE ] YES NO >
Teaching
Check whether gun
Appl process
number is correct or not.
Spot Welding Application Data 1/1

Equipment Number: 1
Check whether gun status
is correct or not. END PREV NEXT
Execution
Do not stop the gun during
the calibrate motion. SAMPLE _
1/20
1: ;
2: GUN ATTACH[ 1 ];
:
10: GUN DETACH[ 1 ];
:

POINT SPOT TOUCHUP >

STATUS GUN CHANGE _

EQ:1 ENABLE Cont.:1 ON 1/4
Check the attached gun
AXS Comment Status
Verification and the gun number of 1 GUN[ 1:Part A ] ATTACH
status screen is same or 2 GUN[ 2:Prat B ] DETACH
3 GUN[ 3:Part C ] DETACH
not.
4 GUN[ 4:Part D ] DETACH

[ TYPE ] EQUIP

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13.2 INITIAL SETUP

The following initial setup is needed to install the servo gun change system.

x Motion parameter setup of servo gun axes

x The configuration setup of servo gun number
x Enable the gun change function.
x Provisional attach

NOTE
These setup must be done at the beginning of system installation.
These setup must be done only one time.

These setup is done at the controlled start.

See “Servo Gun Function Supplementary Manual”.

13.3 GUN CHANGE SETUP

The gun change setup must be done for each gun.

1. Press MENU key.

2. Select “6 SETUP”.
3. Press F1[TYPE].
4. Select “Gun change”
5. Select gun from the list of guns, then press F3:DETAIL. The detail screen is displayed.

SETUP GUN CHANGE

Gun Change / EQ:1 1/4
AXS Comment BatteryType
1 GUN[ 1:Part A ] ON [------]
2 GUN[ 2:Part B ] ON [------]
3 GUN[ 3:Part C ] ON [------]
4 GUN[ 4:Part D ] ON [------]

[ TYPE ] EQUIP DETAIL

SETUP GUN CHANGE

Gun Change / EQ:1 GUN:1 1/5
1 Comment: [ﾊﾟｰﾂ A ﾖｳ]
2 Attach signal: DI [ 0]
3 Identify signal: DI [ 0]
4 Battery: ON
5 Opposable gun: OFF

[ TYPE ] LIST

Common setup
Comment Comment for each gun.
Attach signal This signal used for gun set verification.
Available I/O type = SDI / RDI
- This signal is check before gun attach/detach instruction. If this signal is OFF, the error occurs.
- If the index is zero, the above checking is canceled.
Identify signal This signal used for gun identification.
Available I/O type = SDI / RDI / GI
- This signal is check before gun attach/detach instruction. If this signal is OFF, the error occurs.
- If the index is zero, the above checking is canceled.

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13.GUN CHANGE FUNCTION B-83264EN/03

Comment Comment for each gun.

Battery Select battery type.
ON = Battery backup type
OFF = Batteryless type

(Select the following when Battery is set to OFF in the common settings.)
Calibration Motion Type On battery-less guns, the position (pulse value) is lost when the gun is detached. So,
calibration must be carried out when gun is attached. Calibration involves the following two
operations:
xTurning the motor two turns for positioning the Pulsecoder
(this operation is simply referred to as "positioning" from here on)
xCalibrating at a preset reference position
The user selects from the following types, 1 to 8, to suit the user's particular system
requirements.
(See Table 3.1 and Fig. 3.1.)

Calibration motion type Selection Criteria

Types 7, 8 ( Recommended type )

As with types 3 and 4 ,specify there types on systems that are incapable of holding the gun detachment
position until the gun is attachment next, because their servo gun axis motor does not have a break. Types 7
and 8 use motor torque to detect the gun axis touching the gun close position and set the position as the
reference position.
The reference position is set automatically before the gun is detached. The difference between type 7 and
type 8 is in the operating direction during calibration.(See Table 3.1 and Fig. 3.1)
Type 7: Specify this type when the gun is detected at a position (near the 0 position) where the
distance to the gun close position is equivalent to less than two turns of the motor at the time
of gun attachment.
Type 8: Specify this type when the gun is detected at a position (near the 0 position) where the
distance to the gun close position is equivalent to more than two turns of the motor at the
time of gun attachment.
NOTE
For types 7 and 8, calibration performed during gun attachment is disabled if the tip wear amount
changed while the gun was detached. Therefore tip replacement must be performed for the attached
gun.

Types 1, 2
Select these types on systems capable of holding the gun detachment position as a result of braking the
servo gun axis motor up to the next servo gun attachment.
NOTE
With type 1 and 2 , if calibration is interrupted by a hold or emergency stop, reference position data is
lost. In such a case ,see Appendix B.2,”WHEN ROBOT IS STOPPED
DURING CALIBRATION”.
NOTE
With type 1 and 2,magnetic phase detection cannot be performed
When these types are set, the position where the gun is detached is automatically memorized as the
reference position, and calibration is carried out at that position after the gun is attached. For this
reason, the position when the gun is attached must be the same as position when it is detached.
The allowable errors of the detach and attach positions must fall within the respective following ranges
for the direct-acting axis and rotary axis:

Direct-acting axis: ±(gear ratio/2)mm or less around the detach position

Rotary axis: ±((360/gear ratio)/2)deg or less around the detach position

NOTE that positional misalignment occurs during gun attachment if the above ranges are exceeded.
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B-83264EN/03 13.GUN CHANGE FUNCTION
The difference between types 1 and 2 is in the operating direction during calibration. (See Table 3.1
and Fig. 3.1.)

Type 1: Specify this type when the gun is detached at a position (near the 0 position) where
operation is not possible in the gun close direction
Type 2: Specify this type when the gun is detached at a position (near the open limit) where
operation is not possible in the gun open direction

Types 3, 4
Select these types on systems not capable of holding the gun detachment position as a result of the servo gun
axis motor not having a brake up to the next servo gun attachment. On such a system, the reference position
must be set to another position as the gun detachment position cannot be used as the reference position.

With these types, contact of the gun axis with the open limit is detected by using the motor torque, and the
contact position is set as the reference position. For details on how to set the reference position, see "5.
Setting the Reference Position."
The difference between types 3 and 4 is in the operating direction during calibration. (See Table 3.1 and Fig.
3.1.)

Type 3: Specify this type when the gun is detached at a position (near the 0 position) where the
distance to the open limit is two or more turns of the motor.
Type 4: Specify this type when the gun is detached at a position (near the open limit) where the distance to
the open limit is two or less turns of the motor.
NOTE
With types 3 and 4 , it is necessary to expand the stroke limit so that the gun axis touches the open limit.

Types 5, 6
Like types 3 and 4, specify these types on systems not capable of holding the gun detachment position as a
result of the servo gun axis motor not having a brake up to the next servo gun attachment. With types 5 and
6, however, a detection signal must be provided on the gun by means of a dog or limit switch, and the
contact position must be set as the reference position. For details on how to set the reference position, see "5.
Setting the Reference Position."
The difference between types 5 and 6 is in the operating direction during calibration. (See Table 3.1 and Fig.
3.1.)
Type 5: Specify this type when the gun is detached at a position (near the 0 position) where the
distance to the position where the detect signal turns ON is two or more turns of the motor
in the open direction.
Type 6: Specify this type when the gun is detached at a position (near the open limit) where the
distance to the position where the detect signal turns ON is two or less turns of the motor in
the open direction.
NOTE
With types 5 and 6, a switch suc as a limit switch must be installed in the gun.

Table 13.3 Calibration Motion Type

Type Calibration Motion Set Position of Reference position
Type 1 The servo gun is opened by about two turns of the Position when gun is detached
motor, and then calibrated at the position where it is Reference position is not required. NOTE 2
closed by about two turns. NOTE 1
Type 2 The servo gun is closed by about two turns of the Position when gun is detached
motor, and then calibrated at the position where it is Reference position is not required. NOTE 2
opened by about two turns.
Type 3 The servo gun is opened to its open limit, and then Open limit position
calibrated. Arrival at the open limit is detected by
motor torque.

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Type Calibration Motion Set Position of Reference position

Type 4 The servo gun is closed by about two turns of the Open limit position
motor, opened to its open limit, and then calibrated.
Arrival at the open limit is detected by motor torque.
Type 5 The servo gun is opened until the detection signal Position where detection signal turns ON
turns ON, and then calibrated.
Type 6 The servo gun is closed by about two turns of the Position where detection signal turns ON
motor, opened until the detection signal turns ON,
and then calibrated.
Type 7 The servo gun is opened by about two turns of the Gun close position
motor ,closed to its close position ,then calibrated. Reference position setting is not required.NOTE3
Arrival at the close position is detected by motor
torque.
Type 8 The servo gun is closed to its close position ,then Gun close position
calibrated. Arrival at the close position is detected Reference position setting is not required.NOTE3
by motor torque.

NOTE
1 Gun master data is lost if the operation is canceled due to a hold or an emergency
stop during calibration that is carried out during the gun change sequence when
types 1 or 2 are selected. If this happens, manually carry out zero position
mastering.
2 With types 1 and 2, the system automatically memorizes the position where the
servo gun is detached as the reference position. This memorized reference
position is used in calibration when the same gun is next attached. For this
reason, when types 1 or 2 are selected, the detachment position and the
attachment position must be the same. Do not select types 1 or 2 when a motor
without a brake is used for the servo gun axis.
3 With types 7 and 8, the servo gun is closed during execution of the GUN DETACH
instruction ,and the system automatically memorizes the position where the servo
gun is detached. The memorized reference position is used for calibration
performed when the same un is next attached. For reason, when the calibration
motion type is changed to type 7 or 8, the gun must have been attached.

Type 1 Type 2
When the gun is detached near 0 position When the gun is detached near the open limit

About 2 turns
About2 turns

About 2 turns of motor Position when About 2 turns of motor

gun is detached Position when
(open direction) (close direction) gun is detached

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Type 3 Type 4
When the gun is detached near 0 position When the gun is detached near the open limit
Torque
Torq

Detection
Detection
About 2 turns of motor
Reference position setting Reference position
(close direction) setting position during
position during quick
quick mastering

Type 5 Type 6
When the gun is detached near 0 position When the gun is detached near the open limit
Input
signal ON
ON

OFF OFF
Detection Detection

Reference position setting About 2 turns of motor

position during quick (close direction)
mastering

Type 7 Type 8
When the gun is near the open limit at attachment
When the gun is near 0 position at attachment Torque
Torque

Detection
Detection Reference position
Reference position setting position
About 2 turns of motor during quick mastering
setting position
(open direction) during quick mastering

Fig. 13.3 Calibration motion type

Screen for Calibration Types 1, 2

SETUP GUN CHANGE
5/7
1 Comment: [ ]
2 Attach signal: DI [ 0]
3 Identify signal: DI [ 0]
4 Battery: OFF
5 Calibrate motion type: [TYPE 2]
Calibration Motion Setup
6 Calibration Speed(%): 100
7 Acc Value: ACC100

[ TYPE ] LIST [CHOICE]

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13.GUN CHANGE FUNCTION B-83264EN/03

Screen for Calibration Types 3, 4, 7, 8 Screen for Calibration Types 5, 6

SETUP GUN CHANGE SETUP GUN CHANGE
9/10 9/10
1 Comment: [ ] 1 Comment: [ ]
2 Attach signal: DI [ 0] 2 Attach signal: DI [ 0]
3 Identify signal: DI [ 0] 3 Identify signal: DI [ 0]
4 Battery: OFF 4 Battery: OFF
5 Calibration motion type: [TYPE 4] 5 Calibration motion type: [TYPE 6]
Calibration Motion Setup Calibration Motion Setup
6 Calibration Speed(%): 100 6 Calibration Speed(%): 100
7 Acc Value: ACC100 7 Acc Value: ACC100
8 Position register index:PR[ 0] 8 Position register index:PR[ 0]
9 Touch Torque(%): (+ ) 0.000 9 Detect signal: DI [ 0]
10 Detect speed(mm/s): 30 10 Detect speed(mm/s): 30

[ TYPE ] LIST [ TYPE ] LIST

(1) Open limit operation setting (Set the following when the calibration motion type 1,2,4,6,or 7 is
selected.)
Calibration speed Specify the motion speed of calibration (motion for about two turns of the motor)

(2) Position register No. setting (Set the following for all the Calibration motion Setup.)
Accelerate rate Specify the acceleration of calibration motion.
The standard value is 100(%).

(3) Position register No. setting (Set as follow when types 3 to 8 are set in the Calibration Setup)
Position register No Position register for holding the momentary position where arrival at the reference
position (open limit or signal input position) was detected
Set the position register specified here exclusively for calibration. (Do not use the same
position register in the program, for example.)

(4) Open limit detection torque setting (Set as follows when types 3, 4 , 7, and 8 are set in the Calibration
Setup.)
Touch torque (%) Threshold value of the motor torque for detecting arrival at the open limit
Set the value within range 0.0 to 100.0%.

(5) Detection signal setting (Set as follows when types 5 or 6 are set in the Calibration Setup.)
Detection signal Type and No. of input signal for detecting arrival at the reference position
•SDI
•RDI
Specify a No. available for each of the signals as the signal No.

(6) Detection speed (Set the following when the calibration motion types 3 to 8 s set)
Detection speed Specify the speed of the motion to the reference position.

13.4 SETTING THE REFERENCE POSITION

13.4.1 Battery-less Type Guns

On battery-less guns, the position (pulse value) is lost when the gun is detached. So, calibration must be
carried out when gun is attached.
The position taken as the reference for calibration is called the "reference position."
On battery-less guns, the reference point must be set before the gun is detached.
How the reference point is set differs according to the calibration motion type.

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SETUP Servogun
3/13
1 Tip Wear Comp DISABLE
2 Gun Sag Compensation DISABLE
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1[+Z ]

[ TYPE ] EQUIP GUN PLUS MINUS

NOTE
Before you set the following reference positions, be sure to set the correct
direction at Close Direction (Gun) in the Servo Gun Setup screen.

x Types 1, 2
The system automatically sets the reference position when the servo gun is detached.
x Types 3, 4
Create a program for detecting the reference position using the touch torque, and execute this program
to calculate the reference position.
For details, refer to "E-1-1 Reference Position Setup for Calibration Types 3 and 4."
x Types 5, 6
Create a program for detecting the reference position using the detection signal, and execute this
program to calculate the reference position.
For details, refer to "E-1-2 Reference Position Setup for Calibration Types 5 and 6."
x Types 7, 8
The system automatically sets the reference position when the servo gun is detached.

13.4.2 Battery-mounted Type Guns

On battery-mounted type guns, the position (pulse value) is not lost even if the gun is detached. Therefore,
the reference position used for calibration when the gun is attached need not be set as it needs to be on a
battery-less type gun. However, that we recommend setting a reference position for quick mastering by
witness mark or scribing mark as shown in the figure below for extra safety in the event that the battery
comes loose. For details on how to set the reference position for quick mastering, refer to "E-2 Quick
Mastering Reference Position Setup."

Witness mark or scribing

mark

13.5 GUN CHANGE INSTRUCTION

13.5.1 GUN DETACH Instruction

This instruction can detach the servo gun without power off. When the calibration motion type 7 or 8 is
selected , before the servo gun is detached, the servo gun is closed automatically,and the gun close position
is set the reference position.
Format : GUN DETACH[i]
i: Gun number (1 ∼ 10)

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Specify the gun number which you want to detach.

R[ ] and AR[ ] can be used.
Ex) GUN DETACH[1]
GUN DETACH[R[2]]
GUN DETACH[AR[1]]

13.5.2 GUN ATTACH Instruction

This instruction can attach the servo gun without power off. In case of batteryless gun, the mastering and
calibration are performed automatically.

Format : GUN ATTACH[i]

i: Gun number (1 ∼ 10)
Specify the gun number which you want to detach.
R[ ] and AR[ ] can be used.
Ex) GUN ATTACH[5]
GUN ATTACH[R[3]]
GUN ATTACH[AR[1]]

After servo gun is attached, the tool number is changed to the same number which is specified as a gun close
direction of fixed side in the servo gun setup screen.

SETUP Servogun
4/13
1 Tip Wear Comp DISABLE
2 Gun Sag Compensation DISABLE
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1[+Z ]

[ TYPE ] EQUIP GUN UF UT

13.5.3 Sample Program

Sample Program
[Explanation]
1: J P[1:Approach] 100% FINE 1: Move to approach position
2: L P[2:GUN1 SET] 100mm/sec FINE 2: Set gun axis to 0 position
3: GUN DETACH[1] 3: Gun 1 detach sequence executed
4: L P[1:Approach] 100mm/sec FINE 4: Mechanical detachment operation
:
11: J P[11: Approach] 100% FINE
12: L P[12:GUN2 SET] 100mm/sec FINE
13: GUN ATTACH[2] 13: Gun 2 attach sequence executed.
14: L P[13: Approach] 100mm/sec FINE
:
99: END 99: Normal end

NOTE
The above is merely a sample program. Create programs to suit the requirements
of your system.

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13.5.4 Forward Execution

It is necessary to check that the gun number of instruction is same as the actual gun. And in the case of
attach instruction, the calibration motion type must be set correct type.
In the case of batteryless gun, the calibration motion(3 in the following figure) is done.

1. Move to the attached

position Mastering and
2. Gun attach Calibration are
finished
3. Calibration motion

4. Move to the SPOT position

NOTE
In the case of calibration motion type is Type 1 or Type 2, if the motion is stopped
by e-stop or HOLD during the calibration motion, the mastering data is lost.
If the mastering data is lost, please do the zero mastering and calibration by
manual again.
Otherwise,
1) The current position on TP is not matched to the actual position.
2) If the motion instruction is executed, the following alarm is occurred.
“MOTN-049 Attempt to move w/o calibrated”
3) The GUN DETACH instruction does not work until manual mastering and
calibration are finished.

13.5.5 Backward Execution

Both GUN ATTACH and GUN DETACH instruction can not be execute by backward execution.

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13.6 GUN CHANGE SEQUENCE

GUN DETACH GUN ATTACH
Detach Attach
Robot motion
moving STOP STOP

ON
Robot lock of servo gun OFF
motion group is ON
SRDY of servo gun motor
ON
OFF

Gun attach signal

ON
OFF
Gun attach verification signal
ON
OFF

Motor power line(MCC)

Attach
Detach
Motor power line
GNDline Attach
Detach

Pulsecoder line
+5V Attach
Detach

Pulsecoder line
0V Attach
Detach

Detach/Attach status Gun1 Attach Non gun Non gun Gun2 attach
Gun1 Gun2
Detaching Attaching

13.7 GUN CHANGE STATUS

On the gun change status screen, verify that which gun is attached or detached now.

1. Press MENU key.

2. Select “0 next page”, ”4 STATUS”.
3. Press F1[TYPE].
4. Select “Gun change”.

STATUS GUN CHANGE

EQ:1 ENABLE Cont.:1 ON 1/4
AXS Comment Status
1 GUN[ 1:Part A ] ATTACH
2 GUN[ 2:Prat B ] DETACH
3 GUN[ 3:Part C ] DETACH
4 GUN[ 4:Part D ] DETACH

[ TYPE ] EQUIP

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The following status are displayed.
AXS The axis number of the motion group which is assigned to the current equipment.
Gun The gun number which is assigned to the above axis.
Status Gun status
ATTACH : The gun is attached.
DETACH : The gun is detached.
Comment The comment of each gun.

13.8 SERVO GUN SETUP

On gun change systems, the following settings must be carried out each time that the gun is changed.
For details on how to set each item, refer to the "Servo Gun Function Instruction Manual."

x Servo gun initial setup

x Servo gun general setup
x Pressure conditions setup
x Backup conditions setup
x Manual operation (manual pressuring, manual stroke, manual welding) setup
x Tip wear down value compensation setup

To select the gun to be set in each screen, use F3 GUN.

When setting the above items, the gun to be set need not necessarily be attached. (NOTE, however, that the
gun to be set must be attached when the gun is actually operated by manual pressuring, pressure adjustment
and tip wear down detection.)

Example) Servo Gun General Setup Screen

SETUP Servogun Currently selected gun No

GENERAL / EQ:1 Gun: 1 4/13
1 Tip Wear Comp DISABLE
2 Gun Sag Compensation DISABLE
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1[+Z ]

Enter gun number: 1 Key for switching gun No

[ TYPE ] EQUIP GUN UF UT

13.9 TEACHING
In the gun change system, the normal spot instruction can be used. But, in the gun change system, please
NOTE the following points.

13.9.1 Notice for Teaching

Position data
In the gun change system, the each gun is assigned to the each axis of the servo gun motion group. For
example, if three kinds of gun are assigned to gun change system, the servo gun motion group has three axes
data. This means three axes data are recorded when servo gun position is taught.

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(Ex. The position data of gun1 which is assigned to first axis)

GP1: UF : 0, UT : 1, Config : 'N, 0, 0, 0',
X = 1879.25 mm, Y = -1035.37 mm, Z = 162.65 mm,
W = -178.67 deg, P = -13.68 deg, R = -37.32 deg
GP2: UF : 0, UT : 1,
J1 = 10.00 mm J2 = 0.00 mm J3 = 0.00 mm

Please NOTE that this position data has not only gun1 data but also gun2 and gun3 data. This means this
position data can move gun2 and gun3. If gun2 is attached, gun2 moves to 0mm position. This specification
is for the flexibility of the program. But, if the user attaches different gun, it may cause interfere of gun. To
prevent this problem, please specify different tool number to the gun close direction for each gun. Because
gun attach instruction changes the tool number to specified number of the gun close direction.

SETUP Servogun
GENERAL / EQ:1 Gun: 1 4/13
1 Tip Wear Comp DISABLE
2 Gun Sag Compensation DISABLE Specify this number to each gun
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1 [+Z ]

[ TYPE ] EQUIP GUN

By this function, the position data for each gun has the different tool number. Because of this, even if the
user execute the program with different gun, the program is stopped by “INTP-253 Tool frame number
mismatch”.
When the gun attach instruction is executed, the currently selected coordinate system No. is automatically
switched to the coordinate system No. of the attached gun. So, the trouble of manually switching the
coordinate system No. does not arise even if the above settings are made.

SPOT instruction
The gun number is not specified in SPOT instruction. This means SPOT instruction does not care which gun
is attached. So, same SPOT instruction can control plural guns.
1 : J P[1] 100% FINE SPOT[P=1,S=1,BU=1]
<- Gun number is not specified.
But, in other word, the SPOT instruction taught with gun1 can be executed with gun2. To prevent this
problem, please specify different tool number to the gun close direction for each gun. This is the same
reason in the case of position data. “INTP-253 Tool frame number mismatch” stops the program execution.

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13.9.2 Sample Program

Sample program
[Explanation]
:
11:J P[11] 100% FINE SPOT[P=1,S=1,BU=1] 11:Spot weld with gun1
12:L P[12] 100mm/sec FINE
: SPOT[P=1,S=1,BU=1] 12:Spot weld with gun1
13:J P[13:Approach pos] 100% FINE 13:Move to approach position Move with tool number 1
14:L P[14:Gun1 set] 100mm/sec FINE 14:Set gun1 to gunchanger
15: GUN DETACH[1]
16:L P[13:Approach pos] 100mm/sec FINE 15:Detach gun1
: 16:Release gun1
21:J P[21:Approach pos] 100% FINE :
22:L P[22:Gun2 set] 100mm/sec FINE

23: GUN ATTACH[2]

23:Attach gun2. Tool number is changed to 2
24:L P[23:Approach pos] 100mm/sec FINE
25:J P[24] 100% FINE SPOT[P=1,S=1,BU=1]
26:L P[25] 100mm/sec FINE 25:Spot weld with gun2
: SPOT[P=1,S=1,BU=1] Move with tool number 2
: 26:Spot weld with gun2
99: END
99:Normal end

NOTE
This is sample program. Create the program related to your system.

13.9.3 Gun Change by Multi-task

Using multi-task, the robot motion instruction and Gun change instruction can be run at same time. Cycle
time can be reduced by that Gun change is done in sub-task during the robot is moved. See the following
guide when teach Gun change by multi-task.

• Set the motion mask for main-task to Gun change group is disabled.(1)
• Set the motion mask for sub-task to Gun change group is enabled.(2)
• Set Ignore pause for sub-task to OFF.(3)
• Set Equipment Number in Application Data for sub-task to the equipment number of servo gun.(4)
• Synchronize main-task and sub-task by a register.
Detach instruction must be finished in sub-task before the gun separates off from the robot
physically.(5)
Attach instruction must be finished in sub-task before start welding.(6)
• Teach UTOOL_NUM instruction. And set Tool coordinate system No. to “Gun Close
Direction(Robot)” of this gun just before run sub-task included Gun attach instruction.(7)
As preceding section, Gun attach instruction changes Tool coordinate system No. This process prevents
changing coordinate No. during the motion of (8).
Sample program (Group2 is Gun change group.)

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MAIN-TASK
Group Mask : [1,*,*,*,*] (1) SUB-TASK1
Program name :GUN1DTCH
Group Mask :[*,1,*,*,*] (2)
: Ignore pause :OFF (3)
11: CALL WELD1 Equipment Number :Equipment
12: R[51:FLAG1]=1 for Servogun(4)
13: RUN GUN1DTCH
14:J P[13:APPROACH] 100% FINE 1: GUN DETACH[1]
15:L P[14:GUN1] 100mm/sec FINE 2: R[51:FLAG1] = 0 (5)
(5) 16: WAIT R[51:FLAG1]=0 [END]
17: RO[1:CHUCK OPEN]=ON
18: WAIT RI[1:CHUCK OPEN]=ON
19:L P[13:APPROACH] 100mm/sec FINE
：
SUB-TASK2
31:J P[21:APPROACH] 100% FINE
Program name :GUN1ATCH
32:L P[22:GUN2] 100mm/sec FINE
Group Mask :[*,1,*,*,*] (2)
33: RO[1:CHUCK OPEN]=OFF
Ignore pause :OFF (3)
34: WAIT RI[1:CUCK OPEN]=OFF
Equipment Number :Equipment
35: R[52:FLAG2]=1
for Servogun(4)
(7) 36: UTOOL_NUM=2
37: RUN GUN2ATCH 1: GUN ATTACH[2]
(8) 38:L P[23:APPROACH] 100mm/sec FINE 2: R[52:FLAG2] = 0 (6)
(6) 39: WAIT R[52:FLAG2]=0 [END]
40: CALL WELD2
:

NOTE
Teach the motion instructions by selected coordinate system No. at that time.
In above sample program, LINE motion at line38 must be taught by coordinate
system No.2 because No.2 is selected at line36 before RUN GUN2ATCH.

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14 OVERTORQUE PROTECTION FEATURE

NOTE
No special hardware/software is required. This function is included in Enhanced
Servo Gun option.

14.1 OVERVIEW

Over
Torque Over
Torque

Servo Gun Over Torque Protection is part of the Enhanced Servo Gun Software Option. OverTorque
Protection is designed to reduce the damage to servo guns and servo gun actuators caused by driving the
gun open to its hard stop or closed to where tips collide at excessive force. OverTorque Protection monitors
the motor current on the servo gun axis to determine if an unexpected disturbance, such as the gun being
jogged to its end of stroke, has occurred. It will remove servo power from the motor and post a “Collision
Detect Alarm” if a potential OverTorque condition is captured. There is no guarantee that OverTorque
Protection will prevent a gun from being damaged. It is available to provide additional protection in the
case of operational and axis setup errors. The best protection for any servo gun is still careful setup and
operation of the servo gun axis by a user that respects the mechanical limitations of the gun.

There are no additional setup tasks required to activate and use OverTorque Protection. It is enabled by
default. However, proper setup of the servo gun axis and sometimes, adjustments to the standard settings of
OverTorque Protection are needed to optimize its performance. This Chapter explains how to do this.

Setup tasks important to OverTorque Protection includes selecting the proper motor and defining the tool as
a servo gun at a Controlled Start. Then set the correct max gun pressure, tip displacement ratio and
complete autotuning and calibration before proceeding with teaching operations.

Before the Servo Gun setup is complete, the OverTorque Protection is an estimate, based on theoretical data.
However, as the setup is completed, the parameters are optimized to best protect the gun.

14.2 OVERTRQUE PROTECTION SETUP

Before autotuning: motor torque is limited to a torque corresponding to the max gun pressure based on the
selected motor and tip displacement ratio. In this case a “Collision Detect Alarm” will not be posted, but a
“Move Error Excess” or “Stop Error Excess” may be indicators that the gun could not reach the commanded
position because OverTorque Protection limited the motor torque available.
After autotuning: motor torque is not limited, but actual OverTorque monitoring is active. In this case, a
“Collision Detect Alarm” will indicate a detected OverTorque condition.

Step 1: Proper Motor and Axis Setup at a Control start

1. Add servo gun axis
2. Setup servo gun axis
3. Make sure that motor selection is correct.

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4. Also, provide the proper gear ratio (tip displacement). If you don’t know it, then the gear ratio can be
found experimentally via the Servo Gun Autotuning Utility.
5. Go to a Cold Start ( function + start cold )

Step 2: OverTorque Protection Screen Basic Settings

1. Get to this menu through setup servogun
• Menu-Setup-Servo Gun-General Setup –OverTorque Protection<DETAIL>
SETUP Servogun
GENERAL / EQ:1 GUN:1 14/14
1 Tip Wear Comp: DISABLE
2 Gun Sag Compensation: DISABLE
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1 [+Z]
5 Max Motor Torque(%): 100.0
6 Max Pressure(nwt): 4900.0
Max Gun Torque(%): 10.5
7 Tip stick detect distance(mm): 5
8 Tip Wear Detection: <*DETAIL*>
9 Pressure Cal: INCOMP <*DETAIL*>
10 Tip Wear Standrd: INCOMP <*DETAIL*>
11 Weight compensation: <*DETAIL*>
12 Thickness check: <*DETAIL*>
13 Gun Stroke limit: <*DETAIL*>
14 OverTorque protection <*DETAIL*>

[ TYPE ] EQUIP GUN

Before auto tuning

The following message is displayed. Press F4 OK to go setting screen.

Overtorque protect status: ACTIVE

Collision thresholds are not

available yet, autotuning status
is not complete. But torque%
has been reduced to protect gun.
Please perform autotuning.

OK

After auto tuning

When auto tuning is complete, the following message is displayed. Press F4 OK to go setting screen.

Overtorque protect status: ACTIVE

Autotuning status is complete, and

Over torque detection thresholds
have been set.

OK

2. Make sure that OverTorque Protection is enabled. The software default is enabled.
3. Reduce the jog velocity limit to get more response time during jogging. This is optional.
NOTE: OverTorque sensitivity adjustment is not available prior to completion of autotuning
4. Digital Outputs can be set to inform if OverTorque Protection is enabled or an OverTorque “collision”
is detected

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SETUP servo gun

OVERTORQUE PROT MAIN / EQ:1 Gun:1 1/5 Sensitivity not displayed
1 OverTorque protection: ENABLE until autotuning is complete
2 Sensitivity: 100.00%
3 Parameter Summary: <*DETAIL*>
3 OverTrq protection enabled: DO[ 0]
4 OverTrq condition detected: DO[ 0]
5 Jog velocity limit(mm/sec): 250

[TYPE] EQUIP GUN ENABLE DISABLE

Step 3: Max Pressure Setting at Servogun setup screen

Overtorque Protection will prevent torque in excess of what generates Max Pressure as defined on the
servo gun setup screen and calculated from the user provided calibration data for the servo gun.
1. Get to this menu through setup servogun.
2. Set Max Pressure to the actual maximum allowable tip force for the weld gun (NOTE: the default
value is 500kgf).
The present gun torque limit can be seen beneath the max pressure item. This is % of max amplifier current.
You will also see the message: Gun torque limit is in effect. You cannot directly specify the gun torque %
on this screen .
SETUP Servogun
GENERAL / EQ:1 Gun:1 6/14
：
5 Max Motor Torque(%): 100.0
6 Max Pressure(nwt): 4900.0
Max Gun torque(%): 10.5
：

[ TYPE ] EQUIP GUN

Step 4: Perform Autotuning

See Servo Gun Autotuning section for detail on how to complete autotuning

Step 5: Perform Pressure Calibration

After autotuning, the Max Gun Torque % is still based on theoretical data, before force calibration is
completed. This theoretical limit is conservative since it assumes the weld gun is 100% mechanically
efficient. If motor torque is limited to a value based on this 100% efficiency, then the actual max pressure
won’t likely be achievable. A system variable is provided to deal with this, as described below.

NOTE
The torque limit during calibration is determined by the setting of the system
variable $SGSYSCD.$CAL_TRQ_SEV as follows:

$SGSYSCD.$CAL_TRQ_SEV = 0, the user will be able to command torque

percentages during calibration up to the maximum motor torque, as high as 100%
torque. High torques may damage the gun.

$SGSYSCD.$CAL_TRQ_SEV = 1, the user will be able to command torque

percentages during calibration up to the percentage displayed on the above
prompt. This percentage is the torque that corresponds to max pressure based on
present calibration data or theoretical limit if no calibration data is available.

Procedure
• Perform force calibration as usual.
If max gun torque is exceeded, then a prompt is displayed, as shown below

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SETUP Servogun
PRESSURE CALIB PARMS / EQ:1 Gun:1 1/14
1 Calibration Status: INCOMP
2 Pressuring Time(sec): 1.5
3 Thickness of Gauge(mm): 12.7
4 Gun Open Value(mm): 115.0
Torque(%) Speed(mm/sec) Press(nwt)
5 5.0 % 100 mm/sec 1000.0 nwt
6 10.0 % 100 mm/sec 2000.0 nwt
7 16.0 % 100 mm/sec 3000.0 nwt
Warning: max gun torque is 15.0%

[ TYPE ] CANCEL PRESSURE COMP INCOMP

Step 6: Adjustment and Description of OverTorque Protection parameters

The parameter settings can be viewed from the OverTorque Protection line item seen on the Servo Gun
General Setup Screen. By default, OverTorque Protection will be enabled and set to a sensitivity of 100%.
If you wish to adjust the OverTorque Protection settings for program open motion and jogging, change the
sensitivity on the OverTorque Protection main screen:
• 100% is what the servo gun software perceives to be the optimal setting for the mechanical gun, now
defined.
• The limit can usually be increased to 200% (twice as sensitive) or decreased to a value that varies
based on the Max Pressure for the gun.
• 50% would be ½ the collision sensitivity of 100%. The sensitivity can never be decreased to a
value that would allow a collision above the gun’s Max Pressure.
• Disabling OverTorque Protection, completely disables the OverTorque Protection feature.

SETUP servo gun

OVERTORQ PARAM SUMRY / EQ:1 Gun:1 1/1
1 Display unit: TorqCt
Max Gun torque: 1106
Std OverTorque value: 692
Max Motor torque: 7282
OverTorque thresholds:
Program close stroke(trq): 1106
Program open stroke(trq): 692
Jog close stroke(trq): 692
Jog open stroke(trq): 692

[ TYPE ] EQUIP GUN [CHOICE]

This is a display of the Parameter Summary <DETAIL>. The values on this page are for display
only. They can be used to better understand how the Sensitivity adjustment will actually effect
the collision detection capability and level of protection for the servo gun. The parameters can be
displayed in units of torque counts (TorqCt) or Units Force, based on the results of the Pressure
Calibration for the gun.

Torque counts can be converted into amplifier current by the following equation:
Amps (Pk) = TorqCt/7282 * Amplifier max current output

Item Description / NOTEs

Display Units The user can specify the display units for the Overtorque Parameters
TorqCt = Torque counts are the internal operating units for the software. Torque Counts can be
converted to motor current based on the preceding equation
Force = the TorqCt is converted to a unit of force based on the existing Pressure Calibration data

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Item Description / NOTEs

Max Gun This is the maximum collision torque that OverTorque Protection will allow for the servo
Torque gun axis. This value corresponds to the torque that will yield the Max Pressure, as specified on
the servo gun general setup screen, plus a small margin. Max gun torque is the value at which the
overtorque alarm triggers. Therefore, the margin should be specified so that Max gun torque is
slightly larger than the max torque observed during close (transient torque) and hold (static
torque). The magnitude of the margin is specified by the system variable
$sggun#.$chk_prs.$margin_p and is in units of kgf
Std OverTorque This is the standard collision detection torque. This value is derived from measurement of the
Value static friction during autotuning. When sensitivity is set to 100%, all OverTorque thresholds except
the program close stroke (used for pressuring) will be set to this value. Sensitivity adjustment will
adjust the OverTorque thresholds around the Std OverTorque value. See the equation for how
sensitivity adjustment affects the Overtorque thresholds.
Max Motor This is NOT an OverTorque limit. This value represents the maximum motor torque available from
Torque the amplifier for standard motion, such as acceleration and deceleration.

OverTorque The following values display the actual OverTorque parameters for the (4) different types of servo
thresholds gun motion. These represent the actual torque value at which a Collision Alarm will be
issued.
Program Close This is the limit for program close motion, which is for performing pressuring operations. The
Stroke value corresponds to the torque that yields the Max Pressure specified for the gun. This value can
only be adjusted by changing the Max Pressure. Since pressuring operations require large torque,
this value is always equal to the Max Gun Torque.
Program Open This is the limit for open motion of the gun during program operation. This is based on the Std
Stroke OverTorque Value and the Sensitivity
Jog Close This is the limit for close motion of the gun during jogging operation. This is based on the Std
Stroke OverTorque Value and the Sensitivity
Program Open This is the limit for open motion of the gun during jogging operation. This is based on the Std
Stroke OverTorque Value and the Sensitivity

NOTE
After Sensitivity Adjustment, it is good to check the Parameter Summary screen in
OverTorque Protection to confirm that the open stroke torque limits are still set below
the mechanical limit of the gun’s open hard stop.

NOTE
• Largest allowed gun torque = Max Gun Torque
• Sensitivity adjusts the OverTorque thresholds as follows:
Threshold = 100 / sensitivity * Std OverTorque value.
• Program Close Stroke threshold does not change with Sensitivity adjustment, it is
always equal to Max Gun Torque
• Minimum sensitivity depends on the ratio between Max Pressure and Std
OverTorque value
• If the “Std OverTorque value” is higher than “Max Gun Torque”, the OverTorque
Protection function may return an error status message. Countermeasures to this
condition include:
• Increase Max Pressure until the error status is eliminated
NOTE: Reducing the Max Pressure after this will still reduce the Max Pressure that can be
commanded for pressuring. Only the torque limit for “Program Close Stroke” won’t get
updated. Overtorque Protection for jogging and program open motion will still be maximized
• Stroke the gun many times to reduce the friction in the drive mechanism
then Autotune the gun again to re-measure the Std OverTorque value

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Effect of Tip Sticking on OverTorque Protection

Since OverTorque Protection provides for detection of unexpected motor current disturbances that are
relatively small, there is a possibility that heavy tip sticking following a spot weld will trigger collision
alarms for the servo gun axis. If these alarms are troublesome, attempt the following countermeasures (in
recommended order) to reduce the occurrence of these alarms:

1. Reduce the tip sticking. Only excessive tip sticking will cause a fault in most guns.
2. Reduce the sensitivity of OverTorque Protection. Sensitivity may be reduced to the minimum
percentage, but it is best to only reduce to a level that prevents unwanted alarms from tip sticking.
Reducing sensitivity will remove unwanted alarms in most cases and OverTorque Protection will still
be active.
SETUP servo gun
OVERTORQUE PROT MAIN / EQ:1 Gun:1 1/5
1 OverTorque protection: ENABLE
2 Sensitivity: 100.00%
3 Parameter Summary: <*DETAIL*>
3 OverTrq protection enabled: DO[ 0]
4 OverTrq condition detected: DO[ 0]
5 Jog velocity limit(mm/sec): 250

[TYPE] EQUIP GUN ENABLE DISABLE

3. Disable OverTorque Protection. Do this only as a last resort, especially when users expect to have
OverTorque Protection enabled.

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B-83264EN/03 15.PART THICKNESS CHECK FUNCTION

15 PART THICKNESS CHECK FUNCTION

Part Thickness checks can be carried out with the servo gun during execution of motion option and
standalone SPOT instructions and the Press_Motion instruction.

The part thickness check will perform a measurement to determine the Estimated Part Thickness and
compare it to the Expected part thickness. When the measured value is outside of the user-specified
tolerance a WARNING or fault can be issued, and an output can be asserted. Thickness checks can be
enabled for all spot and press_motion instructions or only when directly specified.

Target applications for Part Thickness check include detection of:

• Missing part
• Incorrect part

NOTE
Compensation for wear on the welding tips (Tip wear compensation) and bending in
the gun arms (Gun Sag compensation) are required for accurate part thickness
measurement. See the appropriate sections for details on each of these
compensation functions.

The user must complete the “Thickness Check Calibration” item on the Servogun Autotune Utility for the
part thickness function to be enabled. In addition, the user is required to:

1. Accurately set the tip displacement ratio for the gun (mm/motor revolution).
2. Keep gun tips accurately mastered so tips touch exactly at zero position. Tip wear compensation
programs are typically used to achieve this.
3. Fixed tip of gun must be in gentle contact with the metal surface during thickness check. Accurate
teaching and gun sag compensation are typically required.

DEFINITIONS:
Estimated (Measured) Part Thickness = position of the gun tips minus expected
gun deflection when the thickness check is performed.

Expected Part Thickness = part thickness from the specified pressure schedule (or
THK_VAL condition if used). This is compared to the Measured Part Thickness to
determine if the measured thickness is out of tolerance.

15.1 THICKNESS CHECK CALIBRATION

Gun Deflection Calibration Procedure
1. Press MENU.
2. Select UTILITIES.
3. Press F1, [TYPE] and select SG Auto Tune. You will see a screen similar to the following.

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UTILS Gun setup

EQ:1 Gun:1 3/3
1.Set gun motion sign: COMP
2.Set Gun specs, master gun: COMP
Tip Displacement: 15.00(mm/rev)
Open stroke limit: -150.0(mm)
Close stroke limit: 20.0(mm)
3.Auto Tune: COMP
4.Press Compensation Setup: <*DETAIL*>
5.Thickness Check calibration: INCOMP
[ TYPE ] EQUIP EXEC RESTART

4. Complete Steps 1-3 of the Servogun Autotune utility.

Refer to the Autotuning Utility sections in R-30iB CONTROLLER Servo Gun Function
OPERATOR’S MANUAL (B-83264EN).
5. Complete Pressure Calibration. Refer to the Pressure Calibration section in R-30iB CONTROLLER
Servo Gun Function OPERATOR’S MANUAL (B-83264EN).
6. Be sure that the tips touch at the zero position exactly (+/- 0.1mm). It is best to complete Tip Wear
Compensation Setup/Initialization since tip wear compensation is needed, and provides for accurate
zero position mastering of the gun tips.
7. Select the appropriate equipment and gun number using the F-keys.
8. Move the cursor to select Step 4, “Thickness Check Calibration”.

NOTE
Before starting the calibration the following items must be confirmed:
• The gun tips must be accurately mastered. Use Tip Wear Compensation Setup
program to achieve this. (any error in mastering will lead to a direct error in part
thickness measurement)
• For accuracy, Pressure Calibration must be complete.
¾ Thickness check calibration is done when Pressure Calibration is incomplete.
¾ In above, the result of calibration is the theoretical value. So this function
cannot do the best performance.
• Robot may have to be placed in AUTO or T2 and all faults cleared.

9. Press Shift + F3 (EXEC) to initiate the calibration. The following prompt box may appear when you
do this.

Accurate gun 0 position is

required for thickness check
calibration. Master gun via
tipwear update program or
automaster if current zero
position is not accurate.

[ OK ]

10. Select OK after read this note of caution.

Thickness Check calibration

exercises will begin.

ARE YOU SURE YOU WANT TO DO

THIS?

[ YES ] NO

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B-83264EN/03 15.PART THICKNESS CHECK FUNCTION
11. Select YES and press enter. The selected gun will open and close 4 times to perform the calibration.
The robot will not move during this process.

Once the deflection calibration is complete, part thickness checking can be used. The next step is to setup
and define the part thickness operation desired.

15.2 THICKNESS CHECK GENERAL SETUP

Thickness Check General Setup Procedure
1. Press MENU.
2. Select SETUP.
3. Press F1, [TYPE] and select Servo Gun. Then select the General Setup page.

SETUP Servogun
12/13
1 Tip Wear Comp DISABLE
2 Gun Sag Compensation DISABLE
3 Close Direction(Gun): PLUS
4 Close Direction(Robot): UT: 1[+Z ]
5 Max Motor Torque(%): 100.0
6 Max Pressure(kgf): 500.0
Max Gun Torque(%): 450.0
7 Tip stick detect distance(mm): 5
8 Tip Wear Detection: <*DETAIL*>
9 Pressure Cal: COMP <*DETAIL*>
10 Tip Wear Standard:COMP <*DETAIL*>
11 Weight compensation: <*DETAIL*>
12 Thickness Check <*DETAIL*>

[ TYPE ] EQUIP GUN

4. Scroll to the Thickness check item and press enter to see the Thickness Check screen.

SETUP Servogun
THICKNESS CHECK / EQ:1 Gun:1 1/8
1 Thickness check: DISABLE
2 Thickness check mode: ON RQST
3 Check at minimum pressure: DISABLE
4 Settling time (ms) 0
5 Alarm severity: WARN
6 Under thickness limit(mm): 0.5
7 Over thickness limit(mm): 0.5
8 Thickness out of tolerance: DO[ 0]

[ TYPE ] EQUIP GUN ENABLE DISABLE

5. Using the table below as a guideline, setup each item on the Thickness Check page to specify the part
thickness check operation that you desire.
Item Description / NOTEs Values
Thickness check This setting specifies whether thickness checking ENABLE Æ checking is done based on
is enabled. In the case of on request mode, this thickness check mode selected below
becomes thickness check permissive. DISABLE Æ (default) checking is globally
disabled and never done.

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15.PART THICKNESS CHECK FUNCTION B-83264EN/03

Item Description / NOTEs Values

Thickness check Specify whether every spot should be checked or ALL Æ if thickness check is set to ENABLE,
Mode only those spots that are preceded by the checks are done for every spot and press
condition, TCHK_RQD motion that is not preceded by the
TCHK_SKP condition.
ON_RQST (“on request”) Æ (default) if
thickness check is set to ENABLE, checks
are done only for each spot and press motion
that is preceded by the TCHK_RQD
condition.
Check at 0kg Specify whether thickness should be checked ENABLE Æ the weld pressure will be set to a
with no pressure in the gun. An additional step is minimum value (i.e. the gun is relaxed) prior
added to relax the gun in this case. to checking thickness, after the measurement
is done the gun will close to weld pressure
before welding.
DISABLE Æ (default) check is performed
when gun reaches the specified weld
pressure, this is the faster of the two
measurement styles.
Settling time Delay after achieving pressure, before reading 0-9999 Æ (default = 0) time in ms that
delay(ms) thickness value. Adding a delay may improve the system will wait after pressure is achieved
repeatability of the measurement but will increase before checking the part thickness.
the time required to complete the measurement
Alarm severity Severity level of message that is posted when out WARN Æ (default) if thickness check yields
of tolerance condition is detected. an out-of-tolerance value, a WARNING
message is posted but the program and weld
will execute normally
FAULT Æ if thickness check yields an
out-of-tolerance value, a fault will be issued
that will immediately stop the robot and pause
the program. No welding will be done.
Under thickness Maximum deviation from specified thickness in 0-99.9mm Æ (default = 0.5mm) A value of
limit (mm) the negative direction. For example, if: 0.0 disables the tolerance check. A value of
Expected thickness = 2.0 0.5mm or higher is recommended for most
under thickness limit = 0.5 users.
Measurements < 1.5mm are out of tolerance
Over thickness Maximum deviation from specified thickness, in 0-99.9mm Æ (default = 0.5mm) A value of
limit (mm) the positive direction. For example, if: 0.0 disables the tolerance check. A value of
Expected thickness = 2.0 0.5mm or higher is recommended for most
Over thickness limit = 0.5 users.
Measurements > 2.5mm are out of tolerance
Thickness out of The output number (DO index) asserted, when a 0 -> 999 Æ (default = 0)
tolerance DO thickness alarm occurs.
Output turns off when gun opens after weld. In
case of press_motion, output stays on until the
next motion instruction starts.

Program-Based Thickness Check Conditions

Thickness checking conditions can be set locally in the teach pendant programs to override certain items
from the Thickness Check setup page.

The TCHK_RQD condition must be used to enable a thickness check when the Thickness Check mode is
set to “On Request”.

These special conditions are activated by placing the condition statement directly before the pressuring
instruction (SPOT or Press_motion) when the thickness check is to be done. The condition is only active
for the next pressuring motion.
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B-83264EN/03 15.PART THICKNESS CHECK FUNCTION

Conditions Comment
TCHK_RQD Used to activate a thickness check when the thickness check
mode is set to On Request (ON_RQST)
TCHK_SKP Used to skip a thickness check when the thickness mode is set to
ALL
Override Conditions (parameters)
THK_TOL(under, over, gun index ) Used to override the under and over tolerance settings from the
Thickness Check setup page, values are in mm and must be >0.0
THK_SEV(severity , gun index ) Used to override the Alarm Severity from the Thickness Check
setup page.
Settings for the severity parameter are:
1 = WARNING (message only)
2 = Fault (pause program)

The optional parameter - gun index - is common to all override conditions. It is only significant when the
gun is part of a dual-gun.
1 = gun A
2 = gun B
A value of 3 (both guns) is assumed by default.

The conditions are added to teach pendant programs by inserting a CALL instruction. Each condition is
actually a MACRO program that is found in the macro program list.

Sample program demonstrating use of Thickness Check Conditions

The following setting is used;
Under thickness limit : 0.5mm (Default)
Over thickness limit : 0.5mm (Default)
Alarm severity: WARN (Default)

TP Program instruction Comments:

1: L P[1] 2000mm/sec CNT100 Expected thickness = 1.5mm
SPOT[ SD=1,P=1,t=1.5,S=1,ED=1] If measurement is greater than 2.0mm or less than 1.0mm,
warning is posted.
2: CALL THK_TOL(0.3,0.3) Under/Over limit override condition for next checking is set
3: CALL THK_SEV(2) Alarm Severity override condition for next checking is set
4: L P[1] 2000mm/sec CNT100 Expected thickness = 1.5mm
SPOT[SD=1,P=1,t=1.5,S=1,ED=1] If measurement is greater than 1.8mm or less than 1.2mm, the
program will stop.
5: L P[1] 2000mm/sec CNT100 Expected thickness = 1.5mm
SPOT[SD=1,P=1,t=1.5,S=1,ED=1] If measurement is greater than 2.0mm or less than 1.0mm,
warning is posted.

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16.GUN OPEN FUNCTION AT WELD FAULT B-83264EN/03

16 GUN OPEN FUNCTION AT WELD FAULT

This function automatically opens servo gun when weld major fault or weld complete time-out is occurred,
then movable tip and fixed tip is removed from panel. (In case of fixed servo gun, panel is removed from
fixed tip)

Executed program is paused, however user can restart welding as soon as release occurred alarm.

Curried Gun

Major fault! Auto-open

Fixed Gun

Major fault! Auto-open

WARNING
Robot move during opening fixed tip. Don't approach a robot during welding and
production.

16.1 CONDITIONS OF GUN OPEN

When fulfilling all the following conditions, gun is opened.

• Teach pendant is disable

• Weld retry have finished specified time.
• Weld major fault or weld complete time-out is occurred with closing servo gun.

However gun is not opened when the following errors are occurred.

• Errors of except weld major fault or weld complete time-out

• Receive HOLD signal during welding.

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B-83264EN/03 16.GUN OPEN FUNCTION AT WELD FAULT

NOTE
This function is DISABLE by default. Please set
$SGGUN#.$FLTOPN.$ENBLE=TRUE, if you want to use this function.
(# =gun number)

NOTE
If any error is occurred during opening gun, opening gun is aborted.

16.2 GUN OPENING MOTION

When major fault occurs, gun and robot moves so that their tips remove form panel.
This offset is the following.

Movable tip: Offset 10mm from panel

Fixed tip: Offset 5mm from teaching point
(In case of fixed gun, offset panel)

Movable tip

Part thickness Curried servo gun:

Fixed tip removes form panel
10mm Stationary servo gun
Panel removes form fixed tip.
Panel
Teaching point 5mm

Fixed tip

WARNING
TCP of Robot moves forward gun open direction at weld fault if this function is
ENABLE.
Please make sure of setup of the servo gun coordinate (ref. 2.2) and gun close
direction (ref.2.3) for your system before welding.

NOTE
In case of standalone SPOT instruction, robot offsets current position, but not
teaching position.

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17 DUAL-GUN CONTROL
17.1 OVERALL
The Enhanced Servo Gun software supports the use of dual-servo guns (i.e. conjoined-gun, twin-gun).
Typically, the guns should be physically connected twin guns that are designed to weld simultaneously.
Each tip is controlled by separate servo motors.
When two servo gun axes are added to the same motion group and equipment, they are automatically
specified by the software as a Dual-Gun. The only exception is when multiple guns are part of a gun change
system and the Gun Change option and function is enabled.

Advantages of Dual-Gun Control:

• Simultaneously welding with both gun tips
• Pressurizing can be done on one or both guns in a single pressuring instruction
• Unique weld schedules can still be specified for each gun in the same welding instruction

Limitations / Requirements:
• Each gun must have the same max tip speed and acceleration rates for proper motion control.
• The same distance and pressure schedule must be used for pressuring operations when both guns are
pressuring simultaneously, although each gun will have unique pressure calibration data

NOTE
Alarms SVGN-203 through SVGN-210 indicate that a motion setting related to
closing motion of a Spot or Press_Motn instruction did not match for the two guns.
Refer to the cause and remedy detail of the alarm for more information.

NOTE
Gun number is posted as cause code for many SVGN alarms.
SVGN-201: The posted error occurred on gun A of the dual gun.
SVGN-202: The posted error occurred on gun B of the dual gun.

If you have multiple guns on a single robot controller, but do not want to use them as a dual-gun, then place
each gun on a separate motion group and define it as a separate welding equipment. In this case, each gun
will have a unique tool center point or frame and cannot weld simultaneously.

The detail in the following sections is provided to discuss the main differences between the servo gun setup
and operation when a dual-gun is used, compared to a standard single-gun.

17.2 DUAL-GUN EQUIPMENT AND AXIS SETUP

Configuring the Equipment
When adding the axis, you must first specify that the welding equipment will be a dual-gun. To do this, set
the Number of guns to DUAL on the Spot Config screen. See the screen below

Since 7DA3 software

1. Place the cursor on the Number of guns.
2. Press the F4 key labeled CHOICE.
3. Select DUAL.

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B-83264EN/03 17.DUAL-GUN CONTROL
SPOT CONFIG
7/34
1 F Number: F00000>
2 Load Spottool Macros: DISABLED
3 Number of equipments: 1
4 Number of weld controllers: 1
5 Current equipment, gun: 1, 1
6 Weld interface: INTEGRAL
7 Number of guns: DUAL
8 Equalization Pressure: DISABLED
9 number of pressures: 0
10 Rst water saver time-out: 500 ms
11 pulse length: 500 ms

[ TYPE ] [CHOICE]

NOTE
If you add the two axes or select the Equip Type to AIR GUN, you can set up a
dual-gun.

Adding the Axes

Both axes for a dual-gun must be added to the same Motion Group.
Refer to 2. INITIAL SETTING , Section 2.1, for details on adding each axis.
After the axes are added, and the equipment type is set to servo gun as described in Section 2.1, the (2) axes
will automatically be designated as a Dual-Gun.

17.3 DUAL-GUN OPERATIONAL SETUP

When you set up dual-guns, it is important to note that most servo gun data is -shared (common). This
means there is only (1) data set for many items related to the operation of the dual-gun.
Below is a brief summary of the items that are unique to each gun and those shared by both guns.

NOTE
Hereafter, the 1st gun of the dual-gun will be referred to as Gun A, and the 2nd as
Gun B. Gun A is the gun that is controlled by the 1st axis of the aux-axis amplifier(s).

17.3.1 Servo Gun Setup

In General Setup Servo gun screen ( MENU->SETUP->F1[TYPE]-> Servo Gun->General Setup), it shows
unique data for each gun. Select the Dual gun common, you can set up common data for both guns.

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17.DUAL-GUN CONTROL B-83264EN/03

Unique Data For Each Gun

SETUP Servogun
GENERAL / EQ:1 Gun:1 1/12
1 Dual gun common: <*DETAIL*>
2 Close Direction(Gun): PLUS
3 Max Motor Torque(%): 100.0
4 Max Pressure(nwt): 4000.0
Max Gun Torque(%): 55.0
5 Tip stick detect distance(mm): 5
6 Tip Wear Detection: <*DETAIL*>
7 Pressure Cal: COMP <*DETAIL*>
8 Tip Wear Standrd: INCOMP <*DETAIL*>
9 Weight compensation: <*DETAIL*>
10 Thickness check: <*DETAIL*>
11 Weight compensation: <*DETAIL*>
12 Thickness check: <*DETAIL*>

[ TYPE ] EQUIP GUN

Change Gun Number

Common/Shared Data for Both Guns
SETUP Servogun
DUAL GUN COMMON / EQ:1 Gun:(1,2) 1/3
1 Tip Wear Comp DISABLE
2 Gun Sag Compensation DISABLE
3 Close Direction(Robot) UT:1 [+Z]

Guns(1,2) use the same data.

[ TYPE ] EQUIP GUN ENABLE DISABLE

NOTE
With dual-guns, the same TCP is used for both Gun A and Gun B. Hence, there is
only one setting for Tip Wear Down Compensation setup, Gun Sag Compensation
setup and Robot Close Direction setup - items that are all related to TCP. Generally,
it is based on TCP of Gun A.

17.3.2 Pressure Schedule, Distance Schedule, and Backup Schedule

Table
Gun A and Gun B are shared data of the pressure schedule, the distance schedule and the backup data table.
The way set up them is same in single-gun.
Refer to 4. MANUAL OPERATIONS and 5. PROGRAMMING.

Pressure Schedule
SERVO GUN DATA
PRESS / EQ:1 Gun:(1,2) 1/99
No. Press(Nwt) Manual Comment
1 0.0 FALSE [ ]
2 0.0 FALSE [ ]
3 0.0 FALSE [ ]
4 0.0 FALSE [ ]

Guns(1,2) use the same data.

[ TYPE ] EQUIP GUN DETAIL COPY >

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B-83264EN/03 17.DUAL-GUN CONTROL
Distance Schedule
SERVO GUN DATA
DIST / EQ:1 Gun:(1,2) 1/99
No. Gun(mm) Robot(mm) Comment
1 10.0 10.0 [ ]
2 10.0 10.0 [ ]
3 10.0 10.0 [ ]
4 10.0 10.0 [ ]

Guns(1,2) use the same data.

[ TYPE ] EQUIP GUN DETAIL COPY >

Backup Data Table

SERVO GUN DATA
MANUAL BKUP / EQ:1 Gun:(1,2) 1/30
No. Comment Stroke(mm) Enable
1 [ ] 0.000 FALSE
2 [ ] 0.000 FALSE
3 [ ] 0.000 FALSE
4 [ ] 0.000 FALSE

Guns(1,2) use the same data.

[ TYPE ] EQUIP GUN RECORD CLEAR

17.3.3 Gun Setup Utility Operation

The gun setup utility should be run for both Gun A and Gun B. When done, each gun will have its own
tuning, mastering, and axis stroke data. However, both Gun A and B should have the same acceleration rates
and gear ratio. If they do not, you will be prompted for instruction to deal with this.
Refer to Section 2.5 of 2. INITIAL SETTING for details about this screen.
When the selected motion group is a dual-gun, the F5 key INDEX will appear as shown below.

Operating Procedure for Gun Setup Utility

1. Press the INDEX key to switch between the two guns. The Gun number is shown at the top of the
screen to indicate which gun is presently selected.

UTILS Gun Setup

EQ: 1 Gun:1 1/1
1.Set gun motion sign: COMP
2.Set Gun specs, master gun COMP
Tip Displacement: 5.000(mm/rev)
Open stroke limit: -999.99(mm)
Close stroke limit: 999.99(mm)
3.Auto Tune: INCOMP
4.Pressure Compensation Setup: <*DETAIL*>
5.Thickness Check calibration: INCOMP

[ TYPE ] EQUIP SKIP RESTART INDEX

2. Finish the setup and tuning for both guns

3. Once both guns are set up and tuned, press the F6 key (Next+F1) labeled DG_CHECK to review the
motion settings for the two guns. A screen like the one below will appear.

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17.DUAL-GUN CONTROL B-83264EN/03

Dual Gun check

EQ: 1
GunA GunB
1.Tip displacment(mm/rev): 14.050 14.050
2.Maximum speed(mm/sec): 702.5 702.5
3.Accel time1(ms): 200 200

Speed, acc are same, press prev to exit

SETSPD SETACC

4. If there is a discrepancy between Gun A and Gun B, press the appropriate key:
• F4 –> to change speeds
• F5 —> to change accel times
for options to resolve the data conflict.
Dual Gun check
EQ: 1
GunA GunB
1.Tip displacment(mm/rev): 14.050 14.050
2.Maximum speed(mm/sec): 702.5 702.5
3.Accel time1(ms): 200 200

Speed differs, press F4 to update speed

SETSPD SETACC

17.3.4 Pressure Calibration

Pressure Calibration must be performed separately for both Gun A and Gun B.
The motion control system for servo gun will guarantee synchronized contact to the programmed metal
surface at the calibrated contact speed, during execution of SPOT instructions. To support this feature, both
Gun A and Gun B must be pressure calibrated with the same contact speeds.
If the contact speed will not be set to the same value for all calibration points, then the procedure below
must be followed to ensure there is no mismatch between Gun A and Gun B contact speed data.

1. Complete Pressure Calibration for Gun A normally.

NOTE
With dual-guns, contact speed is not automatically updated. Adjust contact speed
with monitoring pressure wave.

SETUP Servogun
PRESSURE CALIB PARMS / EQ:1 Gun:1 1/14
1 Calibration Status: INCOMP
2 Pressuring Time(sec): 1.5
3 Thickness of Gauge(mm): 12.7
4 Gun Open Value(mm): 115.0
Torque(%) Speed(mm/sec) Press(nwt)
5 5.0 % 25 mm/sec 1000.0 nwt
6 10.0 % 50 mm/sec 2000.0 nwt
7 15.0 % 75 mm/sec 3000.0 nwt
8 20.0 % 100 mm/sec 4000.0 nwt

[ TYPE ] CANCEL PRESSURE COMP INCOMP

2. Set the contact speed and pressure set-points to the same value for Gun B.

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B-83264EN/03 17.DUAL-GUN CONTROL

SETUP Servogun
PRESSURE CALIB PARMS / EQ:1 Gun:1 1/14
1 Calibration Status: INCOMP
2 Pressuring Time(sec): 1.5 Set speed & press to the
3 Thickness of Gauge(mm): 12.7 same value as Gun A.
4 Gun Open Value(mm): 115.0
Torque(%) Speed(mm/sec) Press(nwt)
5 5.0 % 25 mm/sec 1000.0 nwt
6 10.0 % 50 mm/sec 2000.0 nwt
7 15.0 % 75 mm/sec 3000.0 nwt
8 20.0 % 100 mm/sec 4000.0 nwt

[ TYPE ] CANCEL PRESSURE COMP INCOMP

3. Pressure Calibrate Gun B by finding the Torque % that achieves each pressure set-point at the
specified contact speed.

Refer to Section 2.6 of 2. INITIAL SETTING for details about performing Pressure Calibration.

17.4 DUAL-GUN MANUAL AND PROGRAM OPERATION

Refer to 4. MANUAL OPERATIONS and 5. PROGRAMMING for general details about the following
operations

17.4.1 Manual Operations

Manual Pressurization and Manual Backup Stroke
TP hard keys for the manual pressurization and manual backup stroke operations are the same for Gun A as
in the single-gun system. These operations are controlled with TP hard keys 1 and 2.
Manual pressurization and manual backup operation for Gun B is controlled with TP hard keys 3 and 4,
respectively. These settings are hard-coded with the dual-gun software and cannot be changed.

You can specify whether each gun, A & B, can operate independently or together for these manual
operations by specifying this in the Manual Operation Setup screen.
When the item labeled “Number of Guns to Use” is set to (2), both hard keys associated with the operation
(pressuring or backup) will operate both guns when pressed. When set to (1), only the gun assigned to the
hard key you press will operate. In each case, the schedule that appears in the prompt box at the upper right
corner of the teach pendant will be executed.
When set to (1), only
SETUP Servogun the gun assigned to
MANUAL / EQ:1 Gun:1 1/8 the key you press will
Manual Pressure execute manual
1 Number of guns to use: 1 pressurization.
2 Pressuring Time(sec): 0.0
3 Start distance type: INITIAL DIST
4 End distance type: INITIAL DIST
5 Thickness table(presets): <*DETAIL*> When set to (2). both
Manual Backup guns will execute the
6 Number of guns to use: 2 same manual backup
7 Backup Speed(%): 100 simultaneously when
8 Backup stroke: <*DETAIL*>
either gun’s backup
[ TYPE ] EQUIP GUN
hard key is pressed.

Manual Weld
The manual weld function works nearly the same for dual-gun as for a single-gun. The weld schedule must
be specified for both Gun1 and Gun 2 of the dual-gun (Gun A and B).
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17.DUAL-GUN CONTROL B-83264EN/03

When the weld schedule is set to (0), the gun assigned to that weld schedule will not close or weld.
For the settings shown on the sample screen below:
Gun A of the dual-gun will execute a weld with weld schedule #16.
Gun B of the dual-gun will not execute a weld, it will stop closing at the start distance, wait until the weld
operation is done on Gun A, then open to the End distance.

SETUP Servogun
1/7 Gun A of the dual-gun
Manual Weld (Last Weld) will execute a weld
1 Start distance sched: ( 0) 1 with weld schedule #16.
2 Pressure schedule: ( 0) 4
3 Wld sch(G1): ( 0) 16
4 Wld sch(G2): ( 0) 0 Gun B of the dual-gun will
5 End distance sched: ( 0) 1
not execute a weld, it will
6 Thickness G1: ( 0.0) 2.0
7 Thickness G2: ( 0.0) 0.0
stop closing at the start
Weld duration(ms): 0 distance, wait until the
weld operation is done on
[ TYPE ] EXEC RECD THK MEAS THK Gun A, then open to the End
distance.

17.4.2 Gun Jog Operation

Gun A is jogged with the J1 jog keys (+X, -X)
Gun B is jogged with the J2 jog keys (+Y, -Y)
As always, you must select the motion group assigned to the servo gun before you begin a jog operation.

17.4.3 Programming Operation

SPOT Instruction Format
The basic spot instruction format is designed to allow you to selectively weld with one or both of the guns.
The spot instruction includes a unique weld schedule parameter for both Gun A and Gun B.
The basic format is shown below:

SPOT [SD=m, P=n, t=i, S=(j,k) ED=m]

j : Welding schedule number assigned to Gun A

k: Welding schedule number assigned to Gun B

If either Gun A or Gun B is assigned the welding schedule (0), that gun will not operate during the welding
sequence. Instead, it will stop closing at the Start Distance, wait for the welding operation to complete, and
then open to the End Distance.

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STYLE01 i
1/2
1: !Dual Gun Spot Program Example
2: !Dual Gun
3:L P[1] 2000mm/sec CNT100 Line 3: Both Gun A & B will
: SPOT[SD=1,P=1,t=2.0,S=(1,1),ED=1 execute Weld Schedule #1
: ]
4: !GUN A
5:L P[2] 2000mm/sec CNT100 Line 5: Only Gun A will
: SPOT[SD=1,P=1,t=2.0,S=(1,0),ED=1 execute Weld Schedule #1
: ]
6: !GUN B Line 7: Only Gun B will
7:L P[3] 2000mm/sec CNT100 execute Weld Schedule #1
: SPOT[SD=1,P=1,t=2.0,S=(0,1),ED=1
: ]
[End]

[ INST ] [EDCMD] >

Press Motion Instruction Format

The basic press motion instruction format is also designed to allow you to selectively pressurize with one or
both guns.

NOTE
Depending on your software version, the press motion instruction format may differ.
Check your software version, and execute the correct steps.

The basic format is shown below:

PRESS_MOTN [SD=m,P=n,SEL=(j,k),t=i]

j: Pressure flag number assigned to Gun A

k: Pressure flag number assigned to Gun B

Each pressure flag is set to (1) or (0). If a pressure flag is set to (1), the gun that correspond to the pressure
flag will pressurize. If the pressure flag is set to (0), the gun will not close or pressurize. Instead, it will stop
closing at the Start Distance, wait for the press motion to complete.
If both flags are set to (1), both guns will pressurize.

Below are examples of some valid and in-valid settings from the Press_Motn instruction with dual-gun:

STYLE01 i
1/2
1: !Dual Gun Spot Program Example
2: !Dual Gun
3: PRESS_MOTN[SD=1,P=1,SEL=(1, Line 3: Both Gun A & B will
: 1),t=2.0] execute Pressure Schedule #1
4: !GUN A
5: PRESS_MOTN[SD=1,P=1,SEL=(1,
: 0),t=2.0] Line 5: Only Gun A will
6: !GUN B execute Pressure Schedule #1
7: PRESS_MOTN[SD=1,P=1,SEL=(0,
: 1),t=2.0] Line 7: Only Gun B will
[End] execute Pressure Schedule #1
[ INST ] [EDCMD] >

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17.4.4 Tip Wear and Gun Sag Compensation

Tip wear and Gun Sag compensation for the dual-gun is supported. Tip wear setup and update programs
must be run for both Gun A and Gun B separately. Each gun will be re-mastered individually and have a
unique wear amount for each tip.

• Only Gun A is used in a Spot instruction

The robot tip compensation amount will be based on the robot tip wear (i.e. fixed tip wear) and gun sag
of Gun A
• Only Gun B is used in a Spot instruction
The robot tip wear and gun sag amount of Gun B will be applied as the compensation amount.
• Both Gun are used in a Spot instruction
The robot tip compensation amount will be based on the robot tip wear (i.e. fixed tip wear) and gun sag
of Gun A

If the robot/fixed tip wear amount between Gun A and Gun B varies by too much this may cause a problem
with the welding operation. The system variable $SGDGCFG[eq#].$MAX_DG_DIFF specifies the
maximum allowable difference between the robot tip wear on Gun A and Gun B before the alarm
SVGN-034:“Excessive Robot Tip Difference” is posted. This is set to 5.0mm by default, but you can
change this value if necessary.

17.4.5 Part Thickness Check

The part thickness check can be performed for both Gun A and Gun B on a dual-gun. If Part thickness check
is enabled for both guns, the measurements will occur sequentially.
The basic sequence during a Spot instruction when part thickness check is enabled for both guns is:
1. Gun Tips Close
2. Both Tips achieve specified tip pressure
3. Wait for the longer of the (2) Settling Times
4. Measure Thickness for both guns sequentially
5. Initiate Welding Sequence

17.4.6 Gun Open Function at Weld Fault

When major fault occurs, gun and robot moves so that their tips remove from panel.
This offset is following.

• Distance of robot tip from panel : $sggunA.$fltopn.$open_rbt

• Open distance of Gun A from panel : $sggunA.$fltopn.$open_rbt
• Open distance of Gun B from panel: $sggunA.$fltopn.$open_rbt

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B-83264EN/03 17.DUAL-GUN CONTROL

Gun tip of gun A Gun tip of gun B

Panel thckness
$sggunB.$fltopn.$open_gun
$sggunA.$fltopn.$open_gun
Panel
Teaching point
$sggunA.$fltopn.$open_rbt

Robot tip of gun A. Robot tip of gun B.

Robot tips are executed common motion.

(Same distance of gun A)

Refer to 16. GUN OPEN FUNCTION at WELD FAULT for details.

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18 SERVO GUN WEIGHT COMPENSATION

18.1 OVERVIEW
The weight of the gun moving element might influence a tips and driving system of the servo gun at a
certain welding position. Therefore, an actual pressure might not be able to satisfy the pressure of desire. In
the spot welding, the change of the pressure causes the poor weld and the spatter, and exerts a bad influence
on the welding quality.
Pressure input Actual pressure

=
Gun axis weight Gun axis weight
=

+
=
Actual pressure Actual pressure Pressure input Pressure input

Weight hangs in the closing direction Weight doesn't hang in the closing direction Weight hangs in the opening direction

This function can suppress the change of the pressure by the weight of the gun moving element according to
the welding position.
The accuracy of an actual pressure that relates to the welding quality can be improved by using this
function.

Kind/shape of the servo gun that can use this function is C gun and X gun.

This function consists of the following three functions.

• Auto weight compensation function
• Semi-auto weight compensation function
• Manual weight compensation function

18.2 SERVO GUN WEIGHT COMPENSATION FUNCTION

Auto/Semi-auto weight compensation function
This function estimates the weight of the gun moving element beforehand, the compensation value
corresponding to the welding position is calculated based on the weight estimation result and the welding
position, and the compensation value is added to the pressure.

The procedure of the weight estimation is different depending on an auto weight compensation function and
a semi-auto weight compensation function.
Function Procedure
Auto weight compensation The weight of the gun moving element is automatically estimated by opening and
function closing the gun. Kind/shape of the servo gun that can use auto weight compensation
function is C gun. X gun cannot use the auto weight compensation function.
Semi-auto weight C gun
compensation function The pressure is measured at a welding position different from the posture at the
pressure calibration. The weight of the gun moving element is estimated based on the
measurement result and the welding position at that time.
X gun
The pressures are measured at welding positions different from the posture at the
pressure calibration. The weight of the gun movable element is estimated based on the
measurement results and the welding positions at those times.

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Manual weight compensation function

This function makes the pressure-welding position table beforehand, forecasts the change of the pressure
corresponding to the welding position from this table when the spot instruction is executed, and
compensates the pressure based on the amount of the change.

18.3 SETTING EACH WEIGHT COMPENSATION FUNCTION

This chapter explains the following items.
• Initial setting
• Setting auto weight compensation function: About the weight estimation procedure
• Setting semi-auto weight compensation function: About the weight estimation procedure
• Setting manual weight compensation function: About the pressure-welding position table making
procedure

18.3.1 Initial Setting

Complete the following settings before starting the setting of each weight compensation function.

NOTE
Initial setting is common in the each weight compensation function.

CAUTION
Complete initial setting before executing the pressure calibration when you use the
semi-auto/manual weight compensation function. It is necessary to execute the
pressure calibration again when the initial setting is completed after the pressure
calibration.

SETTING THE COORDINATE SYSTEM

•Carried gun

Z Make sure that Z tool coordinate axes is parallel with the

longitudinal direction of the fixed side tip.

• Pedestal gun

Z Make sure that Z user coordinate axes is parallel with the

longitudinal direction of the fixed side tip.

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NOTE
1 Refer to the 2.2 SETTING THE COORDINATE SYSTEM in R-30iB
CONTROLLER Servo Gun Function OPERATOR’S MANUAL (B-83264EN) for
details concerning the setting of the coordinate system.
2 Set the user coordinate system by using the variable remote TCP function when
this function is used due to pedestal gun. This function need not be used in the
pedestal gun system to which the variable remote TCP function is needless.

CAUTION
The accuracy of Z tool/user coordinate axes largely depends on the accuracy of the
weight estimation and the weight compensation in this function. All settings must be
made to maximize the accuracy of Z tool/user coordinate axes.

SETTING THE COORDINATE SYSTEM NUMBER

Set the coordinate system number according to the following table.
The coordinate system number set here is used for the weight estimation and the weight compensation of
this function.

1. Press the MENU key to display the Screen menu.

2. Select 6 SETUP.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Servo Gun.

SETUP Servogun
GENEREAL / EQ:1 Gun:1 3/13
1 Tip Wear Comp DISABLE
2 Gun Sag Compensation DISABLE
3 Close Direction(Gun): PLUS
4 Close Direction(Rpbot): UT: 3 [+Z]

[TYPE] EQUIP GUN

Carried gun Specify the tool coordinate system number that Z axis is parallel with the longitudinal
direction of the fixed side tip.
Tool coordinate system No.3
Z

Ex) 4 Close Direction(Robot): UT: 3 [+Z ]

Pedestal gun Specify the user coordinate system number that Z axis is parallel with the
longitudinal direction of the fixed side tip.
User coordinate system No.4
Z

Ex) 4 Close Direction(Robot): UF: 4 [+Z ]

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SETTING SERVO GUN TYPE

The procedure of the setting of the each one weight compensation function is different according to
kind/shape of the servo gun. Kind/shape of the servo gun that can use this function is C gun and X gun now.
Other servo gun cannot use this function. Here, kind/shape of the servo gun that wants to compensate the
weight is specified.
Set the servo gun type according to the following table.

1. Press the MENU key to display the Screen menu.

2. Select 1 UTILITIES.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Gun Setup. Move the cursor on <*DETAIL*> of Press Compensation Setup and press ENTER
key.
5. Move the cursor on Weight Compensation, press F4 CHOICE and select the servo gun type. In case of
dual gun, same servo gun type have to be selected. Specify "DISABLE" to servo gun type when you
do not use this function.

UTILS Gun setup Press Compens

EQ:1 Gun:1 2/3 EQ:1 Gun:1 1/2
1.Set gun motion sign: COMP
2.Set Gun specs, master gun: COMP 1.Weight Compensation: CgunType
Tip Displacement: 15.00(mm/rev) 2.Temperature Compensation: DISABLE
Open stroke limit: -150.0(mm)
Close stroke limit: 20.0(mm)
3.Auto Tune: COMP
4.Press Compensation Setup: <*DETAIL*>
5.Thickness Check calibration: INCOMP

Press enter to setup for this item.

[TYPE] EQUIP EXEC RESTART [TYPE] RETURN [CHOICE]

SET UP UT CORRECT ANGLE

If “X gun type” was selected in “Weight compen gun type”, you need to input “WT compen UT correct
ang” in the “WEIGHT COMPEN SETUP”. UT correct angle is the angle from Y-axis of tool or user frame
to Y-axis of gun posture frame. The region of UT correct angle is 0 to 360 degree based on Y-axis of tool or
user frame. Gun posture frame is defined following,
1. Z-axis of gun posture frame is parallel to Z-axis of tool or user frame.
2. Y-axis of gun posture frame is parallel to the axis of rotation that movable tip of X gun is rotated.
3. X-axis of gun posture frame is oriented from the axis of rotation of movable tip to pressurize point.
If “C gun type” was selected in “Weight compen gun type”, you don,’t need to input it.

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Gun Posture Frame Tool Frame

y’ ψ y

z
z’ x’ SETUP Servogun _
x WEIGHT COMPEN SETUP / EQ:1 Gun:1 1/6
1 Semi-auto weight compen: <*DETAIL*>
2 Manual weight compen: <*DETAIL*>
3 WT compen UT Correct ang(deg): 30.0 =ψ
4 WT compn press low lim (nwt): 0.0
5 WT compn val upper lim(nwt): 0.0
6 WT compn val lower lim(nwt): 0.0

[TYPE] EQUIP GUN >

Axis of rotation of movable tip.

18.3.2 Setting Auto Weight Compensation Function

This chapter explains the procedure of the weight estimation for the auto weight compensation function.
Set the auto weight compensation function according to the following procedures.

NOTE
Select servo gun type to do the following procedure.
Please refer to the previous section about selection of servo gun type.

1. Press the MENU key to display the Screen menu.

2. Select 1 UTILITIES.
3. Press F1 TYPE and select Gun Setup.
4. Select "Weight compensation". (Move the cursor on <*DETAIL*> and press ENTER key.) You will
see a screen similar to the following.

UTILS WT compens setup

EQ:1 Gun:1 1/6
1.Weight caluculation: INCOMP
2.Weight of axis = 0.0(N)
3.Angle at calculation = 90.0(deg)
4.Angle at pressurization = 30.0(deg)
5.Angle at pressure cal = 0.0(deg)
6.Pressure for compens = 0.0N

[TYPE] EQUIP EXEC RESET

5. Move the servo gun until the value of "Angle at calculation" becomes about 0 degrees.

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NOTE
Angle at calculation = 0 degrees: the pressure
direction becomes perpendicular and downward.
The accuracy of the weight estimation improves
as the value of the “Angle at calculation”
approaches 0 degrees. Therefore, move the
posture of the servo gun so that the value of
“Angle at calculation” may become about 0
degrees. The tolerance of “Angle at calculation” is
Angle at calculation = 0 degrees ±5 degrees.

UTILS WT compens setup _

EQ:1 Gun:1 1/6
1.Weight caluculation: INCOMP When "Weight
2.Weight of axis = 0.0(N)
calculation" is "INCOMP",
3.Angle at calculation = 3.0(deg)
4.Angle at pressurization = 30.0(deg) present gun posture is
5.Angle at pressure cal = 0.0(deg) displayed.
6.Pressure for compens = 0.0N

[TYPE] EQUIP EXEC RESET

6. Move the cursor to " Weight calculation " and press SHIFT + F3 to start the weight estimation process.
If weight estimation completed successfully a screen similar to the following should appear, and the
result of weight estimation is displayed in "Weight of axis".

UTILS WT compens setup _

EQ:1 Gun:1 1/6
1.Weight caluculation: COMP When "Weight
2.Weight of axis = 11.0(N)
calculation" is "COMP",
3.Angle at calculation = 3.0(deg)
4.Angle at pressurization = 30.0(deg) the posture at calibration
5.Angle at pressure cal = 0.0(deg) is disp layed.
6.Pressure for compens = 1.5N

[TYPE] EQUIP EXEC RESET

CAUTION
The servo gun axis moves at max speed, during weight estimation. Weight
estimation can be performed with the teach pendant enabled or disabled.
Make sure that no personnel are in the vicinity of the gun, when you execute
weight estimation.

NOTE
The following conditions must be met for the weight estimation process to start
from the Gun Setup Utility:
· Not in STEP mode
· No faults exist
· No holds exist
· Servo gun is not in machine lock
· The control reliable keyswitch is in AUTO or T2.
· Gun is in STROKE mode

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NOTE
When robot is in T2 mode, TP is ENABLE, user have to keep pressing SHIFT key
and deadman switch.
When robot is in AUTO mode, TP is DISABLE, user does not have to keep
pressing SHIFT key and deadman switch.

The meaning of each item displayed on this screen is the following. Confirm the status of each item.
Item Description
Weight calculation The state of the weight estimation is displayed. When weight estimation is
completed, the display changes from INCOMP to COMP.
Weight of axis The result of weight estimation is displayed. This value is used in the auto weight
compensation function. This value can be adjusted. Refer to the following weight
adjustment method for details of the adjustment.
Angle at calculation When “Weight calculation“ is COMP, the posture of the gun when estimating is
displayed.
When “Weight calculation“ is INCOMP, the posture of the present gun is displayed.
Angle at pressurization It is used for the “Pressure for compens”.
Angle at pressure cal It is used for the “Pressure for compens”.
When pressure calibration is COMP, the posture of the gun when calibrating is
displayed.
When pressure calibration is INCOMP, 0 degrees are displayed.
Pressure for compens The compensation value is displayed. This value is a example and was calculated
by using “Weight of axis” and “Angle at pressurization”. Refer to the weight
compensation.

Weight adjustment method

Adjust the value of “Weight of axis” when the compensation to the pressure is not good. The adjustment
procedure is as follows.
1. Move the cursor to " Weight calculation " and press ENTER key. You will see a screen similar to the
following.
2. Input the weight. The weight calculated by the weight estimation is displayed. Refer when you input
the weight.
3. Press F3 COMP. The following prompt is displayed. Select YES if there is no problem after
confirming the content of the input.

Set weight of axis

EQ:1 Gun:1 2/3 Weight of axis for
Set weight of axis for compensation. Calculation can be update.
Result of detection is 74.3(N). Weight changes
Input weight for calculation. 82.0 Nwt
82.0 (N)
Do you wish to update weight
Press F3 COMP when finished.
of axis?

[TYPE] COMP [ YES ] NO

NOTE
X gun cannot use the auto weight compensation function.

18.3.3 Setting Semi-auto Weight Compensation Function

This chapter explains the procedure of the weight estimation for the semi-auto weight compensation
function.
The weight estimation in the semi-auto weight compensation function estimates the weight of the gun
moving element from an actual pressure. Do the following work after completing the 12.2.1 Initial setting.
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1. Execute the pressure calibration.
CAUTION
Complete 12.2.1 Initial setting before executing the pressure calibration. When
Initial setting is done after the pressure calibration is completed, it is necessary to
execute the pressure calibration again.

2. Prepare a manual pressurization. (Refer to 4.1 MANUAL PRESSURIZATION.)

CAUTION
Follow the following limitations when you specify the pressure schedule of a
manual pressurization.
· Specify DISABLE for “Weight compensation type”.
· The weld pressure must specify the pressure most often used.
· Specify the weld pressure within the range from the minimum pressure to the
maximum pressure specified by the pressure calibration.

Set the semi-auto weight compensation function according to the following procedures after completing the
above-mentioned work.

1. Press the MENU key to display the Screen menu.

2. Select 6 SETUP.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Servo Gun. Move the cursor on <*DETAIL*> of General Setup and press ENTER key.
5. Select "Weight compensation". (Move the cursor on <*DETAIL*> and press ENTER key.) Weight
compensation setup screen appears.
6. Select "Semi-auto weight compen". (Move the cursor on <*DETAIL*> and press ENTER key.)
Semi- auto weight compensation setup screen appears.
Case: C gun
The pressure is measured at a welding position different from the posture at the pressure calibration. The
weight of the gun moving element is estimated based on the measurement result and the welding position at
that time.
1. Input the same value as the weld pressure of the manual pressurization prepared to the "Command
pressure".
2. Move servo gun to the position separated from the angle at the pressure calibration 70 degrees or more.
The movement angle of servo gun will be able to be obtained from "Current angle(deg)" and
"Angle(deg) at press calib".

NOTE
The angle between the posture at the pressure calibration and the posture of
present servo gun influences the accuracy of the weight estimation. The accuracy
of the weight estimation improves as this angle increases.

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SETUP Servogun _
SEMI-AUTO COMP C_GUN / EQ:1 Gun:1 1/2
Current angle(deg): 150.0
Angle(deg) at press calib: 10.0

1 Command pressure (N): 2000.0

Current weight (N): 0.0
Weight estimation: INCOMP

Press( N ) Angle(deg) Weight( N )

2 0.0 0.0 0.0

[TYPE] CALC UPDATE INCOMP

Move

140deg

150deg

10deg
Posture at the pres sure

calibration Current Posture

10de g

3. Input the value displayed in "Current angle (deg)" to "Angle (deg)" after completing the movement of
the servo gun.
4. Execute a manual pressurization, and measure the pressure with a pressure gage.
5. Input the value of the pressure gage to "Press".

Pressure gage
SETUP Servogun _
SEMI-AUTO COMP C_GUN / EQ:1 Gun:1 1/2
Current angle(deg): 150.0
Angle(deg) at press calib: 10.0

1 Command pressure (N): 2000.0 150deg

Current weight (N): 0.0
Weight estimation: INCOMP

Press( N ) Angle(deg) Weight( N ) 1882 N

2 1882.0 150.0 0.0

[TYPE] CALC UPDATE INCOMP Perpendicular direction

6. Press F2 CALC. The weight is estimated, and the weight is displayed in "Weight".
7. Press F3 UPDATE. The current weight is updated to the latest weight, and “Weight estimation” is
changed to “COMP.”
8. Adjust the value of "Weight" when the compensation to the pressure is not good. The weight can be
input by moving the cursor to "Weight", and pushing the enter key. Press F3 UPDATE when the input
ends.
9. Press F5 INCOMP when you do the weight estimation over again.
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Case: X gun
The pressures are measured at welding positions different from the posture at the pressure calibration. The
weight of the gun movable element is estimated based on the two measurement results and the two welding
positions at those times.
1. Input the same value as the weld pressure of the manual pressurization prepared to the "Command
pressure".
2. Move servo gun to the position separated from the angle at the pressure calibration 70 degrees or more.
The movement angle of servo gun will be able to be obtained from "Current angle(deg) X axis",
"Current angle(deg) X axis", "Press calib angle X axis" and “Press calib angle Y axis”. When you
decide welding positions, refer to “The guide of the welding position for weight estimation”.

-70deg

Move
-10deg
-20de g
-100de g

-80deg
Posture at pressure calib ration -20deg - 10de g

-120deg

SETUP Servogun _
SEMI-AUTO X_GUN / EQ:1 Gun:1 1/3
Current angle(deg) X axis: -120.0
Current angle(deg) Y axis: -80.0
Press calib angle X axis: -20.0
Press calib angle Y axis: -10.0

1 Command pressure (N): 2500.0

Current weight1 (N): 0.0
Current wehght2 (N): 0.0
Weight estimation: INCOMP

Press(nwt) Ang X/Y(deg) Weight(nwt)

2 0.0 0.0 0.0 0.0
3 0.0 0.0 0.0 0.0

[TYPE] CALC UPDATE INCOMP

3. Input the value displayed in "Current angle (deg) X axis" and "Current angle (deg) Y axis" to
"Ang_X/Y(deg)" after completing the movement of the servo gun.
4. Execute a manual pressurization, and measure the pressure with a pressure gage.
5. Input the value of the pressure gage to "Press".

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SETUP Servogun _
SEMI-AUTO X_GUN / EQ:1 Gun:1 1/3
Current angle(deg) X axis: -120.0 pressure gage
Current angle(deg) Y axis: -80.0
Press calib angle X axis: -20.0
Press calib angle Y axis: -10.0

1 Command pressure (N): 2500.0

Current weight1 (N): 0.0
Current wehght2 (N): 0.0
Weight estimation: INCOMP

Press(nwt) Ang X/Y(deg) Weight(nwt)

2 2381.0 -120.0 -80.0 0.0
2381 N
3 0.0 0.0 0.0 0.0

[TYPE] CALC UPDATE INCOMP

6. Repeat the procedure 2-5.

7. Press F2 CALC. The weights are estimated, and the weights are displayed in "Weight".
8. Press F3 UPDATE. The current weights are updated to the latest weights, and “Weight estimation” is
changed to “COMP.”
9. Adjust the value of "Weight" when the compensation to the pressure is not good. The weight can be
input by moving the cursor to "Weight", and pushing the enter key. Press F3 UPDATE when the input
ends.
10. Press F5 INCOMP when you do the weight estimation over again.

The guide of the welding position for weight estimation

In order to estimate the weights of movable element in the gun correctly, be careful of the following points
when you decide a welding positions.
• The two positions are rotated around different axis of rotation, for example 1st position is rotated
around Y-axis from posture at pressure calibration, and then 2nd position is rotated around X-axis
from 1st position.
• Move servo gun to the position separated from every position 70 degrees or more. The accuracy of the
weight estimation improves as this angle increases.

18.3.4 Setting Manual Weight Compensation Function

This chapter explains the procedure to make the pressure-welding position table in the manual weight
compensation function.
In the manual weight compensation, an actual pressure is measured at multiple welding positions, and the
pressure-welding position table is made based on the measurement result, and the compensation formula is
made from the table. Do the following work after completing the 12.2.1 Initial setting.

1. Execute the pressure calibration.

CAUTION
Complete 12.2.1 Initial setting before executing the pressure calibration. When
Initial setting is done after the pressure calibration is completed, it is necessary to
execute the pressure calibration again.

2. Prepare a manual pressurization. (Refer to 4.1 MANUAL PRESSURIZATION.)

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CAUTION
Follow the following limitations when you specify the pressure schedule of a
manual pressurization.
· Specify DISABLE for “Weight compensation type”.
· The weld pressure must specify the pressure most often used.
· Specify the weld pressure within the range from the minimum pressure to the
maximum pressure specified by the pressure calibration.

Set the manual weight compensation function according to the following procedures after completing the
above-mentioned work.

1. Press the MENU key to display the Screen menu.

2. Select 6 SETUP.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Servo Gun. Move the cursor on <*DETAIL*> of General Setup and press ENTER key.
5. Select "Weight compensation". (Move the cursor on <*DETAIL*> and press ENTER key.) Weight
compensation setup screen appears.
6. Select "Manual weight compen". (Move the cursor on <*DETAIL*> and press ENTER key.) Manual
weight compensation setup screen appears.

Case: C gun
An arbitrary pressurizing is done at multiple welding positions, and the pressure is measured. And the
pressure-welding position table is made based on the pressure measurement result and welding positions.
1. Input the same value as the weld pressure of the manual pressurization prepared to the "Command
pressure".
2. Move the servo gun suitably.
3. Input the value displayed in "Current angle (deg)" to "Angle (deg)" after completing the movement of
the servo gun.
4. Execute a manual pressurization, and measure the pressure with a pressure gage.
5. Input the value of the pressure gage to "Press".

SETUP Servogun _
MANUAL COMPEN C_GUN / EQ:1 Gun:1 1/14
1 Command pressure(nwt): 2000.0
Compensation formula: INCOMP
Current angle(deg): 10.0 Pressure gage

Pressure(nwt) Angle(deg) OK/NG

2 1998.0 10.0 NG 1998 N
3 0.0 0.0 NG
4 0.0 0.0 NG Perpendicular
5 0.0 0.0 NG
6 0.0 0.0 NG direction
7 0.0 0.0 NG 10deg

[TYPE] CALC INCOMP

6. Repeat the procedure 2-5 two or more times.

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SETUP Servogun _ Pressure gage

MANUAL COMPEN C_GUN / EQ:1 Gun:1 1/14
1 Command pressure(nwt): 2000.0 1931 N 90deg
Compensation formula: INCOMP
Current angle(deg): 10.0

Pressure(nwt) Angle(deg) OK/NG

2 1998.0 10.0 NG
3 1931.0 90.0 NG
4 1882.0 150.0 NG
5 0.0 0.0 NG
6 0.0 0.0 NG Pressure gage 150deg
7 0.0 0.0 NG
1882 N
[TYPE] CALC INCOMP

NOTE
The accuracy of the manual weight compensation function depends on the
number of data of "Press" and "Angle". Therefore, to improve the accuracy of the
manual weight compensation function, a lot of data is required.

7. Press F3 CALC. The message ”Calculation?” is displayed. When F4 YES is pressed, the
compensation formula is calculated, and "Compensation formula" is changed to "COMP."
Press

1998 Compensation formula

1931

1882

Angle
10 90 150

8. Press F5 INCOMP when you do the calculation over again.

Case: X gun
An arbitrary pressurizing is done at multiple welding positions, and the pressure is measured. And the
pressure-welding position table is made based on the pressure measurement result and welding positions. In
the case of X gun, you need to make three tables for each axis (X, Y and Z-axis).
1. Select the axis to make that table, and press ENTER key.
2. Input the same value as the weld pressure of the manual pressurization prepared to the "Command
pressure".

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SETUP Servogun SETUP Servogun
MANUAL COMPEN X_GUN / EQ:1 Gun:1 1/3 MANUAL COMPEN X_AXIS / EQ:1 Gun:1 1/14
1 Command pressure(nwt): 1000.0
1 Compen form for X-axis:<*DETAIL*> Compensation formula: INCOMP
Current angle(deg):
2 Compen form for Y-axis:<*DETAIL*> around x-axis = 0.0
around y-axis = 0.0
3 Compen form for Z-axis:<*DETAIL*> around z-axis = 0.0

Press(nwt) Angle(deg) OK/NG

[TYPE] 2 0.0 0.0 NG
3 0.0 0.0 NG
4 0.0 0.0 NG
5 0.0 0.0 NG
6 0.0 0.0 NG
7 0.0 0.0 NG

[TYPE] CALC INCOMP

3. Move the servo gun suitably. When you decide welding positions, refer to “The guide of the welding
position to measure the pressure”.
4. Input the value displayed in "Current angle (deg)" on selected axis to "Angle (deg)" after completing
the movement of the servo gun.
5. Execute a manual pressurization, and measure the pressure with a pressure gage.
6. Input the value of the pressure gage to "Press".

SETUP Servogun _
MANUAL COMPEN X_AXIS / EQ:1 Gun:1 1/14
1 Command pressure(nwt): 2500.0
Compensation formula: INCOMP Pressure gage
Current angle(deg):
around x-axis = 10.0
around y-axis = 0.0
around z-axis = 0.0

Press(nwt) Angle(deg) OK/NG 2512 N 10deg

2 2512.0 10.0 NG
3 0.0 0.0 NG
4 0.0 0.0 NG
5 0.0 0.0 NG
6 0.0 0.0 NG
7 0.0 0.0 NG
[TYPE] CALC INCOMP

7. Repeat the procedure 2-5 two or more times.

Pressure gage

SETUP Servogun _
MANUAL COMPEN X_AXIS / EQ:1 Gun:1 1/14
1 Command pressure(nwt): 2500.0
Compensation formula: INCOMP
Current angle(deg):
around x-axis = 130.0 -70deg
around y-axis = 0.0
around z-axis = 0.0 2408 N

Press(nwt) Angle(deg) OK/NG

2 2512.0 10.0 NG Pressure gage
3 2408.0 -70.0 NG
4 2322.0 130.0 NG
5 0.0 0.0 NG
6 0.0 0.0 NG
7 0.0 0.0 NG
[TYPE] CALC INCOMP
13 0deg
2322 N

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8. Press F3 CALC. The message ”Calculation?” is displayed. When F4 YES is pressed, the
compensation formula is calculated, and "Compensation formula" is changed to "COMP."
9. Press PREV key and select other axis, and then execute same procedure for selected axis.
10. Complete calculation for all axes, and then you able to use manual weight compensation function.
11. Press F5 INCOMP when you do the calculation over again.

The guide of the welding position to measure the pressure

In order to compensate the weight of movable element correctly, be careful of the following points when
you decide a welding positions.
Set position on the condition that “Current angle around y-axis” nearly equal zero, when you calculate the
compensation formula for X-axis.
• Set position on the condition that “Current angle around x-axis” nearly equal zero, when you calculate
the compensation formula for Y-axis. However, if “Current angle around y-axis” nearly equal zero,
it’s safe that the angle around X-axis don’t equal zero.
• Set position on the condition that “Current angle around x-axis” and “Current angle around y-axis”
nearly equal zero, when you calculate the compensation formula for Z-axis.

18.4 PRESSURE COMPENSATION

This chapter explains the following.
• Setting weight compensation type
• Weight compensation status

18.4.1 Setting Weight Compensation Type

Weight compensation type can be specified for each pressure schedule.
Set the weight compensation type according to the following procedures.

1. Press the MENU key to display the Screen menu.

2. Press 0 NEXT and 3 DATA.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Pressure. The servo gun Pressure Schedule list screen appears.
5. Press F4 DETAIL. The servo gun Pressure Schedule detail setting screen appears.
6. Move the cursor on “Weight compensation type” and press F4 [CHOICE].

TYPE Description
Auto The pressure is compensated by using the auto weight compensation function.
Semi-auto The pressure is compensated by using the semi-auto weight compensation function.
Manual The pressure is compensated by using the manual weight compensation function.
DISABLE The pressure is not compensated.

SERVO GUN DATA

PRESSURE / EQ:1 Gun:1 No:1 4/4
1 Comment: [ ]
2 Weld Pressure(nwt): 3500.0
3 1Gun Sag Comp Value(mm): 0.0
4 Weight Compensation type: Auto
1 DISABLE
2 Auto
3 Semi-auto
4 Manual
5
6
7
8 -- NEXT --

[TYPE] EQUIP GUN [CHOICE]

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NOTE
The “Auto” cannot be selected to the weight compensation type when X gun is
specified to the servo gun type.

18.4.2 Weight Compensation Status

The status of the compensation can be confirmed on the weight compensation status screen.

1. Press the MENU key to display the Screen menu.

2. Press 0 NEXT and 3 STATUS.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Servo Gun. Move the cursor on <*DETAIL*> of Weight compen status and press ENTER key.
Weight compensation status screen is displayed.

The following items can be referred to on this screen.

Case: C gun
STATUS Servogun
WEIGHT COMPEN STATUS / EQ:1 Gun:1 No:1 1/6

1 Pressure schedule: 0
2 Weight compensation type: DISABLE
3 Weight compen gun type: C gun type
4 Command pressure (nwt): 0.00
5 Compensation value(nwt): 0.00
6 Angle for C gun(deg): 0.00

[TYPE] EQUIP GUN

Item Description
Indicates the pressure schedule number specified for the spot welding
Pressure schedule instruction being executed. If no spot welding instruction is being executed, the
Pressure schedule for the most recently executed spot welding instruction is
indicated.
Weight compensation type The weight compensation type specified in the pressure schedule is displayed.
Weight compen gun type The status of the servo gun type that has been selected is displayed now.
Command pressure The pressure specified in the pressure schedule is displayed.
Compensation value Indicates the compensation value applied during the execution of a spot
welding instruction. This compensation value is calculated by the weight
compensation function specified in the weight compensation type.
Angle(deg) for C gun Indicates the welding position at the execution of the spot welding instruction.

Case: X gun
STATUS Servogun
WEIGHT COMPEN STATUS / EQ:1 Gun:1 No:1 1/9

1 Pressure schedule: 0
2 Weight compensation type: DISABLE
3 Weight compen gun type: X gun type
4 Command pressure (nwt): 0.00
5 Compensation value(nwt): 0.00
6 X gun:
7 Angle for X axis(deg): 0.00
8 Angle for Y axis(deg): 0.00
9 Angle for Z axis(deg): 0.00

[TYPE] EQUIP GUN

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Item Description
Pressure schedule Indicates the pressure schedule number specified for the spot welding instruction
being executed. If no spot welding instruction is being executed, the Pressure
schedule for the most recently executed spot welding instruction is indicated.
Weight compensation type The weight compensation type specified in the pressure schedule is displayed.
Weight compen gun type The status of the servo gun type that has been selected is displayed now.
Command pressure The pressure specified in the pressure schedule is displayed.
Compensation value Indicates the compensation value applied during the execution of a spot welding
instruction. This compensation value is calculated by the weight compensation
function specified in the weight compensation type.
Angle for X axis(deg)
Indicates the welding position at the execution of the spot welding instruction for
Angle for Y axis(deg)
each axis.
Angle for Z axis(deg)

18.5 OTHER FUNCTIONS

This chapter explains other functions.
1. Press the MENU key to display the Screen menu.
2. Select 6 SETUP.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Servo Gun. Move the cursor on <*DETAIL*> of General Setup and press ENTER key.
5. In case of single gun, select "Weight compensation". (Move the cursor on <*DETAIL*> and press
ENTER key.) Weight compensation setup screen appears.

Item Description
WT compn press low lim If the spot welding instruction is executed when the pressure specified in
Default:0.0 (Disable) the pressure schedule is lower than the value specified here, the
Maximum:9999.9 alarm ”SVGN-218 This press can't be compensated” can be generated.
Minimum:0.0 (Disable)
WT compn val upper lim The upper limit value of the compensation value can be specified. When the
Default:0.0 (Disable) calculated compensation value is higher than the value specified here, the
Maximum:9999.9 compensation value is automatically changed to the value specified here.
Minimum:0.0 (Disable)
WT compn val lower lim The lower limit value of the compensation value can be specified. When the
Default:0.0 (Disable) calculated compensation value is lower than the value specified here, the
Maximum:0.0 (Disable) compensation value is automatically changed to the value specified here.
Minimum:-9999.9

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19 SERVO GUN TEMPERATURE COMPENSATION

19.1 OVERVIEW
Temperature compensation function suppresses the change of the pressure by the motor temperature change,
and improves the accuracy of pressure.

WARNING
Temperature compensation function uses the motor temperature. The following
motor or Pulsecoder that can output motor temperature is recommended to be used
when the temperature compensation function is used.
• Motor: A06B-0235-B600 (This is a motor that Pulsecoder of A06B-0235-B605 is
changed from A860-2010-T341 to A860-2000-T301.)
• Pulsecoder: A860-2000-T301
Install a commercial temperature sensor etc. in the motor when you use motor or
Pulsecoder other than the above. And, input motor temperature by using I/O.

WARNING
Please do warm-up beforehand even if you use temperature compensation function.

19.2 INITIAL SETTING

Complete the following settings to use temperature compensation function. Complete the settings in order.

1. Installation of motor or Pulsecoder that can output motor temperature OR Installation of commercial
temperature sensor.

WARNING
Temperature compensation function uses the motor temperature. The following
motor or Pulsecoder that can output motor temperature is recommended to be used
when the temperature compensation function is used.
• Motor: A06B-0235-B600 (This is a motor that Pulsecoder of A06B-0235-B605 is
changed from A860-2010-T341 to A860-2000-T301.)
• Pulsecoder: A860-2000-T301
Install a commercial temperature sensor etc. in the motor when you use motor or
Pulsecoder other than the above. And, input motor temperature by using I/O.

2. Auto tuning
3. Standardization of temperature compensation function
Enable "Temperature Compensation" in pressure compensation setup of servo gun utility screen.

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UTILS Gun setup Press Compens

EQ: 1 Gun:1 2/4 EQ: 1 Gun:1 1/2
1. Set gun motion sign: COMP
2. Set Gun specs, master gun COMP 1.Weight Compensation: DISABLE
Tip Displacement: 20.000(mm/rev)
2.Temperature Compensation: ENABLE
Open stroke limit: -200.0(mm)
Close stroke limit 20.0(mm)
3. Auto Tune: COMP
4. Press Compensation Setup:<*DETAIL*>
5. Weight Compensation Setup: INCOMP
6. Thickness Check calibration: INCOMP

Press enter to setup for this item

[TYPE] EQUIP EXEC RESTART INDEX [TYPE] RETURN [CHOICE]]

4. Confirmation of motor temperature.

Confirm motor temperature can be correctly obtained by seeing "Current temperature" in the
temperature compensation setting screen.
5. Pressure calibration

After the pressure calibration is completed, the screens(following 1 and 2) concerning the temperature
compensation function are displayed.
• Select F4 YES in screen 1. However, push F5 NO when not performing pressure calibration in reality.
• Select F4 OK in screen 2. In this case, the obtaining of the temperature at pressure calibration has failed
because it cannot correctly obtain motor temperature. In the situation in which the motor temperature is
correctly obtained, re-perform the pressure calibration. Or, specify temperature at pressure calibration
directly in the temperature compensation setting screen. It can be confirmed whether motor temperature
can be correctly obtained by seeing “Current temperature” in the temperature compensation setting
screen.

Screen1 Screen2

Is temperature at pressure calib used by Obtaining temperature at pressure calib

temperature compensation func changed? for temperature compensation failed.
Confirm temperature compensation setup.
Yes(F4 key): New value
Temp at press calib: 32.00 (deg C) Current setting
Temp at press calib: 0.00 (deg C)
No (F5 key): Old value
Temp at press calib: 28.00 (deg C)

YES NO OK

19.3 TEMPERATURE COMPENSATION SETTING SCREEN

Set temperature compensation per the following procedures
1. Press the MENU key to display the Screen menu.
2. Press 6 SETUP.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Servo Gun. The Servo Gun Setup screen appears.
5. Move the cursor on <*DETAIL*> of General Setup and press ENTER key. The General Setup screen
appears.
6. Move the cursor on <*DETAIL*> of Temperature Compensation and press ENTER key. The
Temperature compensation setting screen appears.

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SETUP Servo gun
TEMPERATURE COMPEN / EQ:1 Gun:1 1/10
Current temperature (deg C): 32.0

1 Temperature compensation: ENABLE

2 Temperature coefficient (%): 0.088
3 Compensation onset temp (deg C): 20
4 Abnormal temp up lim (deg C): 140
5 Abnormal temp low lim (deg C): 0
6 Temp at pressure cal (deg C): 32.0
7 Temperature information type: AI[ ]
8 Temperature info port number: 2
9 AI,GI conversion factor: 1.0000
10 AI,GI intercept (vertical): 0.0

[TYPE] EQUIP GUN END UPDATE

ITEM DESCRIPTION
Current temperature (deg C) Current motor temperature is indicated to this item. When the motor
temperature is not obtained, ***** is displayed in this item. Confirm motor
temperature is correctly obtained by using this item.
When F5 UPDATE is pressed, current temperature is updated.
Temperature compensation This item specifies whether to perform temperature compensation.
Default value: DISABLE
Temperature coefficient (%) When this item is 0.088%, it means the pressure decreases by 0.088%
Default value: 0.088% (Alpha iS Series) every time the motor temperature rises by 1.0 deg C.
When the FANUC motors are used, this item is automatically decided
according to the following table.

Motor Temperature coefficient

60s: Alpha iS series 0.088%
80s: Beta iS series 0.088%
100s: Alpha iF series 0.168%
50s: Alpha M6 0.168%
Other 0.0%

A default value of this item is 0.0% when the motor is not FANUC motor.
Therefore, inquire of the motor maker about the temperature coefficient.
Compensation onset temp (deg C) This item is a temperature compensation onset temperature. In FANUC
Default value: 20 deg C motor case, 20 deg C is automatically specified to this item because a
decrease in pressure starts when motor temperature exceeds 20 deg C.
If the motor is not FANUC motor, inquire of the motor maker about the
temperature that a decrease of torque starts.
Abnormal temp up lim (deg C) This item is the abnormal motor temperature upper limit value. If motor
Default value: 140 deg C temperature is larger than this value at pressure compensation, following
alarm is generated.
･ SVGN-294 Temp exceed abnormal up lim:G%d
Specify a value that is larger than Temp at pressure cal to here.
Abnormal temp low lim (deg C) This item is the abnormal motor temperature lower limit value. If motor
Default value: 0 deg C temperature is smaller than this value at pressure compensation,
following alarm is generated.
･ SVGN-295 Temp below abnormal low lim:G%d
Specify a value that is larger than Temp at pressure cal to here.
Temp at pressure cal (deg C) Motor temperature at the pressure calibration is indicated to this item.
Default value: 0 deg C When pressure calibration is executed in the situation in which the motor
temperature is correctly obtained, this item is automatically set.

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ITEM DESCRIPTION
Temperature type Specify the method of obtaining the motor temperature.
Default value:Motor • Motor
Select this if you use the following motor or Pulsecoder.
･ Motor: A06B-0235-B600
･ Pulsecoder: A860-2000-T301

• AI
Select this if you receive the motor temperature via AI from a
temperature sensor etc.

• GI
Select this if you receive the motor temperature via GI from a
temperature sensor etc.
Temperature info port number Specify the port number for GI or AI of temperature type to this item.
Default value: 0 Power OFF/ON after changing this item.
AI,GI conversion factor This item is a factor used to convert value of GI or AI into motor
Default value: 1.0 temperature.
Motor temperature(deg C) =
AI,GI conversion factor * AI,GI Input value+AI,GI intercept

AI,GI intercept (vertical) This item is a vertical intercept used to convert value of GI or AI into motor
Default value: 0.0 temperature.
Motor temperature(deg C) =
AI,GI conversion factor * AI,GI Input value+AI,GI intercept

WARNING
The output range of the following motor or Pulsecoder that can output motor
temperature is 0 deg C - 140 deg C.
• Motor: A06B-0235-B600
• Pulsecoder: A860-2000-T301

19.4 PRESSURE COMPENSATION

This chapter explains the following.
• Pressure compensation condition
• Temperature compensation status

19.4.1 Pressure Compensation Condition

When fulfilling all the following conditions, the pressure is compensated according to the motor
temperature during execution of SPOT instructions.
• Motor temperature is correctly obtained.
• Motor temperature exceeds "Compensation onset temp" on the temperature compensation setting
screen.
• "Temperature compensation " on the temperature compensation setting screen is enabled.

19.4.2 Temperature Compensation Status

The status of the compensation can be confirmed on the temperature compensation status screen.

1. Press the MENU key to display the Screen menu.

2. Press 0 NEXT and 3 STATUS.
3. Press F1 TYPE to display the Screen Selection menu.
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4. Select Servo Gun. Move the cursor on <*DETAIL*> of Temp compen status and press ENTER key.
The Temperature compensation status screen is displayed.

The following items can be referred to on this screen.

STATUS Servogun
TEMPERATURE COMPEN / EQ:1 Gun:1 1/4

1 Pressure schedule: 0
2 Command pressure(nwt): 0.00
3 Compensation value(nwt): 0.00
4 Motor temperature(deg C): 0.0

[TYPE] EQUIP GUN

ITEM DESCRIPTION
Pressure schedule Indicates the pressure schedule number specified for the spot welding
instruction being executed. If no spot welding instruction is being executed,
the pressure schedule for the most recently executed spot welding instruction
is indicated.
Command pressure The pressure specified in the pressure schedule is displayed.
Compensation value Indicates the compensation value applied during the execution of a spot
welding instruction. This compensation value is calculated by the temperature
compensation function.
Motor temperature(deg C) Indicates the motor temperature at the execution of the spot welding
instruction.

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20 RELATED VIEW FUNCTION

This section describes the following functions.
- Related view function
- Quick view function

20.1 RELATED VIEW FUNCTION

This function can help to refer to pressure and tip distance schedule for SPOT instruction, PRESS_MOTN
instruction, and TIP_DRESS instruction. Using multi screen displaying of the teach pendant, with the
feature enabled, when user moves the cursor through an allocation instruction in edit screen on the left side,
then related schedule is automatically appeared on the right side screen.

In edit screen (left), move cursor to SD schedule,

in tip distance data screen (upper right), selected schedule is displayed.
Note: ED is same as it, too.

In edit screen (left), move cursor to P schedule,

in pressure data screen (lower right), selected schedule is displayed.

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20.2 OPERATION FOR RELATED VIEW FUNCTION

Use related view function by the following procedure 1 or 2.

Procedure 1
1. Display edit screen.
2. Press FCTN key + i key to bring up the related views menu.
3. Select “Related Views” -> “Servo Gun”.

Procedure 2
1. Display edit screen.
2. Tap i icon in far right of the title bar. (see the lower left figure)
3. Select “Related Views” -> “Servo Gun”. (see the lower right figure)

NOTE
When related view function is enabled, then multi screen displaying (triple) of the
teach pendant is enabled, too.

NOTE
When related view function is enabled, right screens have light blue title bars. It
means right screens are linked to left screen.

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If related view function is enabled, when pressure and tip distance schedule(SD,P,ED) are selected by
cursor on edit screen of the left side, displaying cursor automatically jumps to the selected schedule number
on schedule list screen of the right side.

In addition, by displaying detail screens of tip distance data screen and pressure data screen in advance,
when pressure and tip distance schedule(SD, P, ED) are selected by cursor on edit screen of the left side,
detail screen of the selected schedule number is automatically displayed on the right side screen .

20.3 QUICK VIEW FUNCTION

This function can be referred to pressure and tip distance schedule for SPOT instruction and TIP_DRESS
instruction quickly. This function displays the detailed data of schedule used in instruction to pop-up
window on the right of screen without using multiple screens.

The following option is necessary if you want to use this function.

4D Graphics function A05B-2***-R764
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B-83264EN/03 20.RELATED VIEW FUNCTION

ITEM DESCRIPTION
Process info for WID= WID in instruction that you selected is displayed here. If WID is disabled, 1
is always displayed here.
(SD= , G= , R= ) Start distance schedule in instruction that you selected is displayed here.
SD: Start distance schedule number
G: Gun distance (movable tip)
R: Robot distance (fixed tip)
(P= , F= ) Pressure schedule in instruction that you selected is displayed here.
P: Pressure schedule number
F: Force
(ED= , G= , R= ) End distance schedule in instruction that you selected is displayed here.
ED: End distance schedule number
G: Gun distance (movable tip)
R: Robot distance (fixed tip)

20.4 OPERATION FOR QUICK VIEW FUNCTION

Procedure
1. Display edit screen.
2. Position your cursor anywhere on one of the fields in the SPOT[…] instruction.
3. Press and hold down the iKey, and as long as you hold down the iKey, you should see a pop-up
window.
3. The detailed schedule information for each parameter of the servo gun SPOT instruction is displayed
in the pop-up window.
5. If you have a touch screen, then while still holding the iKey, you can tap on another SPOT[…] in your
program, and the pop-up window will update with information from the SPOT instruction you
touched.
6. Release the iKey to dismiss the pop-up window.

NOTE
Quick View is only active when viewing TP program in Pane 1.

NOTE
Specify 0 to $UI_CONFIG.$IHELP_TIMER if you want to use Quick View

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21.SPOT PROGRAM TOUCHUP FUNCTION B-83264EN/03

21 SPOT PROGRAM TOUCHUP FUNCTION

21.1 OVERVIEW
The spot program touchup function automatically touches up positions attached to spot instructions, to
correct position error in the close/open direction. Spot point touchup function could be used to touchup an
entire program, but spot program touchup function provides the following benefits:
• Reduced time to touchup an entire program.
• Text feedback via status screen and graphical feedback via chart screen
• A log file for archival

This function is optional (not standard).

Spot program touchup function A05B-2***-R725

This function has the following dependencies:

Servogun option A05B-2***-J670

On 7DC1 software, this function for Standard Setting user that order A05B-2**-R651 needs the following
option:
Servo gun setup package A05B-2***-J979

WARNING
Touchup accuracy depends on servo gun mechanical design and panel reaction
(fixturing and stiffness). The following items may adversely affect accuracy.
• X guns with long jaw
• C guns with offset
• Guns with large frictional resistance parting actuator
• Loosely fixed panels
• Soft panels
• Pneumatic equalizers
• Springs or gun float mechanisms

NOTE
Some detection result information is recorded with WARN alarm (in the alarm log) by
spot program touchup function. This information is not recorded if warn messages are
disabled.
Therefore, it’s recommended to set system variable $ER_NOHIS = 0 or 2. Warn
history (messages) are recorded if this setting is used.
Refer to Appendix C, “SYSTEM VARIABLES” in FANUC Robot series R-30iB/ R-30iB
Mate CONTROLLER OPERATOR’S MANUAL (Basic Operation)(B-83284EN) for
more information about the deleting warning history.

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B-83264EN/03 21.SPOT PROGRAM TOUCHUP FUNCTION

SAMPLE _
5/20
3:L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
4:L P P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
5:L P[3] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1] P[4]
6:L P[4] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
P[3]
POINT SPOT GunTchup AutoTchup Touchup > P[2] P[1]

Spot program touchup function sequence

Move to Start Move to upper Upper panel Move to lower

Distance (SD) panel detection detection panel detection
start position start position

Lower panel Thickness check Touchup& Move to End

detection Move to new Distance (ED)
taught position

WARNING
Where TP disable or where TP enable and Thickness update function disable, this
function is done by above sequence. Where TP enable and Thickness update
function enable, refer to Chapter "21.9 THICKNESS UPDATE SETUP "

WARNING
During program touchup, upper panel detection process executes instead of spot
process. Upper panel detection motion differs from spot motion, and robot/gun
trajectory may be different than normal spot trajectory (in open/close direction).
Therefore confirmation of clearance between robot/gun and workpiece / peripheral
devices is recommended.

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NOTE
During the above sequence of program touchup, gun axis and robot move at same
speed regardless of override.

NOTE
PR[90] is the default position register for robot motion during spot program touchup.
Don't use this PR for another purpose. The register number of this PR can be
changed on the setup screen (Refer to Chapter "21.4 SPOT PROGRAM TOUCHUP
SETUP SCREEN".).

21.2 INITIAL SETTING

Execute the items in the order listed below, prior to initial spot program touchup.
• Autotuning
• Pressure calibration
• Setting the tool coordinate system
• Tip wear standard
• Specify "NOWELD" to weld controller mode (NOWELD: weld controller doesn't pass a current to
gun.)
• Specify “STROKE” to gun operation.

Execute the items below, prior to every spot program touchup.

• Tip wear detection
• Thickness check calibration

Like tip wear detection, thickness check calibration can also be performed with a TP program. Please refer
to Chapter “21.20 THICKNESS CHECK CALIBRATION”.

NOTE
TCP of robot and master position of the gun axis must be accurate to use spot
program touchup. Execute tip wear detection to ensure that wear amount and
mastering are correct. Execute thickness check calibration to ensure that deflection
calibration is accurate.

NOTE
For safety reasons, the operator teaches the spot position with weld controller mode
specified as "NOWELD" (NOWELD: weld controller doesn't pass a current to gun.).
Spot program touchup should execute with weld controller mode specified to
"NOWELD" for safety, too.

21.3 SPOT PROGRAM TOUCHUP EXECUTION PROCEDURE

Spot program touchup executes when program touchup mode is enabled.
Program touchup supports two different execution modes:
1. Touchup/modify: determine correct position and modify position data (if position is in tolerance)
2. Verify: determine correct position, but do not modify position data (if position is in tolerance)
Default mode is touchup/modify. Refer to Gun teach setup screen section for detail on verify mode.
If TP enable, following modes can be selected (since 7DC2 software).
3. Measure offset: determine offset for panel deflection at upper detection and add UPDET_OFS
instruction with touchup.
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4. Pass check: execute a motion to check pass for Spot program touchup function. Position data are not
modified.
Refer to Chapter “21.21 SIMPLE SEARCH MODE FOR UPPER DETECTION” about Measure offset.
Refer to Chapter “21.22 PASS CHECK MODE” about Pass check.

NOTE
Assume that execution mode is touchup/modify - unless noted otherwise - in this document

Enable program touchup mode, using the procedure below:

TP enable
1. Press the MENU key to display the Screen menu.
2. Go to spot program teach setup screen, item “Execution mode for TEACH” and select TOUCHUP
mode if you wish to modify points, verify mode if you do not wish to modify points.
3. Press 2 TEST CYCLE.
4. Press F1 TYPE to display the Screen Selection menu.
5. Select Spot Prog Touch. The spot program touchup screen appears.
6. Press F4 ENABLED. Program touchup mode is enabled.

SPOT WELD _
1/3
Spot Program Touchup Mode Setup

1 Program touchup mod for EQ1:ENABLED For equipment 1

2 Program touchup mod for EQ2:ENABLED For equipment 2
3 Program touchup mod for EQ3:ENABLED For equipment 3

[TYPE] ENABLED DISABLED >

NOTE
Message appears on prompt line of test cycle screen, when touchup mode becomes enabled.
If TOUCHUP mode: TOUCHUP execution mode active EQ:1
If VERIFY mode: VERIFY execution mode active EQ:1
If MEAS OFS mode: Det offset for Simple search active EQ:1
If PASS CHECK mode: Pass check mode active EQ:1
MEAS OFS and PASS CHECK modes are supported since 7DC2 software.

7. Execute the program to be touched up. When the spot instructions executes, spot program touchup
executes automatically.

TP disable
1. Press the MENU key to display the Screen menu.
2. Go to spot program teach setup screen, item “Execution mode for AUTO” and select TOUCHUP
mode if you wish to modify points, verify mode if you do not wish to modify points.
3. Press 5 I/O.
4. Press F1 TYPE to display the Screen Selection menu.
5. Select Cell Interface. The cell input screen or cell output screen appears.
6. To switch between the input screen and the output screen, press F3 IN/OUT.
7. Move the cursor to Prg tch mode EQn in the input screen, and allocate the input signal. (Refer to
R-30iB CONTROLLER Spot Welding OPERATOR’S MANUAL (B-83284EN-4) for more
information about the cell interface I/O.)

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I/O Cell Inputs _

1/8
INPUT SIGNAL TYPE # SIM STATUS
3 Rmt wrt svr rese DI[ 0] U ***
4 Ret hom frm poun DI[ 0] U ***
5 Prg tch mode EQ1 DI[ 0] U *** For equipment 1
6 Prg tch mode EQ2 DI[ 0] U *** For equipment 2
7 Prg tch mode EQ3 DI[ 0] U *** For equipment 3
8 Tryout Mode DI[ 0] U ***

[TYPE] CONFIG IN/OUT SIM UNSIM >

8. Move the cursor to Prg tch stat EQn in the output screen, and allocate the output signal.

I/O Cell Outputs _

1/23
OUTPUT SIGNAL TYPE # SIM STATUS
16 One Spot Welded DO[ 0] U ***
17 Prg tch stat EQ1 DO[ 0] U ***
18 Prg tch stat EQ2 DO[ 0] U *** For equipment 1
19 Prg tch stat EQ3 DO[ 0] U *** For equipment 2
20 Tryout ﾄ Status DO[ 0] U *** For equipment 3
21 Heartbeat DO[ 0] U ***
[TYPE] CONFIG IN/OUT SIM UNSIM >

9. Cycle Power for the I/O changes to take effect.

10. Turn on Prg tch mode EQn. Program touchup mode is enabled. Prg tch stat EQn is automatically
turned on when program touchup mode is enabled.
11. Execute the program to be touched up. When the spot instructions executes, spot program touchup
executes automatically.

WARNING
Before starting program touchup, confirm program touchup mode status, with one of
the following indicators:
• Program touchup mode status item on spot program touchup screen
• "Spot program touchup in progress: EQn" status message (displayed when
program executes)
• Status DOUT: Prg tch stat EQn

NOTE
Spot program touchup process is disabled in the following cases, so the instruction
executes as a non-touchup (normal) process, with no-stroke(mode) gun operation.
• Press motion instruction
• Tip dress Instruction
• Spot instruction with SpotProgTouch_Dsb attached (Refer to Chapter "21.13
SPOT PROGRAM TOUCHUP DISABLE INSTRUCTION".).
Also, spot program touchup does not execute for standalone (NOT attached to
motion) application instructions.

Spot program touchup does not execute in the following condition.

• When the gun operation(mode) is nostroke and single step is enabled.

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NOTE
Program touchup mode automatically changes from ENABLED to DISABLED at the
following times:

If TP is ENABLED
• When program touchup mode is disabled on the spot program touchup screen
• When the TP enable switch changes to disabled (case where Prg tch mode EQn
has been turned on is excluded.)
• When gun operation(mode) changes to NOSTROKE (Refer to Chapter “10. TEST
CYCLE”.)
• When power is interrupted
• When equipment type changes to air gun
If TP is DISABLED
• When Prg tch mode EQn is turned off
• When Prg tch mode EQn is not correctly allocated
• When the TP is switched to enabled
• When gun operation changes to NOSTROKE (Refer to Chapter “10.TEST
CYCLE”.)
• When equipment type changes to air gun

NOTE
Spot program touchup, cannot be performed on multiple arms simultaneously (in
multi-arm control systems).

21.4 SPOT PROGRAM TOUCHUP SETUP SCREEN

Set spot program touchup per the following procedures.
1. Press the MENU key to display the Screen menu.
2. Press 6 SETUP.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Servo Gun. The Servo Gun Setup screen appears.
5. Move the cursor on <*DETAIL*> of General Setup and press ENTER key. The General Setup screen
appears.
6. Move the cursor on <*DETAIL*> of Gun Teach Setup and press ENTER key. The Spot Program
Touchup Setup screen appears.

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SETUP Servogun _ SETUP Servogun _

GENERAL / EQ:1 Gun:1 1/14 GUN TEACH SETUP / EQ:1 Gun:1 1/30
1 Tip Wear Comp ENABLE
2 Gun Sag Compensation DIABLE Common Setup: point + program touchup
3 Close Direction(Gun): PLUS Gun offset @record(mm): 5.0
4 Close Direction(Robot):UT: 1 [+Z ] Speed of offset motion(mm/sec): 50
5 Max Motor Torque(%): 100.0 Position register(PR[#]): 90
6 Max Pressure (nwt): 4000.0 Position error offset(mm): 0.0
Max Gun Torque(%): 23.0 Upper det simple search mode:DISABLE
7 Tip stick detect distance(mm):5 Thickness check Setup
8 Tip Wear Detection: <*DETAIL*> Over thickness tolerance(mm): 0.5
9 Pressure Cal: COMP <*DETAIL*> Under thickness tolerance(mm) 2.0
10 Tip Wear Standard:INCOMP<*DETAIL*> Pressure Limit@Check(nwt): 0.0
11 Thickness check: <* DETAIL *> Low pnl detect dist Enb/DSB: DISABLE
12 Gun Stroke limit: <* DETAIL *> Low pnl detection distance(mm): 5.0
13 OverTorque protection: <* DETAIL *> Gun mechanical compensation:
14 Gun Teach setup: <* DETAIL *> Compensation Enb/Dsb: DISABLE
Compensation Dist Calib: INCOMP
Compensation Dist (mm): 0.0
Parameter to correct position for Xgun
Distance correction Enb/Dsb: DIABLE
[TYPE] EQUIP GUN
Detect pos correct dist(mm): 0.0

Point touchup Setup

Execute Thickness check: ENABLE

Program touchup Setup

Execution mode for AUTO: TOUCHUP
Execution mode for TEACH: TOUCHUP
Verify mode active DO[#]: 0
Max allowable position err(mm): 2.0
Min allowable position err(mm): 0.0
Position error DO[#]: 0
Thickness error DO[#]: 0
Detection error DO[#]: 0
Program touchup incomplt DO[#]: 0
Reset DI[#]: 0
Upper panel search margin(mm): 5.0
Maximum retry number: 2
Pause mode Setup
Det/Thk/Pos error pause Sev: DISABLE
SpotProgTouch_Dsb pause Sev: DISABLE
Pause mode status DO[#]: 0
Speed of pass check motion(mm/s):20

[TYPE] EQUIP GUN END >

NOTE
Setting item is depended on software version and/or software option
configuration.

ITEM DESCRIPTION
Common Setup: point + program touchup
Gun offset @record(mm) This item specifies the offset used for the gun tip position at touchup. Actual
Default value: 5.0mm position recorded is: (panel thickness + gun offset record) * gun open
polarity.
Speed of offset motion(mm/sec) This item specifies the robot's speed during move to the new touchup
Default value: 50mm/sec position, and other non-detection motions. Note that this speed is
override-independent. I.E. execution speed is the specified speed whether
the override % is 1% or 100% (for example).
Position register (PR[#]) This item specifies the position register number that is used internally, for
Default value: 90 MOTION DURING SPOT PROGRAM TOUCHUP. Treat this position
register as reserved for program touchup (don't use it for another purpose).
Position error offset(mm) The offset specified here is added to the position error correction at the
Default value: 0.0mm touchup.

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ITEM DESCRIPTION
Upper det simple search mode Select Enable/Disable for Simple search mode.
Default: DISABLE Refer to Chapter “21.21 SIMPLE SEARCH MODE FOR UPPDER
DETECTION” for more information about this function.
Thickness check Setup
Over thickness tolerance(mm) This item is the tolerance for maximum allowable thickness.
Default value: 0.5mm For example, when Over thickness tolerance is 0.5, and specified
thickness=2.0mm
OK: Observed thickness=2.5mm
NG: Observed thickness=2.6mm

If the thickness measured during lower panel detection is greater than

maximum allowable thickness, touchup is canceled, and the following
warning is generated.
• SVGN-254 "Low Panel Mis-detect:(Eq:%d,Ln:%d)

If the thickness measured during thickness check is greater than maximum

allowable thickness, touchup is canceled, and the following warning is
generated.
• SVGN-239 Thickness error:(Eq:%d,Ln:%d)
Under thickness tolerance(mm) This item is the tolerance for the minimum allowable thickness.
Default value: 2.0mm For example, when the under thickness tolerance is 2.0, and specified
thickness=4.0mm:
OK: Observed thickness=2.0mm
NG: Observed thickness=1.9mm

If the thickness measured during lower panel detection is less than the
minimum allowable thickness, touchup is canceled, and the following
warning is generated.
• SVGN-254 "Low Panel Mis-detect:(Eq:%d,Ln:%d)

If the thickness measured during thickness check is less than minimum

allowable thickness, touchup is canceled, and the following warning is
generated.
• SVGN-239 Thickness error:(Eq:%d,Ln:%d)
Low pnl detect dist clamp Enb/Dsb This item specifies whether lower panel detection distance clamp is used
Default value: DISABLE during spot point touchup. If this item is disabled, robot tip moves a
distance of SD=UpperPanel detect distance from previously taught point.
Lower panel detection distance clamp can reduce this distance. Refer to
Chapter “21.6 LOWER PANEL DETECTION DISTANCE CLAMP” for more
information about this item.
Low pnl detection distance(mm) This item can change robot trajectory at upper panel detection and lower
Default value: 5.0mm panel detection start position. Refer to Chapter “21.6 LOWER PANEL
DETECTION DISTANCE CLAMP” for more information about this item.
Gun mechanical compensation
Compensation Enb/Dsb This item specifies whether unmodeled mechanical variables (variables not
Default: Disable observable during detection) are compensated.
Note that this item can not be enabled when compensation distance
calibration is incomplete.
Compensation Dist Calib This item indicates compensation distance calibration status. It is
Default: IMCOMP automatically enabled, after mechanical compensation calibration is
performed. This item is not selectable/editable.
Refer to Chapter “21.19 Gun mechanical compensation calibration” for
more information.

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ITEM DESCRIPTION
Compensation Dist(mm) This item displays compensation distance that was determined during
Default:0.0 calibration. When gun mechanical compensation is enabled, this value is
applied to position of upper panel detection. This item is not
selectable/editable.

Parameter to correct position for Xgun

Distance correction Enb/Dsb This item specifies whether distance correction for X gun is used during
Default value: DISABLE touchup.
Detect pos correct dist is added to the position error correction at touchup
when this item is enabled.
Detect pos correct dist(mm) Distance correction for X gun does not eliminate position error correction
Default value: 0.0mm completely because there are various structures in X gun.
In that case, please correct position error correction by using this item.
The offset specified to here is added to the position error correction at
touchup when Distance correction Enb/Dsb is enabled.
Point touchup Setup
Execute Thickness check This item specifies whether thickness check is performed during spot point
Default value: ENABLE touchup.
Program touchup Setup
Execution Mode for This item specifies execution mode for AUTO (TP disabled).
AUTO: TOUCHUP TOUCHUP = Verify + Touchup
VERIFY = Verify only
Execution Mode for This item specifies execution mode for TEACH (TP enabled).
TEACH:TOUCHUP TOUCHUP = Verify + Touchup
VERIFY = Verify only
MEAS OFS = Measure offset for Simple search + TOUCHUP
PASS CHECK = Execute pass check motion only
Refer to Chapter “21.21 SIMPLE SEARCH MODE FOR UPPER
DETECTION” about Measure offset.
Refer to Chapter “21.22 PASS CHECK MODE” about Pass check.
Verify mode active DO[##]: 0 Index of DOUT asserted when verify mode is active. Verify mode can be
active in AUTO or teach mode and this output is asserted in both cases.
Max allowable position err (mm) This item is the tolerance value for the maximum allowable position error
Default value: 2.0mm correction. If position error correction is larger than this tolerance value,
touchup is canceled, and following warning is generated.
• SVGN-237 Position error:(Eq:%d,Ln:%d)
Min allowable position err (mm) This item is the tolerance value for the minimum allowable position error
Default value: 0.0mm correction. If position error correction is smaller than this tolerance value,
touchup is canceled, and following warning is generated.
• SVGN-237 Position error:(Eq:%d,Ln:%d)
Position error DO[#] If measured position error exceeds max or min position error correction
Default value: 0 (tolerance).,
The dout index specified here is pulsed for 500msec, and
the following alarm message is posted.
• SVGN-237 Position error:(Eq:%d,Ln:%d)
Thickness error DO[#] If measured thickness exceeds underthickness tolerance or overthickness
Default value: 0 tolerance. The dout (index) specified here is pulsed for 500msec.
The following alarm message is also posted.
SVGN-254 "Low Panel Mis-detect:(Eq:%d,Ln:%d)
SVGN-239 Thickness error:(Eq:%d,Ln:%d)

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ITEM DESCRIPTION
Detection error DO[#] If upper panel detection fails,
Default value: 0 the dout (index) specified here is pulsed for 500msec, and
the following alarm message is also posted.
• SVGN-240 Panel Mis-Detect(Eq:%d,Ln:%d)
• SVGN-252 Panel detection was failed:%d
• SVGN-260 Search motion is unsuccess
Refer to chapter “21.23 TROUBLESHOOTING” for more information about
SVGN-252 and SVGN-260.
Program touchup incomplt DO[#] If program touchup program touchup process fails due to one of the reasons
Default value: 0 below, the dout (index) specified here is asserted.
• SVGN-237 Position error:(Eq:%d,Ln:%d)
• SVGN-239 Thickness error:(Eq:%d,Ln:%d)
• SVGN-240 Up Panel Mis-Detect:(Eq:%d,Ln:%d)
• SVGN-252 Panel detection was failed: %d
• SVGN-254 Low Panel Mis-detect:(Eq:%d,Ln:%d)
• SVGN-260 Search motion is unsuccess.
The operator should confirm the state of this signal, when the program
ends,
Reset DI[#] If the program touchup incomplt DO is assigned, the operator requires a
Default value: 0 means to turn off the program touchup incomplt DO externally. The reset
input is the input that provides this function. This item defines the index of
the reset input.
Upr pnl detection distance(mm) This item is the upper panel detection distance. This item can change the
Default value: 5.0mm upper panel detection start position.
Maximum retry number If this item is specified larger than 0, upper panel detection will automatically
Default value: 0 retry if upper panel detection fails due to the following warning.
• SVGN-252 Panel detection was failed
• SVGN-260 Search motion is unsuccess.
When upper panel detection is retried, the robot retries upper panel
detection after it moves to End Distance (ED).
Note:
Refer to chapter “21.23 TROUBLESHOOTING” for more information about
SVGN-252 and SVGN-260.
Pause mode Setup
Det/Thk/Pos error pause Sev This item specifies whether robot pauses at end distance if one of the
Default value: DISABLE following warnings occur.
• SVGN-237 Position error:(Eq:%d,Ln:%d)
• SVGN-239 Thickness error:(Eq:%d,Ln:%d)
• SVGN-240 Up Panel Mis-Detect:(Eq:%d,Ln:%d)
• SVGN-252 Panel detection was failed:(Eq:%d,Ln:%d)
• SVGN-254 Low Panel Mis-detect:(Eq:%d,Ln:%d)
• SVGN-260 Search motion is unsuccess.
If this item is DISABLED
The robot does not pause.
If this item has Warn severity
Alarm is posted as warning, task is paused, (but not faulted), reset is not
required.
• SVGN-236 [PauseMod]Det/Thk/Pos Err
Alarm is posted as warning, task is paused+faulted, reset is not required.
• SVGN-236 [PauseMod]Det/Thk/Pos Err

Remove the cause of pause before restarting the program.

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ITEM DESCRIPTION
SpotProgTouch_Dsb pause Sev This item specifies whether robot pauses at start distance when
Default value: DISABLE SpotProgTouch_Dsb attached to the spot instruction is executed.
If this item is DISABLE
The robot does not pause.
If this item has Warn severity
Alarm is posted as warning, task is paused,(but not faulted), reset is not
required.
• SVGN-238 [PauseMod]SpotProgTouchDsb
Alarm is posted as warning, task is paused+faulted, reset is not required.
• SVGN-238 [PauseMod]SpotProgTouchDsb

This item can be used only when TP is disabled

Refer to Chapter “21.13 SPOT PROGRAM TOUCHUP DISABLE
INSTRUCTION” for more information about SpotProgTouch_Dsb.
Pause mode status DO[#] If the robot pauses due to Det/Thk/Pos error pause with warn Sev or
Default value: 0 SpotProgTouch_Dsb pause Sev, the DOUT index specified here is pulsed
for 500msec. When the robot pauses due to Det/Thk/Pos error pause with
ALARM Sev or SpotProgTouch_Dsb pause Sev, the DOUT index specified
here is not pulsed.
Speed of pass check motion(mm/s) Set TCP and gun axis speed during Pass check motion. This is applied to
Default value: 20mm/s the motion near welding points. This is not applied to air-cut motion.

The following items are set per equipment, they cannot be set per gun.
• Max position err correct
• Min position err correct
• Position error DO
• Thickness error DO
• Detection error DO
• Program touchup incomplt DO
• Reset DI
• Thickness check mode
• Det/Thk/Pos error pause Sev
• SpotProgTouch_Dsb pause Sev
• Pause mode status DO

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WARNING
The following items affect upper panel detection start position. Therefore, confirm that
clearance between gun and workpiece/peripheral devices is ok, if the following items
change.
• Over thickness tolerance
• Max position err correct
• Upr pnl detection distance

Upper panel detection start position

Gun backup amount (About 10mm):
Automatic calculation
Specified thickness (Ex:2.0mm) +
Close Upper panel detection distance (Def:5.0mm) +
direction Over thickness tolerance (Def:0.5mm) +
(Robot) Max position err correct (Def:2.0mm)

Original taught position New taught position

Robot start distance

Upper panel detection start position

Please refer to max detect distance section (next section) for more information on
detection control (parameters).

21.5 MAX DETECTION DISTANCE

If panel position shifts horizontally or if there is a foreign body such as a nut on the upper panel, panel
damage can occur during thickness check. Detect distance check is performed to prevent this damage.
If upper panel is detected at a distance that exceeds the max detection distance range, Warning(SVGN-240
Panel Mis-Detect) is generated and spot program touchup is canceled.

Foreign body
Gap of horizontal direction

New taught position

Original taught position

The max detection distance range is computed per the following items on the setup screen.
• Over thickness tolerance
• Max position err correct

If one of the items mentioned above changes, the following message is displayed on the TP prompt line.

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Prompt message

Detect dist must be nominal thick + 2.5m m

Max detection Specified thickness Over thickness tolerance (Def:0.5mm)

distanc e range: Ex) 2.0mm +
4.5mm Max position err correct (Def:2.0mm )

When the message above is displayed, the max detection distance is 4.5mm. Therefore, distance from
original taught position to 4.5mm is the max detection distance in the closing direction(Robot). If upper
panel is detected at a distance that exceeds the max detection distance range, Warning(SVGN-240 Panel
Mis-Detect) is generated and spot program touchup is canceled.
Upper panel detection start position

Foreign body Warning

range

Max detection
Close Distance
direction 4.5mm
(Robot)

Original taught position New taught position

WARNING
Max detection distance affects upper panel detection start position. Therefore,
confirm that clearance between gun and workpiece/peripheral devices is ok, if one
of the aforementioned items changes.

21.6 LOWER PANEL DETECTION DISTANCE CLAMP

The gun moves in lower (robot open) direction by upper panel detection distance at start of upper panel
detection. In a tight workspace, robot tip might interfere with a workpiece or peripheral devices. If Low pnl
detect dist clamp Enb/Dsb on setup screen is set to ENABLE, the movement distance of gun can be reduced.

Upper panel detection end position

If Low pnl detect dist clamp Enb/Dsb is disabled

Robot start distance: SD

(Default: 10mm)

Upper panel detection distance

(About 10mm)
Interference!!
Workpiece Workpiece
Interference!!
Move to upper Upper panel
panel detection detection Workpiece
start position

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Upper panel detection end position
If Low pnl detect dist clamp Enb/Dsb is enabled

Over thickness tolerance (Def:0.5mm) +

Max position err correct (Def:2.0mm) +
Lower panel detection distance (Def:5.0mm)

Upper panel detection distance

(About 10mm)

Workpiece Workpiece No Interference

Move to upper Upper panel

panel detection detection Workpiece
start position

Adjust lower panel detection distance on setup screen to reduce the distance of gun that robot moves.
However, lower panel detection distance is also used for lower panel detection start position. Refer to next
figure.
A small lower panel detection distance reduces clearance between panel and lower detect position start. If
lower surface is thicker than expected, excessive pressure can be applied to panel.

If Low pnl detect dist Enb/Dsb is enabled

Lower panel detection Start position

Over thickness tolerance (Def:0.5mm) +

6.0mm Lower panel detection distance (Def:5.0mm)

Interference!!

Upper panel Move to lower panel

detection detection start
position

In the figure above, specify lower panel detection distance larger than 5.5mm.

21.7 PARAMETER CALIBRATION SETUP

Depending on mechanistic properties of servo gun and variations of it, spot program touchup function may
detect wrong position and a search motion may stop before gun axis touches a panel. In such a case, by
executing parameter calibration, you can get parameters that are adapted to each servo gun.

NOTE
Parameter calibration is a function to prevent to stop search motion before touching
a panel by misdetection.

Initial Setting
Procedure to turn on the parameter calibration.
1. Press the MENU key to display the Screen menu.
2. Press 6 SETUP.
3. Press F1 TYPE and select Servo Gun. The Servo Gun Setup screen appears.

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4. Move the cursor on <*DETAIL*> of General Setup and press ENTER key. The General Setup screen
appears.
5. Move the cursor on <*DETAIL*> of Gun Teach Setup and press ENTER key. The Spot Program
Touchup Setup screen appears.
6. Press NEXT and F7 DET CFG. The Torque control setup screen appears.
7. Press F4 CHOICE and Select Adaptive.

Execution Procedure
There are two way of executing parameter calibration
1. Execute at Autotuning.
2. Execute at detail of Torque control setup screen(Adaptive).
The calibration for parameters of detection is executed automatically in Servo Gun Autotuning. Refer to
Chapter “2.5 SERVO GUN SETUP AND AUTOTUNING UTILITY” for more information about
Autotuning.
This section describes how to execute the calibration at the detail of Torque control setup screen (Adaptive).
The detail screen is appeared by press F4 DETAIL at above screen. In the detail screen, the calibration is
executed by following procedure.
1. TP enable switch changes to enabled.
2. Press SHIFT + F3 EXEC. The calibration motion is executed.
During calibration motion, keep to press SHIFT key.

SETUP Servogun _
GUN TEACH SETUP / EQ:1 Gun:1 1/7
Upper detect ctrl parms(Adaptive)
Search torque margin(kgf):
1 Standard value: 2.0
2 Calibrated value: 0.0
3 Torque update rate (interval): 70
4 Torque growth rate factor: 0.5
5 Detect authentication count: 3
Search Calibration: INCOMPLETE
6 Select Torque Limit: STANDARD
7 Use Average Speed: DISABLE

[TYPE] HIST EXE CAL END

Confirm no panel and other obstacles

between tips before start calibration.

First, the gun axis moves to start The gun axis moves to close position
position. by a search speed(default: 4mm/sec).

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NOTE
The calculated parameters are shared by Upper detect step1 and Lower detect. If
you execute the calibration at one side, don’t need to do again at other side. The
calibrated parameters are applied when you choice “Adaptive”.

Apply the calibrated parameters

Search calibration is changed to “COMPLETE” after the calibration is done correctly. The calibrated
parameters can be used at this status. Change to enable as following setup.
Select Torque Limit
Setup a margin of the torque limit for gun axis during search motion. If you select “CALIB”, Calibrated
value is used.
Use Averaging Speed
This item will be set “ENABLE” by a calibration process if the controller gather that an alarm “SVGN-274
Too low speed threshold.” is occurred.

ITEM DESCRIPTION
Search torque margin(kgf) Search torque margin is for torque limit during search motion. This is
Standard value: standard value for it.
Upper1 Default:2.0kgf
Lower Default:3.0kgf
Search torque margin(kgf) This is a calibrated margin.
Calibrated value: If this value is larger than standard one, the servo gun will occur
Default:0.0kgf misdetection. Use calibrated value.
Torque update rate (interval) This is an interval to update torque limit.
Default:
Torque growth rate factor This is a limitation that torque limit is grown.
Default:
Detect authentication count Search process waits this count to detect without fail.
Default:
Search Calibration This is a status for calibration is done or not. If it is COMPLETE, you
can apply calibrated parameters.
Select Torque Limit You can select standard or calibrated value for search torque margin.
Use Averaging Speed Set enable or disable to a process that gun speed is averaged during
detecting.
IF SVGN-274 “Too low speed threshold.” is occurred, set ENABLE.

NOTE
The parameters calibrated by this function can reduce detection sensitivity. It has a
risk of bending a panel. Therefore it’s possible that Spot Program Touchup Function
cannot apply at some low stiffness panels. Check the search motion and the
deflection of panels at the low stiffness panels after the calibrated parameters turn
enable.

NOTE
“SVGN-279 Averaging speed is used.” is posted every touchup function where “Use
Averaging Speed” was set ENABLE by calibration. This warning indicates possibility
of a side effect of sensitivity by calibration.
SVGN-279 is not posted when you set enable to “Use Averaging Speed” on screen.

NOTE
Mechanistic properties of servo gun can change by long-term use. Re-execute the
calibration if the misdetection occurs continually.
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21.8 SEARCH PARAMETERS SETUP

Gun’s that have significant friction or another attribute that distorts gun torque can cause panel
mis-detection (gun tip stops before reaching panel). For this case, mis-detection can be prevented by change
parameters for panel detection.
Parameters of upper panel detection and lower panel detection can be changed on the Search Parameters
Setup screen.
To display Search Parameters Setup screen use the following procedure:
1. Press the MENU key to display the Screen menu.
2. Press 6 SETUP.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Servo Gun. The Servo Gun Setup screen appears.
5. Move the cursor on <*DETAIL*> of General Setup and press ENTER key. The General Setup screen
appears.
6. Move the cursor on <*DETAIL*> of Gun Teach Setup and press ENTER key. The Spot Program
Touchup Setup screen appears.
7. Press the Next key and then F6 SRCH PRM. The Search Parameters setup screen appears.

SETUP Servogun _
GUN TEACH SETUP / EQ:1 Gun:1 1/3

Search Parameters Setup

Upper panel detection

Upper detection STEP1: TYPE1
Upper detection STEP2: TYPE1
Lower panel detection TYPE1

[ TYPE ] EQUIP GUN END UPDATE

ITEM DESCRIPTION
Upper panel detection This item is parameters setup for upper panel detection. A gun tip touch panel two
STEP 1 times in a search motion. This item is for first touching.
Default value: 1 When the search motion finish before the movable tip touch panel, change
parameter type.
Press F5 UPDATE after changing this item.
Upper panel detection This item is parameters setup for upper panel detection. Movable tip touch panel
STEP 2 two times in a search motion. This item is for second touching.
Default value: 1 If accuracy of touchup position is bad, change parameter type.
Press F5 UPDATE after changing this item.
Lower panel detection This item is lower panel detection.
Default value: 5 When search motion finish before both tips touch panel, change parameter type.
Press F5 UPDATE after changing this item.

NOTE
Usually, the search parameters need not be changed. Change the search
parameters setting only if the mis-detection occurs frequently.

NOTE
If the panel detection sensitivity is lowered too much depending on search
parameters setting, the panel might be damaged at the panel detection. Change
search parameters carefully.

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21.9 THICKNESS UPDATE SETUP

Spot Program Touchup Function can update a thickness and a position at one time. Setup for thickness
update is set at the thickness update setup for touchup screen.

NOTE
Spot Program Touchup Function can update part thicknesses at following execution
only.
1. Execute this function at TP enable.
2. Execute Spot Point Touchup Function.

To display Thickness Update Setup screen use the following procedure:

1. Press the MENU key to display the Screen menu.
2. Press 6 SETUP.
3. Press F1 TYPE to display the Screen Selection menu. And select Servo Gun. The Servo Gun Setup
screen appears.
4. Move the cursor on <*DETAIL*> of General Setup and press ENTER key. The General Setup screen
appears.
5. Move the cursor on <*DETAIL*> of Gun Teach Setup and press ENTER key. The Spot Program
Touchup Setup screen appears.
6. Press the Next key and then F9 THK PRM. The Thickness Update Setup screen appears.

SETUP Servogun _
GUN TEACH SETUP / EQ:1 Gun:1 1/2
Thickness Update Setup for Touchup
1 Program Touchup Function: <*DETAIL*>
2 Point Touchup Function <*DETAIL*>

[ TYPE ] EQUIP GUN

7. Move the cursor on <*DETAIL*> of Program or Point Touchup Function and press ENTER key. The
detail screen appears.
SETUP Servogun _ SETUP Servogun _
GUN TEACH SETUP / EQ:1 Gun :1 1/6 GUN TEACH SETUP / EQ:1 Gun :1 1/5
Program Touchup Function Program Touchup Function
1 Thick Update @TEACH Enb/Dsb: ENABLE 1 Max Thickness Value(mm): 10.0
2 Max Thickness Valuse(mm): 10.0 Allowable Thk Err to NOT Update
Allowable Thk Err to NOT Update 2 Max Allowable Error(mm): 0.5
3 Max Allowable Error(mm): 0.5 3 Min Allowable Error(mm): -0.5
4 Min Allowable Error(mm): -0.5 Allowable Thk Err to NOT Confirm
Allowable Thk Err to NOT Confirm 4 Max Allowable Error(mm): 0.5
5 Max Allowable Error(mm): 0.5 5 Min Allowable Error(mm): -0.5
6 Min Allowable Error(mm): -0.5 Error = Observed – Specified
Error = Observed – Specified

[ TYPE ] EQUIP GUN ENABLE DISABLE [ TYPE ] EQUIP GUN

In the detail screens, following parameters are set.

ITEM DESCRIPTION
Thick Update @TEACH This turns on the thickness update function in Program Touchup Function.
Enb/Dsb: ENALBE: Spot program touchup function at TEACH updates thickness at the
same time as touchup.
This is for only Program DISABLE: Thickness is not updated.
Touchup Function.

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ITEM DESCRIPTION
Allowable Thk Err to NOT If thickness error is between this and min one, the thickness is NOT updated.
Update See figure below for details.
Max Allowable Error(mm)
Allowable Thk Err to NOT If thickness error is between this and max one, the thickness is NOT updated.
Update See figure below for details.
Min Allowable Error(mm):
Allowable Thk Err to NOT If thickness error is lower than this value, the thickness is updated without
Confirm confirming.
Max Allowable Error(mm) See figure below for details.
Allowable Thk Err to NOT If thickness error is higher than this value, the thickness is updated without
Confirm confirming.
Min Allowable Error(mm) See figure below for details.

Error
+
A
Error = Observed － Specified Thk Err to NOT Confirm : Max Error

B
Thk Err to NOT Update : Max Error
0
C
Specified Observed
Thk Err to NOT Update : Min Error
thickness thickness D

Thk Err to NOT Confirm : Min Error

E
_

Thickness error is in A or E :Confirm to update thickness.

Thickness error is in B or D :Thickness is updated automatically.
Thickness error is in C :Thickness is NOT updated.

NOTE
If max allowable thickness error to not update is larger than one to not confirm, a
process to not update has priority. Thickness is not updated when the thickness
error is in that region.

NOTE
If you set same value to the max(or min) allowable thickness error to not update and
confirm, you always confirm to update with a prompt. In this setting, thicknesses are
not updated automatically.
On the contrary, if you hope that thicknesses are updated automatically, max and
min allowable thickness errors should be set large.

NOTE
If max and min allowable thickness errors are set too large, this function cannot find
an inappropriate thickness. For example, the observed thickness is too large
because the gun clips other panel.
Set these values to right.
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21.9.1 Search Sequence with Thickness Update

SAMPLE
_
5/2 0
3:L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t= 2.0,S=1,ED =1]
4:L P P[2 ] 2000mm/sec CNT50
SPOT[SD=1,P=1,t= 2.0,S=1,ED =1]
5:L P[3] 2000mm/sec CNT50
SPOT[SD=1,P=1,t= 2.0,S=1,ED =1]
6:L P[4] 2000mm/sec CNT50 P[ 4]
SPOT[SD=1,P=1,t= 2.0,S=1,ED =1]

POINT SPOT G unTchup AutTchup Touchup > P[3]

P[2] P[1]

Spot program touchup function sequence with thickness update

Move to Start Move to upper panel Upper panel Move to lower panel
Distance (SD) detection start detection detection start
position position

Prompt to confirm
detected lower Prompt to confirm
position
thickness

If the prompt is If the prompt is

displayed, press displayed, press
answer and press answer and press
SHIFT+FWD to resume SHIFT+FWD to resume
program. program.
Lower panel
detection Thickness check

Touchup & Move to Move to End

new taught position Distance (ED)

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21.9.1.1 Prompt to confirm detected lower position and thickness

Where thicknesses measured by lower detection and thickness check meet the conditions to confirm, the
prompts to confirm are displayed. When they are displayed, the program is paused. Resume program by
press SHIFT+FWD after confirm the thickness and a robot tip position.
Where NOT meet the conditions, the prompts is not displayed and proceed with the sequence.

NOTE
If you do cursor movement or change display at displaying the prompts, the touchup
function is aborted.

Prompt to Confirm Detected Lower Position

When an error between a measured thickness at lower panel detection and a specified one crosses an
allowable thickness error to not confirm, a prompt as below is displayed.

SAMPLE _ _ _
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]
Rec Pos and Thk on this tip pos?(t=1.0)

YES NO

Press F4 YES, the position and the thickness are updated by current value and a next prompt as below is
displayed.
Press F5 NO, the touchup function is aborted. If you resume the program, go to next line.

NOTE
Position and thickness updated at here are not complete. When F4 YES is selected
at above, don’t abort the touchup process to get the position added some
compensation and the correct thickness.

SAMPLE _ _ _
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=1.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]
SHIFT+FWD: Resume program.

POINT SPOT GunTchup AutTchup TOUCHUP

Resume the program and do thickness check.

Prompt to Confirm Thickness

When an error between a measured thickness at thickness check and a specified one crosses an allowable
thickness error to not confirm, a prompt as below is displayed. However, where the measured thickness has
been confirmed at the prompt to confirm detected lower position (selected F4 YES at the above prompt),
this prompt is not displayed if it has no error between thickness at lower detection and one at thickness
check.

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SAMPLE _ _ _
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]
Change thickness: 2.0 to 1.0?

YES NO

Press F4 YES, the thickness is updated and a next prompt as below is displayed.
Press F5 NO, the touchup function is aborted. If you resume the program, go to next line.

SAMPLE _ _ _
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec ﾅﾒﾗｶ 50
SPOT[SD=1,P=1,t=1.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]
SHIFT+FWD: Resume program.

POINT SPOT GunTchup AutTchup TOUCHUP

Resume the program, move to new taught position and do touchup.

NOTE
The robot must be moved to new taught position actually for touchup. In above
process, if you don’t resume the program, the touchup is not done.

21.10 SPOT PROGRAM TOUCHUP STATUS SCREEN

Program touchup status can be confirmed from the spot program touchup status screen.
1. Press the MENU key to display the Screen menu.
2. Press 0 NEXT and 3 STATUS.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Servo Gun. Move the cursor on <*DETAIL*> of program touchup status and press ENTER
key.
Spot program touchup status screen appears.

The following items are shown on this screen. The status of the latest executed program is displayed on the
first line. A maximum of 50 lines can be displayed.

STATUS Servogun _
PROG TOUCHUP STAT / EQ:1 Gun:1 1/30
No. Program name Lin DET THK Pos[mm]
1 SPOT_WELD 6 OK OK 0.2 OK@
2 SPOT_WELD 5 OK OK 3.1 NG
3 SPOT_WELD 4 OK NG ****** **
4 SPOT_WELD 3 OK OK -0.8 OK@
5 SPOT_WELD 2 OK OK 0.2 OK
6 SPOT_WELD 1 NG ** ****** **

[ TYPE ] EQUIP DETAIL ALL_CLR CLEAR

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NOTE
If @symbol appears beside position status, then position was modified.
If @symbol does NOT appear beside position status, then position was not
modified.

ITEM DESCRIPTION
Program name Name of program where spot program touchup was performed.
Lin Line number of program where spot program touchup was performed.
Det OK: Upper panel detection success
NG: Upper panel detection failure
**: Attempted upper panel detection
When this item is NG or **, thickness check and touchup are skipped. Refer to "Upper
panel detection fails" in chapter "21.23 TROUBLESHOOTING".
Thk OK: The error margin of the specified thickness and the observed thickness is within
tolerance value.
NG: The error margin of the specified thickness and the observed thickness is outside
tolerance value.
**: Attempted thickness check
When this item is NG or **, touchup is skipped. Confirm the specified thickness in the
pressure schedule and the under/over thickness tolerance in the setup screen.
Pos[mm] The calculated position error correction is displayed. When this value is positive, the
direction of position error correction is the robot close direction. When this value is
negative, the direction of position error correction is the robot open direction.
OK: The position error correction is within tolerance value.
NG: The position error correction is outside tolerance value.
**: Attempted position error correction calculation
When this item is NG or **, touchup is skipped. Confirm max/min position err correct in the
setup screen.
Position recorded status If position was modified, then @ symbol is placed beside (to the right of) the position
value. Note that position is not modified in the following cases:
. if detection distance, thickness, or position error are out of tolerance
. if verify mode is active
. if program is write-protected

Detailed data can be displayed by moving cursor to desired line and pushing F3 DETAIL.

STATUS Servogun _
PROG TOUCHUP STAT / EQ:1 Gun:1 1/17
1 No.: 1
2 Program name:
SPOT_WELD
3 Program line: 6
4 Max detect dist range(mm): 4.50
5 Detection distance(mm): 2.10 OK
6 Specified thickness(mm): 2.00
7 Observed thickness(mm): 1.83 OK
8 Max allowable pos err(mm): 2.00
9 Min allowable pos err(mm): 0.00
10 Position status: Updated
11 Distance from OldPos to NewPos:
12 Magnitude(mm): 0.20 OK
13 Direction: Robot Close
14 Position error offset 0.00
15 Number of retry: 0
16 Date: 2012/01/01
17 Time: 12:00:00

[ TYME ] RETURN

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ITEM DESCRIPTION
Program name Name of program where spot program touchup was performed.
Program line Line number of program where spot program touchup was performed.
Max detect dist range(mm) This item is max detection distance range.
Refer to Chapter “21.5 MAX DETECTION DISTANCE RANGE” for more
information about this item.
Detection distance(mm) This item is a result of the upper panel detection.
OK: Upper panel detection success
NG: Upper panel detection failure
**: Attempted upper panel detection
When this item is NG or **, thickness check and touchup are skipped. Refer to
"Upper panel detection fails" in chapter "21.23 TROUBLESHOOTING".
Specified thickness(mm) This item is the expected (target) part thickness specified via pressure schedule.
Observed thickness(mm) This item is the observed thickness.
OK: The error margin of the specified thickness and the observed thickness is
within tolerance value.
NG: The error margin of the specified thickness and the observed thickness is
outside tolerance value.
**: Attempted thickness check
When this item is NG or **, touchup is skipped. Confirm the specified thickness in
the pressure schedule and the under/over thickness tolerance in the setup screen.
Max allowable pos err(mm) This item is the tolerance for max position error.
Min allowable pos err (mm) This item is the tolerance for min position error.
PosStat This items specifies whether position data was modified or not
Updated: Position was modified
NOT updated: Position was NOT modified
Magnitude(mm) This item is the magnitude of the calculated position error correction.
OK: The position error correction is within tolerance value.
NG: The position error correction is outside tolerance value.
**: Attempted position error correction calculation
When this item is NG or **, touchup is skipped. Confirm max/min position err
correct in the setup screen.
Direction This item is the direction of the calculated position error correction.
Robot Close：The direction of position error correction is the robot close direction.
Robot Open：The direction of position error correction is the robot open direction.
**: Attempted position error correction calculation
Position error offset(mm) This item is an offset added to position error correction. Confirm the position error
offset in the setup screen.
Number of retry This item is number of retries for upper panel detection.
Date This item indicates date when spot program touchup was performed.
Time This item indicates time when spot program touchup was performed.

Data for a single line can be deleted cursor by moving cursor to desired line and pushing F5 CLEAR.
Data for all lines can be deleted by pushing F4 ALL_CLR.

WARNING
Deleted data cannot be restored (recovered).

Status Check:
A cause of mis-touchup can be known from List and Detail of Touchup status. The cause is wrong setting
for allowable values, detect extra object or others. In this section, remedies are shown.
Refer to Chapter “21.23 TROUBLE SHOOTING”, if mis-touchup cannot be avoided by this. It might do
mis -detection.

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CAUSE REMEDY
List Max detect dist range is a allowable distance between weld point and upper
Det NG panel surface. This is calculated by following parameters.
Detail Max detect dist range(mm)
Max detect dist range = Specified thickness + Over thickness tolerance
< Detection distance + Max allowable position error + Detection distance margin

Detected upper panel surface is out Detection distance is a distance between weld point before touchup and
of range of allowable position. detected upper panel surface. If a result is correct, this is calculated as
follows.
Detection distance (mm)
= Touchup error before this function + Observed thickness
NOTE: Touchup error is an error faced Robot close direction is positive.
If touchup error is positive, there is clearance between robot tip and
under panel surface.

Where the result of detection is correct, confirm setting of allowable

parameters.
Where the result of detection is wrong, confirm an extra object and an
outshoot on weld point. If it has something, remove it or move robot on X-Y
plane to avoid it.
List Where observed thickness is correct, confirm specified thickness in pressure
Thk NG condition. If it has no problem, set larger value than thickness error into Over
Detail or Under thickness tolerance
Observed thickness > Specified
thickness + Over thickness Where observed thickness is wrong, confirm an extra object and an abnormal
tolerance panel assembly. If it has something, remove it or move robot on X-Y plane to
OR avoid it.
Observed thickness < Specified
thickness - Under thickness
tolerance

Thickness error is out of range of

tolerances.
List Where position error correction is larger than max allowable pos err;
Pos NG if it is correct, touchup by Point touchup function or manual or set larger
Detail value into max allowable pos err.
|Position error correction|
>Max allowable pos err if it is wrong, confirm weld point.
OR
|Position error correction| Where position error correction is smaller than min allowable pos err;
< Min allowable pos err if it is correct, set smaller value into min allowable pos err. Mis-touchup is
not occurred by cause of small correction if it is 0.0mm.
Position error correction is out of
range. If Position error offset is not 0.0mm, confirm its value. If it has problem, set
offset by SPTCH_OFS instruction.

21.11 SPOT PROGRAM TOUCHUP CHART SCREEN

Program touchup status can be confirmed from the spot program touchup chart screen.
1. Press the MENU key to display the Screen menu.
2. Press 0 NEXT and 3 STATUS.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select Servo Gun. Move the cursor on <*DETAIL*> of program touchup chart and press ENTER key.
Spot program touchup chart screen appears.

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Chart screen provides a visual perspective of spot program touchup process. Summary blocks (symbols) at
top of screen display overall touchup result and error condition, if any. Charts beneath summary blocks
show magnitude of thickness and position change graphically. Trends over multiple points are exposed. A
screen sample is shown below.

Summary:
• Touchup result screen is displayed for 10 records (1page) at a time
• Current record range is noted in upper right-hand corner
• Most recent data (last / bottom page) is displayed at screen entry
• Records are shown in chronological order, from left to right.

Line

Old New
Spot line number

• 10 blocks at top of screen summarize touchup result for 10records (line# noted within block)
• Charts beneath blocks provide magnitude and direction of change for thickness and position
• Additional info for selected record is shown in information panel, on right side of screen

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Operation procedure:
Key Function
F2 or DN arrow Display NEXT page
F3 or UP arrow Display PREVIOUS page
Shift + (F2 or DN arrow) Display last (bottom) page
Shift + (F3 or UP arrow) Display first (top) page
F4 Record select
F5 Filter select
F7 Configure eval tol settings
Enter Toggle chart tolerance line on/off
RT arrow Select next record on right
LF arrow Select next record on left
Shift + RT arrow Select rightmost record
Shift + LF arrow Select leftmost record

Information panel:

Template Description / comment

Records: # -> # Page start record -> page end record
TotalRecords This is total of the record.
V Currently selected record number.
Note: "V” is displayed beneath summary block of selected record and line is drawn below “V”
symbol through selected record on chart.
Program: # Name of program where spot program touchup was performed.
Line: # Line number of program where spot program touchup was performed.
Time: # This item indicates time when spot program touchup was performed.
Date: # This item indicates date when spot program touchup was performed.
DetDist: # This item is a result of the upper panel detection.
OK: Upper panel detection success
NG: Upper panel detection failure
When this item is NG, thickness check and touchup are skipped. Refer to "Upper panel
detection fails" in chapter "21.23 TROUBLESHOOTING".
# (Max: #) Observed detect distance ( Max detect distance range)
Refer to Chapter “21.5 MAX DETECTION DISTANCE RANGE” for more information about
the max detection distance range.

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Template Description / comment

Thickdiff: # OK: The error margin of the specified thickness and the observed thickness is within
tolerance value.
NG: The error margin of the specified thickness and the observed thickness is outside
tolerance value.
When this item is NG, touchup is skipped. Confirm the specified thickness in the pressure
schedule and the under/over thickness tolerance in the setup screen.
# (Nom: #) Observed thickness ( Nom: Nominal thickness )
Min/Max: #/# Nominal thickness – Under thickness tolerance / Nominal thickness + Over thickness
tolerance
Posdiff: # OK: The position error correction is within tolerance value.
NG: The position error correction is outside tolerance value.
When this item is NG, touchup is skipped. Confirm max/min position err correct in the setup
screen.
# (#) Magnitude of position change (direction of position change)
Min/Max: #/# Min position error correction / Max position error correction
PosStat Displays whether position was touched up (modified) or not.
Updated: Position was modified
Not updated: Position was NOT modified

Summary block symbol meanings:

Symbol Meaning
Detect distance criteria not met
1 Refer to "Upper panel detection fails" in chapter "21.23
Red-framed TROUBLESHOOTING".
Thickness criteria not met
Line above number: The error margin of the specified thickness and the
1 1 observed thickness is outside over tolerance value.
Purple -framed Line below number: The error margin of the specified thickness and the
observed thickness is outside under tolerance value.
Position criteria not met
Line above number: Position error correction is larger than Max position error
1 1 correction.
Blue -framed Line below number: Position error correction is smaller than Min position error
correction.
Detect distance, thickness and position criteria all met and point (position data)
1 was modified.
Bright green

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Symbol Meaning
Detect distance, thickness and position criteria all met, but position data was
1 not modified. This case occurs if touchup executes in VERIFY mode or if
White evaluation tolerance is active.

F5: FILTER SEL (data selection):

Filter SEL is used to select data subset. For example, only points that were NOT touched up (SHOW BAD).
Current filter selection is shown in upper left hand corner of screen. 6 filter selections are available:

Filter SEL Description

SHOW ALL All pts available
SHOW GOOD Pts that were touched up
SHOW BAD Pts that were NOT touched up
SHOW DETERR Pts with detect distance overtol
SHOW THKERR Pts with thick chg over / undertol
SHOW POSERR Pts with pos chg over / undertol

Chart section:

ThickDiff (thickness criteria)

Thkdiff = Observed thickness – Nominal thickness

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thicker than nominal

Over thickness tolerance

Nominal thickness

Under thickness tolerance

thinner than nominal

PosDiff (position criteria)

Posdiff = Observed position – Nominal position
• Posdiff > 0

Robot close direction

Max position err correct

Min position err correct

Nominal position

Robot open direction

• Posdiff < 0

Robot close direction

Nominal position
Min position err correct

Max position err correct

Robot open direction

Evaluation tolerance configuration screen

Eval tol is used with touchup diagnostic mode. In touchup diagnostic mode, thickness upper tolerance is set
to a large value (to avoid thickness error), and min pos error is set larger than max pos error. This
combination of settings leads to measurement of thickness and position change (diff), without touchup.
Eval tolerance is then set to an appropriate tolerance for identification of bad points and applied to these
measurements.
Note: diagnostic mode can also be used to confirm program touchup accuracy. Users would find the
position error of a given point and then confirm the result via direct manual measurement.

When evaluation tolerance is active:

• Touchup summary block is colorized per the measurement and eval tolerance, rather than the tolerance
that was present at measurement time
• Tolerance lines on chart are displayed with a PINK line (tolerance line is normally red).
• “EvalTol active” is written to the bottom of chart
• Detect distance and touchup status boxes are blank

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NOTE
** displays when measurement data is unavailable due to:
Detect distance error: Thkness and PosDiff status = **.
Thickness error: PosDiff status = **.

Parameter Comment
Evaluation tolerance Use eval tol, instead of org tol to evaluate criteria
Thickness tolerance upper Upper (over) thickness tolerance for evaluation
Thickness tolerance lower Lower (under) thickness tolerance for evaluation
Position tolerance upper Allowable position error in robot close direction for evaluation
Position tolerance lower Allowable position error in robot open direction for evaluation

21.12 TOUCHUP STATUS RECORDING FUNCTION

This function automatically records program touchup status in LS file. The data recorded in the LS file are
the following.

Parameter Comment
No. This is a data number. Data becomes new as this number increases.
Date This item indicates date when spot program touchup was performed.
Gun This item is gun number.
Program name Name of program where spot program touchup was performed.
Line number Line number of program where spot program touchup was performed.
Position ID Position ID of program where spot program touchup was performed.
Comment This item is comment for position ID.

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Parameter Comment
Position error[mm] This item is position error correction. When this value is positive, the
direction of position error correction is the robot close direction. When
this value is negative, the direction of position error correction is the
robot open direction.
OK/NG/** OK: The position error correction is within tolerance value.
NG: The position error correction is outside tolerance value.
**: Attempted position error correction calculation
Max pos err[mm] This item is the max position error correction.
Detection distance[mm] This item is a result of the upper panel detection.
OK/NG/** OK: Upper panel detection success
NG: Upper panel detection failure
**: Attempted upper panel detection
Max detect dist[mm] This item is max detection distance range.
Refer to Chapter “21.5 MAX DETECTION DISTANCE RANGE” for more
information about this item.
Thickness value[mm] This item is the observed thickness.
OK/NG/** OK: The error margin of the specified thickness and the observed thickness is
within tolerance value.
NG: The error margin of the specified thickness and the observed thickness is
outside tolerance value.
**: Attempted thickness check
Thickness error[mm] This item is an error margin of the specified thickness and the observed
thickness.
Under thick err[mm] This item is under thickness tolerance.
Over thick err[mm] This item is over thickness tolerance.
NominalThickness[mm] This item is the expected (target) part thickness specified via pressure schedule.
Min pos err[mm] This item is the min position error correction.
Number of retries Number of retry attempts (after failure) for this point
Point modification status 0: Point was not modified
1: Point was modified

Two LS files are prepared per equipment. The name of two LS files is the following.
• ~SGOFSET1#.LS (#:equipment number)
• ~SGOFSET2#.LS (#:equipment number)

These are text files, with csv format.

100 data is recorded in each LS file in the maximum.

~SGOFSET1#.LS ~SGOFSET2#.LS
No. No.
1 101
2 102
3 103
… …
100 200

If the number of data exceeds 200, ~SGOFSET2#.LS is copied onto ~SGOFSET1#.LS. And, the latest data
is recorded in ~SGOFSET2#.LS.

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~SGOFSET1#.LS ~SGOFSET2#.LS
No. No.
101 201
102
103
…
200

When an all backup (batched save) operation is performed, the LS file is saved.

21.13 SPOT PROGRAM TOUCHUP DISABLE INSTRUCTION

If a spot instruction is executed with program touchup mode enabled, spot program touchup will execute.
However, there may be some cases where automatic touchup is undesirable. For example, if the robot or
gun interfere with part of a workpiece or peripheral devices, etc. when the robot or gun move to the upper
panel detection start position in a complicated environment. In such a case, program touchup mode needs to
be kept enabled, but it should be disabled only when a specific spot instruction is executed.
The spot program touchup disable instruction can be used to disable selected touchup at specific spot points
in a program. This is done by attaching this attaching the touchup disable instruction to the spot instruction.
This instruction only has an effect on spot instructions.

To teach the spot program touchup disable instruction, place the cursor behind the spot motion instruction
and press the F4 CHOICE key to display the supplementary motion instruction menu. Select a
SpotProgTouchDsb from the menu.

Motion Modify 2 SAMPLE _ _

1 TIPDRESS 5/6
2 Press_m 4: L P[1] 2000mm/sec CNT50
3 SpotProgTouchDsb SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
4 SPTCH_OFS 5: L P[2] 2000mm/sec CNT50
5 SPTCH_RSD SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
6 Wrist Joint SpotProgTouch_Dsb
7 Acc 6: L P[3] 2000mm/sec CNT50
8 –next page— SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
[END]

When the program above executes, the following sequence executes for line 5.

TP enable: Touchup by manual after pause

Move to next
Restart taught
position

Pause after it Touchup by Pause after it

moves to Start manual moves to End
Distance (SD) Distance (ED)

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TP enable: Not touchup by manual after pause

Move to next
Restart taught
position

Pause after it Pressurization Move to End

moves to Start position Distance (ED)
Distance (SD)

TP disable

Move to next
taught
position

Move to Start Pressurization Move to End

Distance (SD) position Distance (ED)

When this instruction is executed with the TP enabled, robot pauses at start distance. Perform touchup if
necessary, manually.
When this instruction is executed with the TP disabled, robot does not pause at the start distance. However,
when SpotProgTouch_Dsb pause Sev on setup screen is specified as alarm, robot pauses at the start distance.
Do the touchup if necessary by manual.
Moreover, when this instruction is executed, the prompt message "Paused by Spot Prog Touch Dsb" is
displayed for about one second.

NOTE
• Spot program touchup disable should only be attached to spot instructions. Do not
attach it to other application instructions.
• Spot program touchup disable instruction is useful only when program touchup
mode is enabled.
• Add spot program touchup disable instruction to end of spot instruction.

21.14 SPTCH_OFS INSTRUCTION

Offset specified by position error offset in setup screen is added to position error correction for successful
touchup. SPTCH_OFS is used to specify this offset at a specific line/spot. The value specified by
SPTCH_OFS is used instead of value on the setup screen for this line.

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To teach SPTCH_OFS instruction, place the cursor behind the spot motion instruction and press the F4
CHOICE key to display the supplementary motion instruction menu. Select a SPTCH_OFS from the menu.
Specify the offset for SPTCH_OFS.
SPTCH_OFS can use the following two methods.
• Direct specification: A numerical value is directly specified.
• Indirect specification: The value of register [i] is specified.
The input range of SPTCH_OFS is -2.0mm <= SPTCH_OFS <= 2.0mm.

Motion Modify 2 SAMPLE _ _

1 TIPDRESS 5/6
2 Press_m 4: L P[1] 2000mm/sec CNT50
3 SpotProgTouchDsb SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
4 SPTCH_OFS 5: L P[2] 2000mm/sec CNT50
5 SPTCH_RSD SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
6 Wrist Joint SPTCH_OFS = -1.1mm
7 Acc 6: L P[3] 2000mm/sec CNT50
8 –next page— SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
[END]

When the program above executes, the offset of -1.1mm is added to the position error correction by for line
5. In other lines, the offset specified by position error offset in setup screen is added to position error
correction.

NOTE
SPTCH_OFS instruction is useful only when program touchup mode is enabled.

21.15 SPTCH_RSD INSTRUCTION

When Low pnl detect dist Enb/Dsb on setup screen is enabled, lower panel detection distance on setup
screen is used for the movement distance in the lower direction of gun at the upper panel detection.
SPTCH_RSD (robot start distance) can temporarily replace lower panel detection distance with value
specified by SPTCH_RSD.

To teach SPTCH_RSD instruction, place the cursor behind the spot motion instruction and press the F4
CHOICE key to display the supplementary motion instruction menu. Select a SPTCH_RSD from the menu.
Specify the lower panel detection distance for SPTCH_RSD.
SPTCH_RSD can use the following two methods.
• Direct specification: A numerical value is directly specified.
• Indirect specification: The value of register [i] is specified.
The input range of SPTCH_RSD is 0.0mm <= SPTCH_RSD <= 20.0mm.

Motion Modify 2 SAMPLE _ _

1 TIPDRESS 5/6
2 Press_m 4: L P[1] 2000mm/sec CNT50
3 SpotProgTouchDsb SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
4 SPTCH_OFS 5: L P[2] 2000mm/sec CNT50
5 SPTCH_RSD SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
6 Wrist Joint SPTCH_RSD = 4.0mm
7 Acc 6: L P[3] 2000mm/sec CNT50
8 –next page— SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
[END]

When line 5 of the above-mentioned program execute, gun motion (distance) changes as follows.

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Over thickness tolerance (Def:0.5mm) +

Max position err correct (Def:2.0mm) +
SPTCH_RSD (=4.0mm)
Upper panel detection distance
(About 10mm)

Workpiece Workpiece

Move to upper Upper p an el

panel detection detection Workpiece
start position

Servo gun doesn’t collide with workpiece during search motion by this instruction even if there is no
enough distance between Gun and workpiece at weld point.

Over thickness tolerance (Def:0.5mm) +

Max position err correct (Def:2.0mm) +
SPTCH_RSD（＝3.0mm）
Start Distance(ROBOT)(Default:10mm)

Upper panel detection distance

Upper panel detection distance (About 10mm)
(About 10mm)

Workpiece

NOTE
SPTCH_RSD instruction is useful only when program touchup mode is enabled.

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21.16 SINGLE STEP MODE

When spot program touchup is executed with single step enabled, the following sequence executes.

Spot program touchup function sequence: Single step mode

Restart

Pause after it moves Move to upper Upper panel

to Start Distance (SD) panel detection detection
start position

Move to lower Lower panel Thickness check Touchup&

panel detection detection Pause after
start position reaching taught
position

Restart Restart

Manual touchup Pause after it

(F4) moves to End
Distance (ED)

Move to next line

When spot program touchup is executed with the single step enabled, robot pauses at the taught position and
the end distance. Do manual touchup if necessary.

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21.17 OTHER SPECIFICATIONS

BWD
Spot program touchup does not execute at BWD execution. Therefore, the robot and gun do the same
motion as motion of BWD execution of the spot instruction.

Pause
The robot restarts spot program touchup from the upper panel detection start position at next restart when
the robot and the gun are paused while upper panel detection is executing. The robot restarts spot program
touchup from the lower panel detection starting position at next restart when the robot and the gun are
paused during lower panel detection or thickness check.

Jog
The robot restarts spot program touchup from the start distance at next restart when the robot and the gun
are jogged while spot program touchup is being executed.

Touchup
Spot program touchup is canceled when manual touchup is occurs during while spot program touchup is
executing. Therefore, the robot restarts from the end distance at next restart.
Moreover, the spot point touchup function cannot be used until the robot reaches the taught position while
spot program touchup is executing or paused.

Skip
If user changes execution line, spot program touchup is cancelled for that point, but will continue at the next
spot point.

Dual gun
Gun tip selection for dual gun configuration is based on weld schedule in spot instruction.
GunA is used if S=(1,1) or S=(1,0).
GunBis used if S=(0,1)
The following switch can be used to force touchup to always use the same tip.
$SGSYSTCH.$DGIDXSELOPT
1: Always use GunA
2: Always use GunB
3: MN based: Use GunA unless mnemonic instruction specifies GunB only operation.

Default specification for position recorded for “other” gun is same position as touchup gun.
However, the following switch can be used to record current angle for other gun.
$SGSYSTCH.$DGPOSRECOPT
0x1: Same position for both guns
else: record current angle for other gun

21.18 SPOT POINT TOUCHUP FUNCTION

21.18.1 Over View

Spot point touchup provides the following options
1. Spot point touchup with upper panel detection
Upper panel is detected by upper panel detection, and the touchup of the robot is done based on detected
upper panel.

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2. Spot point touchup without upper panel detection

After gun tip is moved to upper panel by jog, the touchup of the robot is done based on the position of gun
tip.

1. With upper panel detection

Servo gun suitably Upper panel detection

positions.

2. Without upper panel detection

Gun tip is moved to upper Lower panel detection Thickness check Touchup&
panel by jog Move to new taught
position

Spot point touchup function is standard of Servogun option. This function has the following dependency:
Servogun option A05B-2***-J670

On 7DC1 software, this function for Standard Setting user that order A05B-2***-R651 needs the following
option:
Servo gun setup package A05B-2***-J979

WARNING
Touchup accuracy depends on servo gun mechanical design and panel reaction
(fixturing / stiffness). The following items may adversely affect accuracy.
• X guns with long jaw
• C guns with offset
• Guns with large frictional resistance parting actuator
• Loosely fixtured panels
• Soft panels
• Pneumatic equalizers
• Springs or gun float mechanisms

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NOTE
PR[90] is the default position register for robot motion during the spot program
touchup motion sequence. Don't use this PR for another purpose. The register
number of this PR can be changed on the setup screen (Refer to Chapter "21.4
SPOT PROGRAM TOUCHUP FUNCTION SETUP".).

21.18.2 Initial Setting

Execute the items in the order listed below, prior to initial spot program touchup.
• Autotuning
• Pressure calibration
• Setting the tool coordinate system
• Tip wear standard
• Specify “STROKE” to gun operation. (If Execute thickness check in Gun Teach Setup is disable, this
setting is not needed.)

Execute the items listed below, prior to every spot program touchup.
• Tip wear detection
• Thickness check calibration

Thickness check calibration can also be executed from TP program. Please refer to Chapter “21.20
THICKNESS CHECK CALIBRATION”.

NOTE
TCP of robot and master position for the gun axis should be accurate to use spot
point touchup. Execute tip wear detection without fail, and make the wear amount of
robot's tip and the wear amount of gun's tip appropriate.

21.18.3 Operating Procedure for Spot Point Touchup with Upper Panel
Detection
To use spot point touchup with upper panel detection, follow the procedure below:
1. Move robot to a suitable position near welding point.

The position of gun tip and robot tip need

not be accurate.
The robot can be moved to taught position
by executing spot instruction at single step.

2. Move the cursor to the spot instruction that requires position correction (add a spot instruction to the
TP program, if no spot instructions exist). The position at this time need not be accurate.

3. Press SHIFT key & F4"AutTchup" to start the upper panel detection. In the following operations, the
robot and the servo gun work. Keep pushing SHIFT key.

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SAMPLE
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]
First, the robot and the gun tip remove from
POINT SPOT GunTchup AutTchup TOUCHUP >
the panel. Second, the gun axis moves.
Third, the robot moves.

NOTE
During spot point touchup, gun axis and robot move at same speed regardless of
override.

4. The gun tip stops at the detected position after detecting upper panel. And, the following prompt is
displayed.

SAMPLE
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]

Is GunTip on panel? (Rbt will close<12.5mm)

Gun tip stops on upper panel.
YES NO

NOTE
The robot detects the lower panel in the next step. "Rbt will close" in the prompt
message shows the maximum displacement of the robot in the next step. Therefore,
"Rbt will close" is a distance from robot tip to lower panel.
When the shape of panel is abnormal or when there is a protrusion on the lower
panel, the robot cancels lower panel detection on the way, and pauses.

Press F4"YES" when there is no problem concerning the position of the gun tip. Go to procedure 5.
Press F5"NO" when there is a problem concerning the position of the gun tip. Spot point touchup is
canceled.

5. Lower panel detection begins.

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SAMPLE
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]

Closing both tips…

Gun and robot move to touch the panel

with both tips.

When panel is touched with both tips, the thickness of the panel is simply measured.
As a result of simple measurement, a prompt as below is displayed when the thickness error is longer
than allowable thickness error to not confirm. When the thickness error is shorter than it, the prompt is
not displayed and go to procedure 6.
Refer to Chapter “21.9 THICKNESS UPDATE SETUP” for more information about this.

SAMPLE
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1] Nominal thickness
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]

Check thickness on this robot tip pos?

YES NO Shape of panel is abnormal or
there is obstacle on the lower panel

Confirm the robot tip position.

Press F4"YES" when you want to continue spot point touchup. Go to step 6.
Press F5"NO" when you do not want to continue spot point touchup. Spot point touchup is canceled.

NOTE
As a result of simple measurement, a prompt as below is displayed when the
thickness error is longer than allowable thickness error to not confirm. This prompt is
to confirm result of search.
Refer to Chapter “21.9 THICKNESS UPDATE SETUP” for more information about
this.

NOTE
Robot tip moves to lower panel based on nominal thickness when "Execute
Thickness check" on the setup screen is DISABLE. When nominal thickness is
thicker than actual thickness, a gap will be present between robot tip and lower
panel.

6. Thickness check begins.

NOTE
This step does not execute when "Execute Thickness check" is disabled on the
setup screen. Go to procedure 8.

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SAMPLE
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]
Detecting thickness…

Thickness check executes .

If result of thickness check is shorter than allowable thickness error to not confirm, go to procedure 7.
If result of thickness check is longer than it, a prompt as below is displayed.
Refer to Chapter “21.9 THICKNESS UPDATE SETUP” for more information about this.

SAMPLE _ _ _
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]
Update thickness: 2.0 to 1.0?

YES NO

Press F4 YES, the thickness is updated and the touchup process is continued.
Press F5 NO, it is not update and the touchup process is continued. And a prompt as below is displayed.

SAMPLE _ _ _
2/3
1: L P[1] 2000mm/sec ﾅﾒﾗｶ 50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec ﾅﾒﾗｶ 50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% ｲﾁｷﾞﾒ
[END]
Record this position?

YES NO

Press F4 if you allow this position. And then go to procedure 7.

Press F5 if not so. Spot point touchup is canceled.

7. The robot and the servo gun move to the taught position.
Servo gun opens a distance of observed thickness + gun offset @record at this time.

SETUP Servogun
GUN TEACH SETUP / EQ:1 Gun:1 1/28

Common Setup: point + program touchup

Gun offset @record(mm): 5.0
Gun offset @record Speed of offset motion(mm/sec): 50
Position register (PR[#]): 90
Position error offset(mm): 0.0

[TYPE] EQUIP GUN END >

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NOTE
Servo gun opens a distance of nominal thickness + gun offset @record when
"Execute Thickness check" on the setup screen is DISABLE.

NOTE
The taught position of the robot is corrected based on the wear amount on robot tip
side.

When the movement to taught position is completed, following warning SVGN-183 is displayed.

SVGN-183 Program Name/Program Line/Correct value/Thickness

SVGN-183 SAMPLE/ 2 / 0.5 / 2.0

SAMPLE
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]

Position has been recorded to P[3].

POIN T SP OT GunT ch up AutTchu p T OUCH UP >

SVGN-183 provides the result(Program name/ Program Line /Corrected value / Thickness) of the
touchup operation. In this example, the spot taught position in second line in SAMPLE.TP was
corrected 0.5mm, and the result of thickness check was 2.0mm.
The position and the thickness are updated based on above results. However, where the thickness error
is shorter than the allowable thickness error to not update or you answered NO at the prompt to
confirm the thickness in procedure 6, the thickness is not updated. In this case, the position is updated.
Refer to Chapter “21.9 THICKNESS UPDATE SETUP” for more information about this.

NOTE
Corrected value in SVGN-183 is the difference in the robot close direction between
original taught position and new taught position. When this value is positive, the
direction of position error correction is the robot close direction. When this value is
negative, the direction of position error correction is the robot open direction.

21.18.4 Operating Procedure of Spot Point Touchup without Upper

Panel Detection
To use spot point touchup without upper panel detection, follow the procedure below:
1. Move the robot, and touch the gun tip to the upper panel.

Touch the gun tip to the upper panel

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2. Move the cursor to the spot instruction that requires correction. Add the spot instruction when the spot
instruction is not in the TP program. The position at this time need not be accurate.

3. Press SHIFT + F3"GunTchup" to start the lower panel detection.

SAMPLE _ _ _
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]

Is GunTip on panel? (Rbt will close<12.5mm)

YES NO

NOTE
The robot detects the lower panel in the next step. "Rbt will close" in the prompt
message shows the maximum displacement of the robot in the next step. Therefore,
"Rbt will close" is a distance from robot tip to lower panel.
When the shape of panel is abnormal or when there is a protrusion on the lower
panel, the robot cancels lower panel detection on the way, and pauses.

Press F4"YES" when there is no problem concerning the position of the gun tip. The lower panel
detection is started.
Press F5"NO" when there is a problem concerning the position of the gun tip. Spot point touchup is
canceled.

In the following operations, the robot and the servo gun work. Keep pushing SHIFT key.

SAMPLE
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]

Closing both tips…

Gun and robot move to touch the panel

with both tips.

NOTE
During spot point touchup, gun axis and robot move at low speed disregarding
override.

When panel is touched with both tips, the thickness of the panel is simply measured.
As a result of simple measurement, a prompt as below is displayed when the thickness error is longer
than allowable thickness error to not confirm. When the thickness error is shorter than it, the prompt is
not displayed and go to procedure 4.
Refer to Chapter “21.9 THICKNESS UPDATE SETUP” for more information about this.

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SAMPLE
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1] Nominal thickness
2: L P[2] 2000mm/sec CNT50
SPOT[S D=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]

Check thick ness on this robot tip pos?

YES NO Sha pe of panel is abnormal or
there is obstacle on the lower panel

Confirm the robot tip position.

Press F4"YES" when you want to continue spot point touchup. Go to step 4.
Press F5"NO" when you do not want to continue spot point touchup. Spot point touchup is canceled.

NOTE
As a result of simple measurement, a prompt as below is displayed when the
thickness error is longer than allowable thickness error to not confirm. This prompt is
to confirm result of search.
Refer to Chapter “21.9 THICKNESS UPDATE SETUP” for more information about
this.

NOTE
Robot tip moves to lower panel based on nominal thickness when "Execute
Thickness check" on the setup screen is DISABLE. When nominal thickness is
thicker than actual thickness, a gap will be present between robot tip and lower
panel.

4. Thickness check begins.

NOTE
This step is not executed when "Execute Thickness check" on the setup screen is
DISABLE. Go to procedure 5.

SAMPLE
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]
Detecting thickness…

Thickness check executes .

If result of thickness check is shorter than allowable thickness error to not confirm, go to procedure 5.
If result of thickness check is longer than it, a prompt as below is displayed.
Refer to Chapter “21.9 THICKNESS UPDATE SETUP” for more information about this.

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SAMPLE _ _ _
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]
Update thickness: 2.0 to 1.0?

YES NO

Press F4 YES, the thickness is updated and the touchup process is continued.
Press F5 NO, it is not update and the touchup process is continued. And a prompt as below is displayed.

SAMPLE _ _ _
2/3
1: L P[1] 2000mm/sec ﾅﾒﾗｶ 50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec ﾅﾒﾗｶ 50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% ｲﾁｷﾞﾒ
[END]
Record this position?

YES NO

Press F4 if you allow this position. And then go to procedure 5.

Press F5 if not so. Spot point touchup is canceled.

5. The robot and the servo gun move to the taught position.
Servo gun opens a distance of observed thickness + gun offset @record at this time.

SETUP Servogun
GUN TEACH SETUP / EQ:1 Gun:1 1/28

Common Setup: point + program touchup

Gun offset @record(mm): 5.0
Gun offset @record Speed of offset motion(mm/sec): 50
Position register (PR[#]): 90
Position error offset(mm): 0.0

[TYPE] EQUIP GUN END >

NOTE
Servo gun opens a distance of nominal thickness + gun offset @record when
"Execute Thickness check" on the setup screen is DISABLE.

NOTE
The taught position of the robot is corrected based on the wear amount on robot tip
side.

When the movement to taught position is completed, following warning SVGN-183 is displayed.

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SVGN-183 Program Name/Program Line/Correct value/Thickness

SVGN-183 SAMPLE/ 2 / 0.5 / 2.0

SAMPLE
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1, ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1 ,t =2.0, S=1,ED=1]
3: J P[3] 100% FINE
[END]

Position has been recorded to P[3].

POINT SPOT GunTchup AutTchup TOUCHUP >

SVGN-183 provides the result(Program name/ Program Line /Corrected value / Thickness) of the
touchup operation. In this example, the spot taught position in second line in SAMPLE.TP was
corrected 0.5mm, and the result of thickness check was 2.0mm.
The position and the thickness are updated based on above results. However, where the thickness error
is shorter than the allowable thickness error to not update or you answered NO at the prompt to
confirm the thickness in procedure 4, the thickness is not updated. In this case, the position is updated.
Refer to Chapter “21.9 THICKNESS UPDATE SETUP” for more information about this.

NOTE
Corrected value in SVGN-183 is the difference in the robot close direction between
original taught position and new taught position. When this value is positive, the
direction of position error correction is the robot close direction. When this value is
negative, the direction of position error correction is the robot open direction.

21.18.5 Spot Point Touchup Cancellation

Spot point touchup is canceled at the following times:
• When a hold or an emergency stop are pressed
• When the alarm is generated
• When a shift key is released
• When program edit screen changes to another screen
The following prompt is displayed after touchup cancellation, except when edit screen changes to another
screen or controller is turned off.

SAMPLE _ _ _
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]
Return to start position?

YES NO

If F4"YES" is pressed, robot and gun return to their position prior to spot point touchup.
If F5"NO" is pressed, robot and gun stay at current position (position at touchup cancellation).

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NOTE
After cancellation, and restart, Point touchup starts from the first operation.

WARNING
Robot and gun move during point touchup, so robot and gun may not be at taught
point, if point touchup is cancelled. Therefore execute program with backward then
forward, for safe resume.

21.18.6 Pressure Motion after Spot Point Touchup (single step)

Whether pressure motion is done after spot point touchup is completed at single step can be chosen.

SAMPLE _ _ _
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]
Close gun to resume this SPOT?

YES NO

If F4"YES" is pressed, pressure motion executes at next restart after spot point touchup completes.

Restart

Spot point touchup Move to Start Pressurizing Move to End

completion Distance (SD) Distance (ED)

Pressure motion

If F5"NO" is pressed, pressure motion does not execute at next restart after touchup is completes.

Restart

Spot point touchup Move to Start Pressurizing Move to End

completion Distance (SD) Distance (ED)

Pressure motion is skipped.

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NOTE
Even if F5"NO" is pressed, pressure motion is executed at the following times:
• When the cursor is moved to another line, and when another spot instruction is
executed.
• When BWD is executed, and when this spot instruction is re-executed.
• When the program is aborted
• When power is cycled.

21.19 GUN MECHANICAL COMPENSATION CALIBRATION

Overview
In program touchup and spot point touchup, there may be uniformity detection error depended on gun
mechanism like the following. The detection error affects evenly accuracy of touchup.
• Strength of gun arm
• Friction of gun driven mechanism.
• Error between command open distance and actual open distance in X gun.
Gun mechanical compensation compensate uniformity detection error depended on the above characteristic.
Before using compensation, it is necessary to calibrate compensation distance.

Calibration of compensation distance is performed with calibration plate and calibration utility program.
When calibration program is executed, gun touchup motion is performed with calibration plate.

WARNING
Accuracy of compensation distance calibration may be adversely affected by the
following items.
• X guns with long jaw
• C guns with offset
• Guns with large frictional resistance parting actuator
• Loosely fixtured panels
• Soft panels
• Pneumatic equalizers
• Springs or gun float mechanisms

NOTE
This function is provided together program touchup function. If program touchup
function is not installed, this function can not be available.

Preparation
A calibration plate is required for mechanical compensation calibration. Calibration plate should meet the
following specifications.

Material: Steel
Thickness: About 3~5mm.
Calibration plate is fixed to firm pedestal. Perform calibration near the fixed end, no more than 30mm from
fixed end.
Panel strength is ok if 200N force, displaces plate < 2mm.

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30mm

3～5mm

NOTE
The most important specification is calibration plate strength. If plate is not rigidly
fixtured and/or plate is not rigid, compensation distance may be inaccurate.

NOTE
In X gun case, there is error between command open distance and actual open
distance. Typically, the error is increases when open distance is larger. In this
case, plate should be chosen to meet two criteria: .1 sufficient strength, 2:
minimum thickness.

NOTE
For best accuracy, thickness of calibration panel should match programmed
thickness as closely as possible.
I.E. Thickness + Start distance(SD) of robot tip (at actual welding) = Thickness +
Robot tip distance (at calibration)

If calibration plate is thicker than typical weld panel, shorten robot tip open
distance via parameters in KAREL utility program( SGKTCHCL.PC).
Recommended robot tip distance at calibration is 1mm or larger.

NOTE
Fixture used during tip wear measurement can be used for calibration, if it meets
the specification above,

Execution method
1. Setup servo gun to use spot program touchup and point touchup function. Perform gun zero mastering,
gun auto tune, pressure calibration and thickness calibration.
2. Create TP program like the following. Teach motion instruction and call KAREL utility
program( SGKTCHCL.PC).

TCHCAL _ _ _
1/2
1: L P[1:Calb plate Pos] 250mm/sec FINE
2: CALL SGKTCHCL(1, 5.0, 10, 10, 3)
[END]

POINT SPOT GunTchup AutTchup TOUCHUP >

Sample user-created program to perform mechanical calibration

3. Accurately teach position (P[1] in the above) to touch robot tip at lower surface of calibration plate
before calling KAREL utility program. Also teach this point at a location that deflects less than 2mm
when 200N force is applied.
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Taught potion to perform calibration

4. Specify argument, gun number, thickness, gun and robot tip distance, and calibration time, in order.
CALL SGKTCHCL(Gun number, Thickness, Gun tip opening, Robot tip opening, Calibration time)

NOTE
Specify thickness as accurately as possible.

WARNING
During calibration, gun tip and robot tip open to distance specified value that is
passed into SGKTCHCL.PC. Distance should be set to avoid interference with
object around calibration plate.

NOTE
Calibration process can be configured for a single iteration or multiple iterations. If
2 or more iterations are specified calibration is performed that number of times,
and compensation distance is the average of these iterations.

5. Enable Program touchup mode via TEST screen or cell interface I/O. And confirm the
following system status.
- Reset all alarm, and turn off HOLD.
- Disable single step and machine lock.
- Enable gun stroke.
6. Execute calibration TP program, then calibration is performed with specified time.

NOTE
If calibration motion is paused with HOLD or any alarm, the calibration is not
resumed.
When calibration time more than 2 is specified, the next calibration starts after
program resumed.

7. When calibration finishes successfully, the following warning message is posted.(for example).
SVGN-265 Mech Comp Calib. succeeded.
SVGN-266 Comp Dist: -0.2 mm (3/3)
SVGN-265 indicates calibration finishes successfully.
SVGN-266 is posted together SVGN-265 as cause code. SVGN-266 shows compensation distance
determined during calibration. The value in () shows success time/specified time of calibration. In the
above example, SVGN-266 shows that specified 3 times calibration is successful at all , the calibration
result decided –0.2mm(average of 3 times ) of compensation distance.

Calibration status can be confirmed in gun teach setup screen.

When calibration is complete, gun mechanical compensation can be enabled.

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SETUP Servogun
GUN TEACH SETUP / EQ:1 Gun:1 10/28
Gun mechanical compensation:
Compensation Enb/Dsb: DISABLE
Compensation Dist Calib: COMPETE
Compensation Dist (mm): -0.2

[TYPE] EQUIP GUN ENABLE DISABLE >

Alarm for gun mechanical compensation calibration.

The following alarms can occur for gun mechanical compensation calibration. Refer to cause/remedy info
for troubleshooting.

SVGN-267 Mech Comp Calib. failed

[Cause]
Mechanical calibration for point/program touchup function failed.
Compensation distance could not be found.
[Remedy]
Refer to SVGN-268 for cause.

SVGN-268 << Message is displayed >>

[Cause]
This message identifies cause of gun mechanical compensation (calibration) failure. It is posted, along with
SVGN-267. Cases are:
1. input data is invalid - parameter specified in SGKTCHCL() is invalid.
2. Calibration cannot start due to system error or illegal condition.
3. Calibration started but did not run to completion

[Remedy]
Remedy for per massage.
Invalid gun number: Correct gun number is specified.
Invalid thickness: Correct thickness is specified.
Invalid Gun Open Distance: Correct gun open distance is specified.
Invalid Robot Open Distance: Correct robot open distance is specified.
Invalid Num of Calib: Correct calibration time is specified.
ALL Calib. NOT SUCCESS: Confirm alarm list screen. Identify alarm during calibration.
Check system status: Set system status to perform calibration with the following.
- Reset all alarm, and/or turn off HOLD.
- Disable single step and/or machine lock.
- Enable gun stroke (mode)
- Enable program touchup mode.

SVGN-269 Spot program touchup disabled

[Cause]
Program touchup mode is disabled during calibration
[Remedy]
Enable program touchup mode.

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21.20 THICKNESS CHECK CALIBRATION

Overview
It is necessary to execute thickness check calibration to improve the accuracy of thickness check in spot
program touchup and spot point touchup. Execute thickness check calibration immediately after the tip
wear detection.
Thickness check calibration can be executed from TP program and utility screen. This chapter describes
how to execute thickness check calibration from TP program.

Execution method
1. Make a suitable TP program.
2. Call SGKTHKCL.PC in the TP program. Specify gun number to the argument.

THKCAL _ _ _
1/1
1: CALL SGKTHKCL(1) ;
[END]

POINT SPOT GunTchup AutTchup TOUCHUP >

NOTE
Confirm the following items before executing thickness check calibration.
• Make sure the master position for the gun axis is correct.
• Make sure the tip wear detection is completed.
• Make sure the single step is invalid.
• Make sure the gun operation (mode) is stroke.
• Make sure the machine lock is off.
• Make sure the override is 100%.

3. Execute the TP program. Gun will open and close several times to perform the calibration.
4. When thickness check calibration is completed, following warning SVGN-191 is displayed.
SVGN-191 Thickness Check Calib Updated.

NOTE
If thickness check calibration fails, the following alarms are displayed.
SVGN-192 Thickness Check Calib Not Updated.
At this time, the data of thickness check calibration is automatically restored to the
original status.

NOTE
If thickness check calibration fails, the following causes are expected.
• Cause: Master position for the gun axis is not correct.
Remedy: Retry the tip wear detection.
• Cause: Tip wear amount exceeds maximum tip wear amount.
Remedy: Replace new tip, and retry the tip wear detection.
• Cause: Gun does not close completely during thickness check calibration.
Remedy: Confirm master position for the gun axis. If master position for the gun
axis is correct, tip contacting position is mis-detected because friction in gun
mechanism increases. Do the action similar to the appendix “G.1.1 Gun does not
close completely with pressure motion”.

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NOTE
About resuming specification after thickness check calibration fails, it is depended
on software version.
Before,7DA7/09, 7DA7/14
After thickness check calibration fails, thickness check calibration cannot be
restarted. It is necessary to call SGKTHKCL again to restart thickness check
calibration.
Since,7DA7/10, 7DA7/15, 7DA3/33A1
After thickness check calibration fails, thickness check calibration can be retried by
resuming program together the following warning massage.
SVGN-306 Thickness Check Calib retrying...
Program does not go to the next step until thickness calibration succeeds.

NOTE
The following sample program performs thickness check calibration after tipwear
update. However, thickness cal is not critical for normal production, so program
below performs thickness calibration only if touchup is active.

TW_UPD01
18: !Param2: New tips: 1, used tips:0
19: !CALL TWUPDAT(1, 0)
sample user program
20: CALL TW_UPDAT(1,R[30:Tip Change])to update tipwear and
21: IF DO[5:PrgTchStatEQ1] = ON,
CALL SGKTHKCL(1) thickness check
[END]
calibration
POINT SPOT GunTchup AutTchup TOUCHUP >

21.21 SIMPLE SEARCH MODE FOR UPPER DETECTION

Overview
Simple search mode can be provided a short cycle time of touchup by simplified search motion.

NOTE
This function might not keep accuracy by deterioration with using and/or condition
change(stiffness of panel, jig, etc.) because panel deflection is corrected by
constant.

NOTE
Simple search mode for Upper detection is supported since 7DC2 software.

Preparation
Enable Simple search mode, using the procedure below:
1. Press the MENU key to display the Screen menu.
2. Press 6 SETUP.
3. Press F1 TYPE and select Servo Gun. The Servo Gun Setup screen appears.
4. Move the cursor on <*DETAIL*> of General Setup and press ENTER key. The General Setup screen
appears.
5. Move the cursor on <*DATAIL*> of Gun Teach Setup and press ENTER key. The Spot Program
Touchup Setup screen appears.
6. Move the cursor on Upper det simple search mode and press F4 [ENABLE].
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SETUP Servogun
GUN TEACH SETUP / EQ:1 GUN:1 5/30

Common Setup: point + program touchup

Gun offset @record(mm): 5.0
Speed of offset motion(mm/sec): 50
Position register(PR[#]): 90
Position error offset(mm): 0.0
Upper det simple search mode:ENABLE

[TYPE] EQUIP GUN ENABLE DISABLE >

In Simple search mode, Fanuc recommends using “Non-Adaptive2”. Set the detect mode as below.
7. In Gun teach setup screen, press NEXT and F7 DET CFG. The Torque control setup screen appears..
8. Press F4 CHOICE and select “Non-Adaptive2”.

21.21.1 UPDET_OFS INSTRUCTION

In Simple search mode, the panel deflection is not detected by search algorithm. Therefore, the panel is
bended at the detected point. Adding UPDET_OFS instruction, you can correct the panel deflection at
touchup of Simple search mode.

Motion Modify 2 SAMPLE

1 TIPDRESS 1/2
2 Press_m 1:L P[1] 2000mm/sec CNT50
3 SpotProgTouchDsb : SPOT[SD=1,P=1,T=1.0,S=1,ED=1]
: UPDET_OFS=3.0mm
4 SPTCH_OFS
[END]
5 SPTCH_RSD
6 UPDET_OFS
7 Wrist Joint Enter value
8 --next page-- DIRECT INDIRECT [CHOICE] >

There are 3 ways to set UPDETOFS instruction the offset. 1st way is measure and set offset directly. And
other ones are follows.

21.21.1.1 SET OFFSET WITH SPOT POINT TOUCHUP

In this function, a panel deflection is measured by using Spot point touchup function with upper panel
detection. This function uses the original search motion even if Simple search mode is enabled. A procedure
for this function is the same as Spot point touchup.
Set cursor on a line of SPOT what is added or revised UPDET_OFS instruction. Press SHIFT key &
F7"MEAS OFS" to start touchup and add offset. In the following operations, the robot and the servo gun
work. Keep pushing SHIFT key.

SAMPLE
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]
Start the original touchup motion and the gun
[INST] MEAS OFS MEAS [EDCMD] >
tip stop on the panel.

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SAMPLE
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]
Confirm the tip is on the panel.
Is GunTip on panel? (Rbt will close<15.0) If press F4 “YES”, offset is set and the touchup
YES NO motion is continued.
If press F5 “NO”, offset is set 0.0mm and the
touchup motion is aborted. Set offset by retrying
measure offset or directly.

SAMPLE _
2/3
1: L P[1] 2000mm/sec CNT50
ｽﾎﾟｯﾄ[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
UPDET_OFS=3.0mm
3: J P[3] 100% FINE
[END]

[INST] MEAS OFS MEAS THK [EDCMD] >

21.21.1.2 SET OFFSET WITH PROGRAM TOUCHUP

In this function, a panel deflection is measured by using Spot program touchup function. This function uses
the original search motion even if Simple search mode is enabled. A procedure for this function is the same
as Spot program touchup.
Enable Measure offset mode, using a procedure below.
1. Press the MENU key to display the Screen menu.
2. Press 6 SETUP.
3. Press F1 TYPE and select Servo Gun. The Servo Gun Setup screen appears.
4. Move the cursor on <*DETAIL*> of General Setup and press ENTER key. The General Setup screen
appears.
5. Move the cursor on <*DATAIL*> of Gun Teach Setup and press ENTER key. The Spot Program
Touchup Setup screen appears.
6. Move the cursor on Execution mode for TEACH and press F4 [CHOICE]. Select MEAS OFS.

1 SETUP Servogun
1 TOUCHUP GUN TEACH SETUP` / EQ:1 GUN:1 16/30
2 VERIFY
3 MEAS OFS Point touchup setup
4 PASS CHECK Execute Thickness Check: ENABLE

Program touchup setup

Execution mode for AUTO: TOUCHUP
Execution mode for TEACH: MEAS OFS
Verify mode active DO[#]: 0
Max allowable position err(mm):2.0

[TYPE] EQIP GUN [CHOICE] >

NOTE
This function can be used at TP enable.
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Enable Spot program touchup function.
7. Select 2 TEST CYCLE from the Screen menu.
8. Press F1 TYPE and select Spot Prog Touch. Spot Program Touchup Mode Setup screen appears.
9. Press F4 ENABLED. Measure offset mode is enabled.

SPOT WELD _
1/1
Spot Program Touchup Mode Setup

1 Program Touchup mod for EQ1:ENABLED

Det offset for simple search active / EQ:1

[TYPE] ENABLE DISABLE >

The offset is measured and added or updated by executing the program. When the SPOT instruction not
added UPDET_OFS instruction is taught, a following message is displayed for confirming. This message is
not displayed at the SPOT instruction added UPDET_OFS. This message is displayed after the touchup is
done.

SPOT
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=1.0,S=1,ED=1]
3: J P[3] 100% FINE
[END]

UPDET_OFS=3.0mm:Update upper det offset?

YES NO

If press F4 YES, measured offset is set to UPDET_OFS.

If press F5 NO, UPDET_OFS=0.0mm is set. Set offset by retrying measure offset or directly.

SPOT
2/3
1: L P[1] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=2.0,S=1,ED=1]
2: L P[2] 2000mm/sec CNT50
SPOT[SD=1,P=1,t=1.0,S=1,ED=1]
UPDET_OFS=3.0mm
3: J P[3] 100% FINE
[END]

SHIFT+FWD:Resume program.
POINT SPOT GunTchup AutTchup TOUCHUP >

Resume program and continue to measure offset.

21.22 PASS CHECK MODE

Overview
Robot and servo gun are moved by a trajectory differ from welding one at search motion for Spot program
touchup function. Therefore, a servo gun has the potential to bump into peripheral equipments during
search motion. And a tip has the potential to bump into panel before search motion.
In this function, robot and servo gun move about a working range of search motion. You can confirm
settings for Spot program touchup function before execute touchup.

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NOTE
Servo gun is at risk of contact to peripheral equipments and panels. Keep up a
stance to check the moving gun and hold the robot if you execute this function.

NOTE
Pass check mode is supported since 7DC2 software.

Preparation
Enable Pass check mode, using the procedure below:
1. Press the MENU key to display the Screen menu.
2. Press 6 SETUP.
3. Press F1 TYPE and select Servo Gun. The Servo Gun Setup screen appears.
4. Move the cursor on <*DETAIL*> of General Setup and press ENTER key. The General Setup screen
appears.
5. Move the cursor on <*DATAIL*> of Gun Teach Setup and press ENTER key. The Spot Program
Touchup Setup screen appears.
6. Move the cursor on Execution mode for TEACH and press F4 [CHOICE]. Select PASS CHECK.

1 SETUP Servogun
1 TOUCHUP GUN TEACH SETUP` / EQ:1 GUN:1 16/30
2 VERIFY
3 MEAS OFS Point touchup setup
4 PASS CHECK Execute Thickness Check: ENABLE

Program touchup setup

Execution mode for AUTO: TOUCHUP
Execution mode for TEACH: PASS CHECK
Verify mode active DO[#]: 0
Max allowable position err(mm):2.0

[TYPE] EQIP GUN [CHOICE] >

NOTE
This function can be used at TP enable.

Enable Spot program touchup function.

7. Select 2 TEST CYCLE from the Screen menu.
8. Press F1 TYPE and select Spot Prog Touch. Spot Program Touchup Mode Setup screen appears.
9. Press F4 ENABLED. Pass check mode is enabled.

SPOT WELD _
1/1
Spot Program Touchup Mode Setup

1 Program Touchup mod for EQ1:ENABLED

Pass active mode active / EQ:1

[TYPE] ENABLE DISABLE >

Pass Check Motion

In Pass check mode, robot and servo gun are moved some feature points that are a range of search motion
and a point start search motion. Here are the feature points.

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Sequence of Pass Check Motion for Spot Program Touchup Function

Move to SD. Move to backup Move to start of

position. search motion.
(Move gun axis.) (Open gun axis.)

Move to end of
search motion. Move to ED.
(Move robot.)

Points to be Checked and Remedy for Pass Check Motion

If robot and servo gun touch to peripheral equipments and /or panels at following points to be checked, Spot
program touchup function cannot be done. Set some parameters to execute correct motion.

Points to be Checked Remedy

Gun stroke limit is occurs Start of search motion is moved toward panel. However it doesn’t need remedy if
before move to backup gun tip doesn’t collide panel surface at start of search motion.
position for upper panel If not so, set Max allowable position error and/or over thickness tolerance low
detection. margin. Gun tip move toward panel. Or add SPTCH_RSD instruction. Robot tip
move toward panel.
If this problem occurs all welding points, use Lower panel detection distance clamp.
Movable gun arm collides jig Set Max allowable position error and/or over thickness tolerance low margin. Gun
or others at backup position tip move toward panel.
for upper panel detection.
Robot tip collides panel This problem might occur when Lower panel detection distance clamp is enabled or
surface at backup position SPTCH_RSD instruction is added.
for upper panel detection. Set Max allowable position error large margin. Robot tip move away form panel.
Gun tip collides panel Set Max allowable position error and/or over thickness tolerance large margin. Gun
surface at start of search tip move away from panel.
motion.
Fixed gun arm collides jig or Set Max allowable position error low margin. Or add SPTCH_RSD instruction.
others at end of search Robot tip move toward panel.
motion. If this problem occurs all welding points, use Lower panel detection distance clamp.

After settings, execute Pass check motion again. And then check the troubled points are corrected and new
troubles are not occurred at other points.

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NOTE
Don’t set Max allowable position error lower margin than assumed position error.
And don’t set Over thickness tolerance lower margin than assumed thickness
error.

21.23 TROUBLESHOOTING
This chapter provides troubleshooting information for cases where spot program/point touchup does not
operate as expected. These cases are organized by search motion and symptom. Point/Program touchup
alarm information can be found in chapter 21.24.

To resolve the problem:

• If you can identify symptom and search motion case in the list below, apply that remedy.
• If you cannot identify symptom or if symptom does not fall into one of the cases listed below,
- Execute servo gun pre-conditioning operation (repeated pressurization) for about 30 seconds
- If problem persists, refer to items 2, 9 and determine which search motion is failing
• If problem persists after troubleshooting actions above are applied:
- Acquire diagnostic data. See diagnostic data collection procedure at end of this chapter.
- Contact a FANUC technical representative.

Upper Panel Detection Step 1

1. Gun crushed panel.
[Cause]
Initial error was larger than “Max allowable position error”. Therefore, gun crushed panel during move
from start distance(SD) to upper panel detection start position.
[Remedy]
Set “Max allowable position error” in gun teach setup screen to a value larger than maximum error expected.
Upper panel detection starts sooner (at a larger open distance), when “Max allowable position error” is
increased. Refer to Chapter “21.4 SPOT PROGRAM TOCHUP SETUP SCREEN” for more information
about upper panel detection start position. However, increasing open distance also increases search (and
touchup) time. “Max allowable position error” should be set based on all of these considerations.

2. Panel is mis-detected.
[Cause]
Upper panel detection occurs when speed reduction is observed. Normally, speed reduction occurs only
when gun tip touches panel. However, some guns may have a friction characteristic that reduces gun speed
before panel.
[Remedy]
Change parameters for upper panel detection step1. Refer to Chapter “21.8 SEARCH PARAMETERS
SETUP” for more information.
3. Panel bends too much during search motion.
[Cause]
The panel is too soft and/or fixture is not rigid enough. A deflection of 3mm or more during search motion,
is an indication that panel is too soft.
[Remedy]
If the panel is too soft, spot program touchup cannot be applied at this location on panel, touchup must be
performed manually. Disable program touchup at this weld point. Refer to Chapter “21.13 SPOT
PROGRAM TOUCHUP DISABLE INSTRUCTION” for more information.

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Upper Panel Detection Step 2

4. The position detected by upper panel detection is not correct: Part 1
The position detected when ANY point is touched up repeatedly varies widely. Position error is in
both directions (positive and negative).
-Confirm gun tip position when lower panel detection starts.
[Cause]
Non-observable gun attribute(s) caused contact detection event (in software) to differ from actual physical
contact, which leads to error in position detection. This symptom can be caused by large-scale X guns or
gun with large resistance to motion in actuator.
[Remedy]
Change parameters for upper panel detection step2, to reduce variance. Refer to Chapter “21.8 SEARCH
PARAMETERS SETUP” for more information.

5. The position detected by upper panel detection is not correct: Part 2

The position detected when ANY point IS touched up repeatedly is consistent, but shifted in one
direction from the panel. This offset (error) always has the same direction and distance.
-Confirm gun tip position, when lower panel detection starts.
[Cause]
Non-observable gun attribute(s) caused contact detection event (in software) to differ from actual physical
contact. Flexible gun arms, robot compliance, etc, can cause this symptom.
[Remedy]
Detection accuracy can be improved by gun mechanical compensation. Refer to Chapter “21.19 GUN
MECHANICAL COMPENSATION CALIBRATION” for more information.

6. The position detected by upper panel detection is not correct: Part 3

The position detected when a SPECIFIC point is touched up repeatedly is consistent, but shifted in
one direction from the panel. This offset (error) always has the same direction and distance.
-Confirm gun tip position when lower panel detection starts.
[Cause]
Non-observable gun attribute(s) caused difference between contact detection event (in software) and actual
physical contact. Insufficient panel clamping and/or compliance of gun at faceplate can cause this
symptom.
[Remedy]
Apply a corrective offset at this particular point, via SPTCH_OFS instruction. Refer to Chapter “21.14
SPTCH_OFS INSTRUCTION” for more information about SPTCH_OFS instruction.

7. Upper panel detection fails.

[Cause]
The following alarms might have been generated.
• SVGN-240 Up Panel Mis-detect:(Eq:%d,Ln:%d)
• SVGN-248 Panel not detected.
• SVGN-252 Panel detection was failed.
• SVGN-260 Search motion is unsuccess.
[Remedy]
Consider and take the following actions:
• Refer to SVGN-240 in this chapter if SVGN-240 has been generated.
• Refer to SVGN-248 in this chapter if SVGN-248 has been generated. If upper panel detecting motion
stopped before gun tip contacted panel surface.
• Refer to SVGN-252 in this chapter if SVGN-252 has been generated.
• Refer to SVGN-260 in this chapter if SVGN-260 has been generated.

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8. Peripheral equipment interferes with robot/gun during spot program

touchup motion.
[Cause]
Robot moves a short distance during upper panel detection step 2. Interference with peripheral equipments
can occur if clearance between gun/robot arm and external equipment is less than 10mm.
[Remedy]
Reduce distance that robot moves via SPTCH_RSD instruction. Determine amount of clearance actually
available, and specify this value in SPTCH_RSD instruction. Refer to Chapter “21.15 SPTCH_RSD
INSTRUCTION” for more information about SPTCH_RSD instruction.
If this problem persists, disable touchup at this point, and touchup manually. Refer to Chapter “21.13 SPOT
PROGRAM TOUCHUP DISABLE INSTRUCTION” for more information.

Lower Panel Detection

9. Lower panel detection stops before robot tip contact lower panel surface
[Cause]
Lower panel detection occurs when speed reduction is observed. Normally, speed reduction occurs only
when gun tip touches panel. However, some guns may have a friction characteristic that reduces gun speed
before panel.
[Remedy]
Change parameters for upper panel detection step1. Refer to Chapter “21.8 SEARCH PARAMETERS
SETUP” for more information.

10. Lower panel detection crushes a gap between panels.

[Cause]
Point was taught at incorrect location on panel (a flange or a protrusion with a gap).
Touchup function does detect this condition, when gap strength is low.
[Remedy]
Reteach point or disable program touchup at this weld point. Refer to Chapter “21.13 SPOT PROGRAM
TOUCHUP DISABLE INSTRUCTION” for more information.

After searching
11. Touchup position is not correct.
[Cause]
When a panel is too soft, spot program touchup accuracy can be poor. An indication that panel is too soft is
deformation of 3mm or more during search motion.
[Remedy]
Spot program touchup cannot be applied at this point. Disable this function at this point, and touchup
manually. Refer to Chapter “21.13 SPOT PROGRAM TOUCHUP DISABLE INSTRUCTION” for more
information. Note: if the deformation amount is small and the strength of panel is sufficient, refer to
Troubleshooting items 4-6.

Diagnostic data acquisition procedure

Acquire diagnostic data per the following procedures.
1. Install memory device.
2. Select memory device.
• $SGSYSTCH.$OUT_DEVICE = 0: Memory card
• $SGSYSTCH.$OUT_DEVICE = 1: USB memory device
3. Change the system variable as follows. Diagnostic data acquisition becomes effective.
• $SGSYSTCH.$LOG_FLAG=TRUE
• $SGSYSTCH.$RSCHLOG_ENB=TRUE
• $SYSDEBUG=50
4. Power OFF/ON.
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5. Execute spot program touchup and reproduce the problem.
6. Diagnostic data is preserved in memory device. The preserved diagnostic data is the following.
• tchalog_acdet_chart.dt
• tchalog_acdet_data.dt
• tchalog_acdet_lines.dt
• tchalog_acdet_result.dt
• tchalog_acdet_detect.dt
• tchalog_acdet_ofst.dt
• tchalog_acdet_posns.dt
• rsrch_upperdet.dt
• rsrch_accudet.dt
• rsrch_lowerdet.dt
7. Pass the diagnostic data to FANUC technical representative.
8. Change the system variable as follows. Diagnostic data acquisition becomes invalid.
• $SGSYSTCH.$LOG_FLAG=FALSE
• $SGSYSTCH.$RSCHLOG_ENB=FALSE
• $SYSDEBUG=0
9. Power OFF/ON.

21.24 ALARMS
This chapter describes the alarm of program/point touchup function.

SVGN-175 Position not recorded

[Cause]
GunTouchup(F3) or AutoTouchup(F4) was requested but touchup did not occur. This alarm (SVGN-175)
only indicates that touchup failure has occurred, SVGN-176 identifies cause of SVGN-175. Note:
SVGN-175 is not posted during program touchup.
[Remedy]
See SVGN-176. NOTE: SVGN-175 is an optional alarm (enabled by default). Set
$SGSYSTCH.$PTNOTRECALM = FALSE to disable SVGN-175.

SVGN-176 %s
[Cause]
Refer to message in string.
[Remedy]
Refer to remedy for message in string.

SVGN-183 %s,%s,%s,%s
[Cause]
Gun touchup function has modified position of spot point. This message is provided for informational
purposes only, it is not a fault/problem. Note: SVGN-183 is not posted during program touchup.
[Remedy]
The 4 parameters in SVGN-183 p1/p2/p3/ p4 provide details about the modified point.
p1: Program name of the modified point.
p2: Program line number of the modified point
p3: Corrected value is the difference between new recorded position and old recorded position. Note: robot
close direction is positive polarity, so if new position is shifted in robot open direction (relative to old
position) corrected value will be negative.
p4: Thickness value is actual thickness measured during thickness check. Note: If thickness check is
disabled, nominal thickness (value in pressure schedule) is reported.

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SVGN-184 Point touchup cancelled.

[Cause]
Spot point touchup was cancelled, because shift key was released and program edit screen was de-selected
(new screen was selected).
[Remedy]
Execute point touchup again, and don't exit editor screen.

SVGN-190 Backup open before search is clamped.

[Cause]
Open (search start) distance for upper panel detection exceeded gun stroke limit, so open distance was
clamped to gun open limit.
Note: Gun open distance for upper panel search depends on touchup type:
if point touchup: open distance = initial pos + search prep dist
if prog touchup: open distance = thk.nom + thk.err.max + pos.err.max + search prep dist
SVGN-190 does not cause any problem if panel contact occurs AFTER search start.
However, if panel occurs BEFORE search start, excessive push and/or touchup failure may result.
[Remedy]
If point touchup is being performed, close gun (jog) to reduce open distance. If program touchup is being
performed, reduce one or more of the following parameters: upper panel detect distance, max thickness
error, max pos error.

SVGN-191 Thickness Check Calib Updated.

[Cause]
Thickness Check Calibration parameter is updated correctly. This is just information.
[Remedy]
No Need.

SVGN-192 Thickness Check Calib Not Updated.

[Cause]
Thickness Check Calibration parameter is not updated.
Thickness Check Calibration could not finished correctly
Note: If thickness Check Calibration had been done prior to present attempt,
the last parameter is restored.
[Remedy]
Please see cause code or other relative alarm on alarm screen
Remove cause that makes pausing stopping sequence, and
retry Thickness Check Calib sequence to updated parameter.

SVGN-236 [PauseMod]Det/Thk/Pos Err :Eq%d

[Cause]
Program execution paused because position and/or thickness is out of tolerance. This pause occurs when
DET/THK/POS error pause severity is set to warn or alarm, and one more of the following conditions exist:
. SVGN-237 Position error:(Eq:%d,Ln:%d)
. SVGN-239 Thickness error:(Eq:%d,Ln:%d)
. SVGN-240 Up Panel Mis-Detect:(Eq:%d,Ln:%d)
. SVGN-252 Panel detection was failed:(Eq:%d,Ln:%d)
. SVGN-254 Low Panel Mis-detect:(Eq:%d,Ln:%d)
. SVGN-260 Search motion is unsuccess.
[Remedy]
Set Det/Thk/Pos error pause Sev in the gun teach setup screen to DISABLE if you do not want robot to
pause when the alarms above occur.

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SVGN-237 Position error:(Eq:%d,Ln:%d)

[Cause]
Measured position error is greater than maximum allowable position error or less than min allowable
position error.
[Remedy]
Take the following actions.
1. Confirm the tip wear amount is correct. Re-execute the tip wear measurement when the tip wear
amount is not correct.
Note: if you take above action, re-execute the thickness check calibration.
If this problem persists after taking the above actions, confirm that:
1. Max allowable Pos error (on gun teach setup screen) is large enough.
2. Min allowable Pos error (on gun teach setup screen) is small enough.
If not, measured position error is made greater than min allowable position error and less than maximum
allowable position error in the following ways.
1. Touch up correct position using jog or point touchup(not program touchup).
2. Increase maximum allowable position error or decrease min allowable position error on gun teach
setup screen.
Note: if initial position error is too large, program touchup cannot touch up. Fanuc recommends using point
touchup(not program touchup) at the initial touchup.
If this problem still persists after taking the above actions, take the following actions.
1. Confirm the position error offset in the spot program touchup setup screen. This alarm might be
generated immediately after the position error offset is changed.
2. Confirm the parameter to correct position for Xgun in the spot program touchup setup screen. This
alarm might be generated immediately after the parameter to correct position for Xgun is changed.
If this problem persists after taking the all actions, perform the following actions:
1. Acquire the diagnostic data. See the procedure for diagnostic data collection at Troubleshooting
section.
2. Contact a FANUC technical representative.

SVGN-238 [PauseMod]SpotProgTouchDsb:Eq%d
[Cause]
Program execution paused because TCHDSB is attached to spot instruction, and SpotprogTouch_DSB
pause severity = warn or alarm.
[Remedy]
If you do not want robot to pause, either:
a. set SpotProgTouch_Dsb pause Sev in the gun teach setup screen to DISABLE OR
b. remove TCH_DSB from spot instruction

SVGN-239 Thickness error:(Eq:%d,Ln:%d)

[Cause]
Measured thickness is out of tolerance. Note: SVGN-242 Act thick:x.x, Nom thick: y.y is posted as cause
code for SVGN-239.
[Remedy]
Confirm that:
1. actual panel thickness is correct.
2. nominal thickness in the pressure schedule is correct.
3. OverThickness and UnderThickness tolerance values on gun teach setup screen are appropriate

SVGN-240 Up Panel Mis-detect:(Eq:%d,Ln:%d)

[Cause]
Upper panel detection distance is larger (gun more open) than max detect distance. where: max detect
distance = pos.err.max + thk.nom + thk.err.max This alarm occurs only during program touchup (not point
touchup). Note: SVGN-243 ActDetDist:x.x, MaxDetDist: y.y is posted as cause code for SVGN-240.
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[Remedy]
Confirm that:
1. no obstruction exists between guntip and panel.
2. ensure that panel is present on correct position.
3. the master position for the gun axis is correct and the tips touch at the zero.
4. the tip wear amount is correct. Re-execute the tip wear measurement when the tip wear amount is not
correct.
If the above item is OK, confirm that:
1. nominal thickness in pressure schedule is correct.
2. OverThickness tolerance (on gun teach setup screen) is large enough.
If the above items are OK, confirm that:
1. Max allowable Pos error (on gun teach setup screen) is large enough.
If the above item is NG, the position error is made less than maximum allowable position error in the
following ways.
1. Touch up correct position using jog or point touchup(not program touchup).
2. Increase maximum allowable position error on gun teach setup screen.
Note: if initial position error is too large, program touchup cannot touch up. Fanuc recommends using point
touchup(not program touchup) at the initial touchup.

SVGN-241 ActPosErr:%smm > MaxPosErr:%smm

[Cause]
Measured position error exceeds Max allowable pos error. SVGN-241 supplies the actual(measured)
position error and maximum allowable position error for alarm SVGN-237.
[Remedy]
See SVGN-237.

SVGN-242 Act thick:%smm Nom thick:%smm

[Cause]
Thickness error exceeds OverThickness tolerance or UnderThickness tolerance. SVGN-242 supplies the
actua(measured)l thickness and nominal thickness for SVGN-239.
[Remedy]
See SVGN-239.

SVGN-243 ActDetDis:%smm MaxDetDis:%smm

[Cause]
Detect distance (observed) exceeds Max Detect distance. SVGN-243 supplies the actual detection distance
and max detect distance for SVGN-240.
[Remedy]
See SVGN-240.

SVGN-244 Retry Thickness Check calibration

[Cause]
Thickness check (0kgf) calibration is incomplete. Thickness check calibration is required for touchup.
[Remedy]
Execute thickness check calibration on gun setup util.

SVGN-245 Gun not open to undeflect pos

[Cause]
Position register (PR) that stores undeflect (relax) position for gun/robot could not be set. Refer to cause
code for specific reason.
[Remedy]
Correct problem identified in cause code, and retry touchup.

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SVGN-246 Machine lock required for pnlsim

[Cause]
Panel simulation is enabled, but machinelock is disabled on robot group or gun group. Machinelock must be
ENABLED on both robot group and gun group, when panel simulation is enabled.
[Remedy]
Disable panel simulation($SGSYSTCH.$SIM_PNL_ENB=FALSE) or ENABLE machinelock on robot
group and gun group.

SVGN-247 Concurrent multiarm touchup unsupported.

[Cause]
Touchup is already in progress on an arm and touchup is being requested on another arm (at the same time).
Touchup can only be performed on one arm at a time.
[Remedy]
Wait for touchup operation that is already in progress to complete, before starting touchup on another arm.

SVGN-248 Panel not detected.

[Cause]
Upper or lower panel search ended, but panel was not detected. I.E. gun never met search condition, during
search. The following conditions can cause this problem:
1. missing panel
2. large gun friction
3. large pressure margin
[Remedy]
Confirm that:
1. ensure that panel is present.
2. execute servo gun pre-conditioning operation (repeated opening & closing and pressurization) for about
30 seconds.
3. decrease pressure margin.
If problem persists, contact a FANUC Robotics technical representative.

SVGN-249 Panel detection was failed.

[Cause]
Panel was not detected during second part of upper panel search. Internal condition for search termination
was not met. This can occur if panel is soft.
[Remedy]
Retry touchup.

SVGN-250 Spot program touchup enabled !

[Cause]
A tp program started (or resumed) and spot program touchup function is enabled with execution mode =
TOUCHUP. Touchup mode means that points will be evaluated AND positions will be modified.
[Remedy]
If verify (not touchup) mode is desired, change execution mode via Touchup setup screen:
a. if tp is disabled, set Execution mode for AUTO = VERIFY mode,
b. if tp is enabled, set Execution mode for TEACH = VERIFY mode,
If normal spot (not touchup or verify) operation is desired, disable program touchup via:
a. DIN, if tp is disable.
b. Touchup mode setup screen, if tp is enable.

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SVGN-251 ActPosErr:%smm < MinPosErr:%smm

[Cause]
Position error (change between observed position and recorded position) is less than MinPosError. This
message is posted to display magnitude of observed position error and minimum pos error, when
SVGN-237 occurs. Note that min pos error is used in conjunction with max pos error to control when
points are touched up. Points are only touched up if position error is >= min pos error and <= max pos error.
Min pos error tolerance identifies when position change is small and/or insignificant.
[Remedy]
If position error is acceptable, decrease min pos error and execute touchup again. Set min pos error = 0.0, to
disable min pos error check completely.

SVGN-252 Panel detection was failed.

[Cause]
Upper panel detection failed. The integer parameter ()identifies the failure type:
type1: gun tip did not contact panel during search motion (internal condition to terminate search was not
met).
type2: exact position of detection could not be found (no distinct transition in the data)
[Remedy]
Confirm that:
type1: ensure that panel is present. If panel is not present, touch up new point by jog or point touchup.
type2: confirm strength of panel. Rough indication of strength is that deflection during search motion does
not eceed 3mm.

SVGN-254 Low Panel Mis-detect:(Eq:%d,Ln:%d)

[Cause]
Measured thickness was too large at lower panel detection.
[Remedy]
Confirm that:
1. no obstruction exists between panel and either tip.
2. actual panel thickness is correct
3. nominal thickness in pressure schedule is correct.

SVGN-255 Search motion is unsuccess.

[Cause]
Detection data for the second upper panel search is invalid.
[Remedy]
Retry spot program touchup. Confirm that gun tip contacts panel at upper panel detection. If this problem
persists after taking the above actions, perform the following actions:
1. Acquire the diagnostic data. See the procedure for diagnostic data collection at Troubleshooting section.
2. Contact a FANUC technical representative.

SVGN-256 Invalid parameter in SPTCH_XXX

[Cause]
Parameter specified in SPTCH_OFS/SPTCH_RSD is out of range.
Note: SPTCH_OFS is attached to spot instruction to specify offset/adjustment value that is added to final
offset for point modification. SPTCH_RSD is attached to spot instruction to specify offset distance for
robot tip.
[Remedy]
Set a valid parameter for the instruction:
1. SPTCH_OFS: >= -2.0mm && <= 2.0mm
2. SPTCH_RSD: >= 0.0mm && <= 20.0mm

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SVGN-257 Invalid register number.

[Cause]
Register specified for SPTCH_OFS or SPTCH_RSD is invalid.
[Remedy]
Specify a valid register number in SPTCH_OFS or SPTCH_RSD instruction:
min: 1
max: posreg max (position registers item, on program limits setup screen)

SVGN-258 SPOT prog touchup retry:(Num:%d).

[Cause]
Initial touchup attempt failed, but retries are enabled, and touchup will be attempted again.
[Remedy]
n/a - this message is provided for information purposes only.
Note: set maximum retry number = 0 on gun teach setup screen, to disable retries.

SVGN-259 Retry number > Max retry number.

[Cause]
Initial touchup attempt and retries failed.
[Remedy]
Confirm strength of panel. Rough indication of strength is that deflection during search motion does not
exceed 3mm. If panel is harder than this indication, retry spot program touchup.
If this problem persists after taking the above actions, perform the following actions:
1. Acquire the diagnostic data. See the procedure for diagnostic data collection at Chapter “21.23
Troubleshooting” in R-30iB CONTROLLER Servo Gun Function OPERATOR’S MANUAL
(B-83264EN) for Servo Gun Function.
2. Contact a FANUC technical representative.

SVGN-260 Search motion is unsuccess.

[Cause]
Upper panel detection failed. Robot motion stopped before gun tip touched panel. Data for the detection is
invalid.
[Remedy]
Retry search motion.

SVGN-261 Disturbance of gun is abnormal.

[Cause]
Gun torque command is erratic. This gun may have mechanical issues.
[Remedy]
Examine the servo gun. Confirm that there is no actuator damage or binding. If gun is ok, retry touchup
function.

SVGN-262 Disturbance of gun is abnormal.

[Cause]
Gun torque command is erratic. This gun may have mechanical issues.
[Remedy]
Examine the servo gun. Confirm that there is no actuator damage or binding. If gun is ok, retry touchup
function.

SVGN-263 Variation in disturbance is too much.

[Cause]
Gun torque command is erratic. This gun may have mechanical issues.

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[Remedy]
Examine the servo gun. Confirm that there is no actuator damage or binding. If gun is ok, retry touchup
function.

SVGN-264 Variation in disturbance is too much.

[Cause]
Gun torque command is erratic. This gun may have mechanical issues.
[Remedy]
Examine the servo gun. Confirm that there is no actuator damage or binding. If gun is ok, retry touchup
function.

SVGN-265 Mech Comp Calib. succeeded

[Cause]
Mechanical calibration for point/program touchup function completed successfully.
[Remedy]
n/a - this is a status message for informational purposes. Refer to SVGN-266 (posted as cause for
SVGN-265) for details.

SVGN-266 Comp dist:%s mm(%s)

[Cause]
This message shows the compensation value for point/program touchup function. Value in () means Num
of Successful calibration / Specified Num of calibrations.
[Remedy]
n/a - this is a status message for informational purposes.

SVGN-267 Mech Comp Calib. failed

[Cause]
Mechanical calibration for point/program touchup function failed.
Compensation distance could not be found.
[Remedy]
SVGN-268 or other alarm as cause code is posted together. Confirm cause code, then solve it.
Also, confirm other alarm in alarm list screen.

SVGN-268 %s
[Cause]
This message identifies cause of gun mechanical compensation (calibration) failure. It is posted, along with
SVGN-267. Cases are:
1. input data is invalid - parameter specified in SGKTCHCL() is invalid.
2. Calibration cannot start due to system error or illegal condition.
3. Calibration started but did not run to completion
[Remedy]
1. input data is invalid - parameter specified in SGKTCHCL() is invalid. The remedy
depends on the parameter (p1-p5) that is identified:
p1:Invalid gun number. Specify Gun number between 1 and $SGSYSCFG.$GUN_NUM
p2:Invalid thickness: Specify thickness value greater than or equal to 1.0
p3:Invalid Gun Open Distance:
p4:Invalid Robot Open Distance
p5:Invalid Num of Calib: Calibration iterations (number) is invalid. Minimum=1
2. Calibration cannot proceed due to system error or illegal condition.
- An alarm occurred, and/or HOLD is turn on
- Enable single step and/or machine lock
- Disable gun stroke (mode)
- Spot program touchup disabled
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3.ALL Calib. NOT SUCCESS: Calibration failed due to one of the following:
Alarm or HOLD during calibration.
Misdetect error
Thickness out of tolerance
Position out of tolerance

SVGN-269 Spot program touchup disabled

［Cause］
This indicates spot program touchup is disabled.
［Remedy］
Enable spot program touchup via TEST CYCLE or CELL INTERFACE I/O.

SVGN-270 Too large torque limit.(Upper)

[Cause]
Gun tip contacted upper panel surface before search motion started. Torque limit became
unexpectedly-large during upper panel detection step1.
[Remedy]
Confirm that distance of gun panel contact is not larger than search start distance. Retry spot program
touchup. If gun tip contacts upper panel surface before search start distance, confirm that:
1. no obstruction exists between guntip and panel.
If the above item is OK, confirm that:
1. nominal thickness in pressure schedule is correct.
2. OverThickness tolerance (on gun teach setup screen) is large enough.
If the above items are OK, confirm that:
1. Max allowable Pos error (on gun teach setup screen) is large enough.
If the above item is NG, the position error is made less than maximum allowable position error in the
following ways.
1. Touch up correct position using jog or point touchup(not program touchup).
2. Increase maximum allowable position error on gun teach setup screen.
If this problem persists after taking the above actions, perform the following actions:
1. Acquire diagnostic data. See the procedure for diagnostic data collection at Troubleshooting section.
2. Contact a FANUC technical representative.

SVGN-271 Too large torque limit.(Lower)

[Cause]
Robot tip contacted lower panel surface before search motion started. Torque limit became
unexpectedly-large during lower panel detection.
[Remedy]
Confirm that distance of panel contact is not larger than search start distance. Retry spot program touchup.
If robot tip contacts lower panel surface before search start distance, increase start distance(SD) for robot
tip and/or lower panel detection distance. Refer to Chapter "21.6 LOWER PANEL DETECTION
DISTANCE CLAMP" or "21.15 SPTCH_RSD INSTRUCTION" for more information about the lower
panel detection distance. If this problem persists after taking the above actions, perform the following
actions:
1. Acquire diagnostic data. See the procedure for diagnostic data collection at Troubleshooting section.
2. Contact a FANUC technical representative.

SVGN-272 Lower Det start pos was wrong.

[Cause]
Open distance of a gun axis was too short at start position of lower panel detection.
[Remedy]
Confirm that robot tip has enough clearance from panel surface at start position. If distance between robot
tip and panel is too short, increase start distance(SD) for robot tip and/or lower panel detection distance.
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Refer to Chapter "21.6 LOWER PANEL DETECTION DISTANCE CLAMP" or "21.15 SPTCH_RSD
INSTRUCTION" for more information about the lower panel detection distance Retry spot program
touchup. If this problem persists after taking the above actions, perform the following actions:
1. Acquire the diagnostic data. See the procedure for diagnostic data collection at Troubleshooting
section.
2. Contact a FANUC technical representative.

SVGN-273 Det was irregular stop. R:%d, P:%d

[Cause]
A gun tip was contacted an upper panel surface on a free running section before search motion.
[Remedy]
R:1 means that error occurred during upper panel detection. Confirm that gun tip has enough clearance from
upper panel surface at start position. If distance between the tip and the panel is too short, confirm that:
1. no obstruction exists between guntip and panel.
If the above item is OK, confirm that:
1. nominal thickness in pressure schedule is correct.
2. OverThickness tolerance (on gun teach setup screen) is large enough.
If the above items are OK, confirm that:
1. Max allowable Pos error (on gun teach setup screen) is large enough.
If the above item is NG, the position error is made less than maximum allowable position error in the
following ways.
1. Touch up correct position using jog or point touchup(not program touchup).
2. Increase maximum allowable position error on gun teach setup screen.
R:3 means that error occurred during lower panel detection. Confirm that robot tip has enough clearance
from panel surface at start position and that there is no obstacle between the panel and the robot tip at start
position. If distance between the tip and the panel is too short, increase start distance(SD) for robot tip
and/or lower panel detection distance. Refer to Chapter “21.6 LOWER PANEL DETECTION DISTANCE
CLAMP” or “21.15 SPTCH_RSD INSTRUCTION” in R-30iB CONTROLLER Servo Gun Function
OPERATOR’S MANUAL (B-83264EN) for Servo Gun Function for more information about the lower
panel detection distance.
Retry spot program touchup.
If this problem persists after taking the above actions, perform the following actions:
1. Acquire the diagnostic data. See the procedure for diagnostic data collection at Chapter “21.23
Troubleshooting” in R-30iB CONTROLLER Servo Gun Function OPERATOR’S MANUAL
(B-83264EN) for Servo Gun Function.
2. Contact a FANUC technical representative.
Note: This alarm is posted when the time to execute phases2,3 take longer than anticipated, during upper1
detection and lower detection.
R: Request number. R:1 is upper1 detection. R:3 is lower detection.
P: Phase number. P:2 is phase of acceleration. P3: is phase to collect data to calculate threshold.
If the tip touch panel during above phase, this alarm is posted. Please check whether the tip touch panel or
the gun is closed(or grabbed panel) at position of search start.

SVGN-274 Too low speed threshold.

[Cause]
Threshold to detect panel contact became unexpectedly-low.
Two causes are expected as follows.
1. Gun tip is contacted to panel before start search motion.
2. Speed of gun axis is not stable during search motion.
[Remedy]
1. If gun tip contacted panel surface at start position, increase start distance(SD) for gun tip.
If robot tip contacted lower panel surface at start position, increase start distance(SD) for robot tip
and/or lower panel detection distance.

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B-83264EN/03 21.SPOT PROGRAM TOUCHUP FUNCTION
Refer to Chapter "21.6 LOWER PANEL DETECTION DISTANCE CLAMP" or "21.15
SPTCH_RSD INSTRUCTION" for more information about the lower panel detection distance. Retry
spot program touchup.
2. Suppress variation in axis speed at search motion by turning on Use Averaging Speed in Parameter
Calibration Setup.
Refer to Chapter “21.7 Parameter Calibration Setup” for more information about the Use Averaging
Speed.

If this problem persists after taking the above actions, perform the following actions:
1. Acquire the diagnostic data. See the procedure for diagnostic data collection at Troubleshooting
section.
2. Contact a FANUC technical representative.

SVGN-275 Search starts@:%smm(%s desired).

[Cause]
Search start distance was clamped due to gun open limit. SVGN-275 is posted as cause code for SVGN-190.
Actual search start distance is displayed, along with desired (unclamped) search start distance.
[Remedy]
See SVGN-190.

SVGN-276 Search mode was not selected.

［Cause］
Touchup function cannot be executed because search mode was not selected.
［Remedy］
Set $SGSYSTCH.$ACCUDET_ENB=TRUE, and restart spot program touchup function.

SVGN-278 Averaging speed is enabled.

［Cause］
Axis speed will be varied during search motion. So counter-measure is turned ENABLE automatically.
［Remedy］
If the gun has no abnormality, there is no remedy.

SVGN-279 Averaging speed is used.

［Cause］
Axis speed will be varied during search motion. So counter-measure is used automatically.
［Remedy］
If the gun has no abnormality, there is no remedy. Turn Use averaging speed ON manually if you want to
disable this message.

SVGN-306 Thickness Check Calib retrying...

[Cause]
Retrying thickness check calibration.
[Remedy]
This message is provided for informational purposes only, it is not a fault.

SVGN-340 Prog:%s is write protected.

[Cause]
Spot program touchup function could not modify program position, because file is write-protected.
[Remedy]
Disable write protection.

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SVGN-341 Spot program touchup pending.

[Cause]
Spot program touchup has been enabled with execution mode = TOUCHUP mode during spot instruction
execution, so spot program touchup will not start until next spot. The following sequence can lead to this
condition/message:
1. Start program with spot program touchup disabled
2. Pause program during execution of spot instruction
3. Enable spot program touchup (in TOUCHUP mode)
4. Resume (continue) program
[Remedy]
Note: purpose of this warning is operator notification, this is not a fault condition. In order to
execute program touchup immediately, either execute shift backward (to restart spot) or abort
program.

SVGN-342 Spot program verification enabled !

[Cause]
A tp program started (or resumed) and spot program touchup function is enabled with execution mode =
VERIFY. Verify mode means that points will be evaluated but positions will NOT be modified.
[Remedy]
If touchup (not verify) mode is desired, change execution mode via Touchup setup screen:
a. if tp is disabled, set Execution mode for AUTO = TOUCHUP mode.
b. if tp is enabled, set Execution mode for TEACH = TOUCHUP mode.
If normal spot (not touchup or verify) operation is desired, disable program touchup via:
a. DIN, if tp is disabled.
b. Touchup mode setup screen, if tp is enabled.

SVGN-343 Spot program verification pending

[Cause]
Spot program touchup has been enabled in VERIFY mode during spot instruction execution, so spot
program touchup will not start until next spot. Conditions leading to this case are: 1. Start program with spot
program touchup disabled 2. Pause program during execution of spot instruction 3. Enable spot program
touchup (in VERIFY mode) 4. Resume (continue) program
[Remedy]
Note: purpose of this warning is operator notification, this is not a fault condition. In order to execute
program touchup immediately, either execute shift backward (to restart spot) or abort program.

SVGN-344 Torque calibration incomplete.

［Cause］
Touchup was requested with torque control type 2, but torque calibration is incomplete.
［Remedy］
Complete touchup torque calibration or change $sggun#.$tchup.$updt_tq_typ=1 and
$sggun#.$tchup.$lwdt_tq_typ=1.

SVGN-385 Prg tch mode switch err

［Cause］
Spot program touchup mode had become ENABLE immediately before spot instruction is executed.
［Remedy］
Make the spot program touchup mode ENABELE earlier.
Make this mode ENABLE before the program to touchup is executed.
If you call a sub program to touchup in a main one, make this mode ENABLE before CALL instruction.

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B-83264EN/03 22.SERVO TIP DRESSER CONTROL

22 SERVO TIP DRESSER CONTROL

22.1 OVERVIEW
This function will provide more advanced feedback and control of the dressing operation by building the
servo motor of FANUC into tip dresser.

This function is optional (not standard).

Servo Tip Dresser Control A05B-2***-R708

22.2 SERVO TIP DRESSER AXIS SETUP

Setup of Servo Tip Dresser axis is required in order to use this function. You can setup Servo Tip Dresser
axes in MAINTENANCE screen at controlled start status. Servo Tip Dresser axes are set as the axes of
motion group 0.

Procedure
1. Perform a controlled start.
2. Press the MENU key and select “9.MAINTENANCE”. The following screen appears.

ROBOT MAINTENANCE
3/10
Setup Robot System Variables

Group Robot Library/Option Ext Axes

1 R-2000iB/165F 0
2 Servo Gun Axes 0
0 Basic Positioner 0

[TYPE] ORD NO AUTO MANUAL

3. Move the cursor to “Basic Process Axis” and press F4 “MANUAL”.

4. The following screen appears. Input the number of Servo Tip Dresser axes here. Input 1 if you use one
Servo Tip Dresser. Input 2 if you use two Servo Tip Dresser.

Enter the total number of ISDT

axes to be installed (max 8):

5. Enter FSSB line with which the Servo Tip Dresser axes is connected.

Enter the FSSB number (from 1,2,3 or 5)

on which ISDT axis x is installed:

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6. Type the hardware number for the starting axis. Enter 8 to here if robot is a 6-axis robot, and servo gun
is 1-axis gun.

Enter the hardware axis number

for ISDT axis x:

7. Enter the amplifier number used to drive this motor.

Enter the amplifier number

for ISDT axis x:

8. The following screen appears.

***Group 0 Proc Axis Installation***

P1
*
1. Display/Modify Proc axis 1~x
2. Add Proc axes
3. Delete Proc axes
4. Exit
Select?

9. To add a Servo Tip Dresser axes, choose “2. Add Proc axes”. To delete a Servo Tip Dresser axes,
choose “3. Delete Proc axis”.
10. If “2. Add Proc axes” is chosen, the following screen appears. Enter the axis number that you want to
add.

Add Proc axex

Enter axis to add (1~x)?

11. Select Motor Size used for Servo Tip Dresser.

-- MOTOR SIZE (alpha iS) --

60. aiS2 64. aiS22

61. aiS4 65. aiS30
62. aiS8 66. aiS40
63. aiS12
0. Next Page
Select ==>

12. Select Motor Type.

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-- MOTOR TYPE --

1. /2000 11. /4000

2. /3000 12. /5000
13. /6000
Select ==>

13. Select Current Limit for amplifier.

-- CURRENT LIMIT FOR AMPLIFIER--

2. 4A 10. 20A
5. 40A 12. 160A
7. 80A

Select ==>

14. Select Current Limit for motor.

-- CURRENT LIMIT FOR MOTOR --

2. 4A 10. 20A
5. 40A 12. 160A
7. 80A

Select ==>

15. Enter the amplifier number used to drive this motor.

Enter amplifier number (1~16)?

16. Enter “1: Yes”, to indicate the motor just selected is for the Servo Tip Dresser.

PROCESS AXIS TYPE

Is this axis a Servo Tip Dresser

0: No
1: Yes
Select:

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17. Enter Gear Ratio. The gear ratio is the number of motor revolutions required to spin the cutting blade
1 full revolution.

GEAR RATIO

Enter Gear Ratio (value > 0)

18. Enter Maximum Speed of the axis. The default speed is the speed achieved by the cutting blade if the
servo motor used is spinning at 100% maximum speed. The tip dresser gears may not be able to handle
this full speed, so lower it when required.

MAX JOINT SPEED SETTING

Current Speed = 0.000(rpm)

Default Speed = 600.000(rpm)
(Calculated with Max motor Speed)

Enter(1:Default, 2:Change, 3:No Change)?

19. Select Motion Sign. The motor direction is the direction the motor shaft must be turned to spin the
cutting blade in the cutting direction. TRUE=counter-clockwise, FALSE=clockwise

MAX DIRECTION

Proc_axs 1 Motion Sing = TURE

Enter (1:TURE, 2:FALSE)?

20. Enter exponential acceleration time. If you want to change the value, choose “1:Change”, then enter
the new value.

EXP_ACCEL TIME

Default exp_accel time = 120(ms)

Enter (1:Change, 2:No Change)?

21. Enter Load Ratio. This value is the ratio of all load inertia to the rotor inertia. The valid range of Load
Ratio is from 1.0 to 5.0 . If you don’t set this value, enter “0”. Consult with tip dress manufacturer to
determine the appropriate setting.

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B-83264EN/03 22.SERVO TIP DRESSER CONTROL

-- LOAD RATIO --

LoadInertia + MotorInertia
LoadRatio = --------------------------
MotorInertia

Enter Load ratio? (0:None 1~5:Valid)

22. Enter Brake Number.

BRAKE SETTING

Enter Brake Number (0~4)?

23. Come back to the screen of step 8.

***Group 0 Proc Axis Installation***

P1
I
1. Display/Modify Proc axis 1~x
2. Add Proc axes
3. Delete Proc axes
4. Exit
Select?

• To display/modify the Servo Tip Dresser axis setting, choose “1: Display/Modify Proc axis 1~x”.
• To add the next Servo Tip Dresser axis, choose “2:Add Proc axis”, then start the procedure from step
9.
• To delete the Servo Tip Dresser axis, choose “3:Delete Proc Axis”.
• To finish Servo Tip Dresser axis setup, choose “4:Exit”.

22.3 TIPDRESS INSTRUCTION

TIPDRESS is a instruction that allows you to close, pressurize for the dress time or for the number of cutter
head revolutions, and open a servo gun without welding.

Instruction format
Stand Alone format:
1: TIPDRESS [SD=m, P=n, t=j, TD=i, ED=m]

m: Distance schedule numbers (1-99)

n: Pressure schedule number (1-99)
i: Tip dress schedule number* (0-2)
j: Thickness of dresser (mm)
*Tip dress schedule can be set on the Tip dress setup menu.
Motion Option format:
1: L P[1] 2000mm/sec FINE TIPDRESS [SD=m, P=n, t=j, TD=i, ED=m]

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22.SERVO TIP DRESSER CONTROL B-83264EN/03

• Close the gun using the specified start distance in the (SD=) field.
• Turn on the blowoff valve identified in the TIPDRESS SETUP menu
• Close the gun at the pressure specified in the Pressure (P=) and Thickness (t=) field.
• Once pressure is achieved, do one of the following:
1. If end of dress type in the dress schedule is TIME, then hold pressure for the time specifiedin the
schedule assigned in the Tip Dress (TD=) field.
2. If end of dress type in the dress schedule is REVS, then hold pressure for the number of cutter
head revolutions specified in the schedule assigned in the Tip Dress (TD=) field.
• Once the Tip Dress time or number of revolutions has expired, turn on the blowoff valve if configured
for End of dress, open the gun to the end distance specified in the (ED=) field, and then turn off the
blowoff valve.
• Increment the guns tip dress count, and increment the tip dressers cutter count.

22.4 TIP DRESS SETUP MENU

Display the TIPDRESS SETUP menu, using the procedure below:
1. Press the MENU key. Select “6 SETUP”.
2. Press F1“[TYPE]” to display the pull-up menu.
Select “9 Tip Dress”.
3. TIPDRESS SETUP menu appears.
TIP DRESS
1/29

- Dresser #:1
Current # of cuts: 0
Max # of cuts: 0
Max Cuts alarm Sev: FAULT
Blow Off Valve: DO[ 0]
Fault output: DO[ 0]
Alert output: DO[ 0]
Fault/Alert Reset: DI[ 0]
Max Free Torque: 0
Max Free Torqe Sev: FAULT
Last Dress # of REVS:
Contact to Force: 0.0
Force to End of Dress: 0.0
Dress End to Gun Open: 0.0

- Gun #:1
Dresser number for gun: 1
Current # of dresses: 0
Max # of dresses: 0
Max dress alarm Sev: FAULT

- Sched #: 1
Step #1:
Duration (ms): 1
Speed (rpm): 0
Rotation: POS
Torque Max increase %: 1
Torque Min increase %: 0
Max/Min alarm Sev: FAULT
End of Dress Method: TIME
Comment:
-----------------------------------
Step #2:
Duration (ms): 0
Speed (rpm): 0
Rotation: POS
-----------------------------------
Step #3:
Duration (ms): 0
Speed (rpm): 0
Rotation: POS
-----------------------------------

[TYPE] CHART SUM_CHAR

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B-83264EN/03 22.SERVO TIP DRESSER CONTROL
The SETUP menu is broken up into 3 sections.
• Dresser info
ITEM DESCRIPTION
Dresser # You can enter the dresser number you want to configure here. There is only 1
Default: 1 dresser configured by default. To increase the number of dressers, set
$sgtdcfg.$num_dresrs, and then perform a CTRL start, then FCTN START COLD.
The maximum number of dressers is 8 which is the maximum number of preocess
axes.
Current number of cuts This item is incremented automatically after each successful dress. You can reset
Default: 0 this count on this screen by cursoring to the item and setting it to 0, or
programmatically by setting $sgtdset[Dresser_num].$cut_count.
Max # of cuts This is the maximum cuts for the cutter blade to perform before it requires to be
Default: 0 changed. When current cuts is greater than max cuts, then the system will post a
Fault or Warning depending on the Max cuts alarm sev. Setting.
Max Cuts Alarm Sev. This is the severity of the alarm which occurs when the max number of dresses on
Default: FAULT the specified dresser is exceeded. It can be a Fault or Warning.
Blow off Valve This is the index of the DOUT to control the blowoff valve when a dress is being
Default: 0 performed.
Fault output This is the index of the DOUT that will turn on when there is a TIPDRESS error, and
Default: 0 the severity has been configured as a FAULT. The user is responsible to reset this
output.
Alert output This is the index of the DOUT that will turn on when there is a TIPDRESS error, and
Default: 0 the severity has been configured as an Warning. The user is responsible to reset
this output.
Fault/Alert Reset The reset input can turn off Fault output and Alert output
Default: 0
Send Schedule to WC (This is an optional setting that will only be displayed if $SGTDCFG.$DSP_WSCHD
Default: FALSE = TRUE.) If Send Schedule to WC = TRUE, then when a tipdress is executed, a
weld will actually be performed, and the tip dress time will be determined by the weld
complete time. Some customers fire a special weld schedule that does not pass
current for the dressing operation. This item is here to support that operation. If this
item is displayed, then another optional item will be displayed in the TIP DRESS
schedule section which will determine which weld schedule to fire.
Max Free Torque Free torque is defined as the torque required to spin the dresser servo motor at the
Default: 0 requested dressing speed with no load applied by the gun tips. This item represents
the maximum free torque that can occur before on the Max Free Torque Exceeded
alarm is issued. Excessive free torque can be an indication the dresser gears are
wearing out or need re-greasing.
Max Free Torqe Sev This is the severity of the Max Free Torque exceeded alarm. It can be a Fault or
Default: FAULT Warning.
Last Dress # of REVS The following 3 items will report the number of cutter revolution during the last
dress. They are status items not adjustable by the user.
Contact to Force This is the number of revolutions of the cutter head from the time the servo gun
contacts the cutter head until force is achieved.
Force to End of Dress This is the number of revolutions of the cutter head from the time force is achieved
with the servo gun until the end of the dress is detected.
Dress End to Gun Open This is the number of revolutions of the cutter head from the time the dress ends
until the servo gun releases the cutter head.

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• Gun info
ITEM DESCRIPTION
Gun # A servo gun is mapped to a dresser, so when a servo gun is used, the system
Default: 1 knows which dresser to control. Here you can enter the gun number to configure.
Dresser number for gun This maps the gun to a specific dresser so that when this gun executes a
Default: 1 TIPDRESS instruction, the correct dresser can be controlled.
Current # of dresses This item is incremented automatically after each successful dress. You can reset
Default: 0 this count on this screen by cursoring to the item and setting it to 0, or
programmatically by setting $sggun#.$setup.$dress_cnt.
Max number of dresses This is the maximum dresses for this gun’s tips to perform before they require to be
Default: 0 changed. When current dresses is greater than max dresses, then the system will
post a Fault or Warning depending on the Max dress alarm severity setting
Max Dress Alarm Sev This is the severity of the alarm which occurs when the max number of dresses is
Default: FAULT exceeded. It can be a Fault or Warning.

• Schedule info
ITEM DESCRIPTION
Sched # You can enter the tip dress schedule number you want to configure here. There are
Default: 1 2 schedules by default. To increase the number of schedules, set
$sgtdcfg.$num_sched, and then perform a CTRL start, then FCTN START COLD.
The maximum number of schedules is 10.
Step # There is always at least one step in your dress schedule, and that is the default. The
maximum number of steps in a schedule is 3. Set $sgtdcfg.$numstepsdsp to the
number of steps you want your schedule to have.
Duration (ms) OR # of REVS This is the duration in ms for the dress if end of dress type is TIME, this time begins
Default: 0 once pressure is achieved with the servogun tips. OR this is the number of
revolutions of the cutter head, this # of REVS begins once pressure is achieved with
the servogun tips
Speed (rpm) This is the speed of the cutter head - not the motor shaft - in rpm’s for step #1 of the
Default: 0 dress.
Rotation This is the direction of rotation of the cutter head. Positive is the cutting direction. It
Default: POS can be positive or negative, but it must always be positive for step #1 of the dress.
You can have a multi-step dress schedule, for ex. 3 steps, step 1 is a rough cut, step
2 is a fine cut, and step 3 is a reverse direction to knock off any burs on the weld tips.
Torque Max increase% This is the upper limit of dresser torque allowed during Step #1 of the dress. The
Default: 0 units are % of the amplifiers maximum torque output above the measured free
spinning torque. If the torque increases from the free torque by more than this value
anytime during Step 1 of the dress, then a fault or warning is posted depending on
Max/Min alarm Sev.
Torque Min increase % This is the lower limit of dresser torque required during Step #1 of the dress. The
Default: 0 units are % of the amplifiers maximum torque output above the measured free
spinning torque. This is the percent increase above the free spinning torque which is
required to determine a dress has been done. If the torque does NOT reach this
minimum value during Step 1 of the dress, then a fault or warning is posted
depending on Max/Min alarm Sev.
Max/Min Alarm Severity This is the severity of the alarm which occurs when the dresser motor torque does
Default: FAULT not fall within the range specififed by the Torque Max/Min increase items during the
1st step of the tip dress. It can be a Fault or Warning.
End of Dress Method This item allows the user to configure what determines the end of a dress. It can be
Default: TIME time based, or it can be number of revolutions of the cutter head.
Weld Schedule (This is an optional setting that will only be displayed if $SGTDCFG.$DSP_WSCHD
Default: 1 = TRUE.) If Send Schedule to WC = TRUE, then when a tipdress is executed, a
weld will actually be performed, and the servo gun pressure will be maintained until
the weld complete signal is received. Some customers fire a special weld schedule
that does not pass current. This allows them to control tip dress counts in the weld
controller. This is the value of the weld schedule to fire with this tip dress schedule.
Comment Allows you to associate a comment with this tip dress schedule.
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B-83264EN/03 22.SERVO TIP DRESSER CONTROL

NOTE
When TIPDRESS is executed with low override, the pressurizing time might become
longer than the specified duration. Change the push depth to 5mm when you want to
evade this. The push depth can be changed by the system variable $sgsch#[pressure
schedule number].$pushing_depth. A default value of the push depth is 10mm.

22.5 OTHER FUNCTIONS

22.5.1 Last Dress / Master Dress Chart

You can get a graphical display of the speed and torque of the last dress performed by the tip dresser.
Display the Last Dress/Master Dress Chart, using the procedure below:
1. Press the MENU key. Select “6 SETUP”.
2. Press F1“[TYPE]” to display the pull-up menu.
Select “9 Tip Dress”.
3. Press F2“CHART”.

The following screen will be displayed.

SPEED

Free Torque + Torque Max increase

TORQUE Free Torque + Torque Min increase

Time(sec)

Pressurizing

GUN#1

ITEM DESCRIPTION
SPEED This is a speed variance of the cutter head from the start of TIPDRESS instruction
Unit:rpm to the end.
TORQUE This is a free torque variance from the start of TIPDRESS instruction to the end.
Unit:% Use this to determine the best alarm settings for max, min, and free torque in the tip
dress schedule.

Operation
ITEM DESCRIPTION
F2 SAVE This chart is saved in the file named TDLOG#.CSV(# is gun number) to external
device.
F3 GUN# This changes the gun number.
F4 SET_MAST This can be used to save the current chart as the "Master Chart" which can be
recalled at any time by pressing the SHO_MAST button.

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ITEM DESCRIPTION
F5 SHO_MAST Use this button to toggle between showing the results from the last dress done and
the master dress.

NOTE
When power supply is turned off, the last dress result is lost. Press F2 “SAVE” if you
do not want to lose the last dress result.

22.5.2 Dress Summary Log File and Chart

For each dress that occurs, a record is written to the summary log. The name of summary log is
TDSUMLOG.DG.
Summary log is viewable via the robot homepage from a web interface.
1. Press the MENU key, then Select “0 --NEXT--”, “8BROWSER”.
2. Press F5“HOME”. The following robot homepage is displayed.

3. Move the cursor to "Error/Diagnostic files (text) available on MD", and press enter key. The following
screen is displayed.

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4. Move the cursor to "TDSUMLOG.DG", and press enter key.

The following summary log is displayed.

ITEM DESCRIPTION
GUN_NUM This is gun number.
TD_SCHED This is tip dresser schedule number.
MAX_TORQ This is max motor torque (% of amplifier current) from dresser motor which was
Unit:% measured during 1st step of dress.
MIN_TORQ This is min motor torque (% of amplifier current) from dresser motor which was
Unit:% measured during 1st step of dress.
FREE_TORQ This is motor torque (% of amplifier current) from dresser motor which was
Unit:% measured when dresser motor reached dressing speed
TIP_DIST This is distance the servo gun tips (mm) moved forward from the time tip pressure
Unit:mm was achieved until dress is done.
TIPCNTC_DIST This is position of servo gun tips (mm) when the dresser motor torque increased
Unit:mm enough to determine the servo gun tips were in contact with the cutter blades.
TIME_DATE This is time/date of the dress, according to the robot system clock.
PRESS_SCHED This is pressure schedule number in TIPDRESS instruction.
PRESS_VAL(kgf) This is the pressure of the pressure schedule number specified in TIPDRESS
instruction.
TOTAL_TIP_WEAR This is current total servo gun tip wear.
Unit:mm

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ITEM DESCRIPTION
END_TORQ This is not being used now.
TOTAL_REVS This is the number of revolutions of the cutter head from the time force is achieved
with the servo gun until the end of the dress is detected.

• Summary log will hold approximately the last 130 dresses.

• Summary log is saved on the MD: device and is backed up during a "backup all of above".

Summary log has a chart menu so you can see the result of the last several dresses, including any trends.
This provides the user with graphical data to help them setup their torque alarm thresholds in the Tip Dress
schedule. For example, the user can review the results from the 1st 10 dresses that occur in production or
during initial setup/runoff, then use that to determine the best alarm settings for max, min, and free torque in
the tip dress schedule.
Display the chart menu, using the procedure below:
1. Press the MENU key. Select “6 SETUP”.
2. Press F1“[TYPE]” to display the pull-up menu.
Select “9 Tip Dress”.
3. Press F3“SUM_CHAR”.

The following screen will be displayed.

Max Torque
Increase Tip Contact
Pos.
Min Torque
Increase
Gun Pressure

Free Torque

Tot. Tip Wear

Tip Advance

Number of times Number of times

GUN# CLEAR SCHED# [DISPLAY] GUN# CLEAR SCHED# [DISPLAY]

ITEM DESCRIPTION
Max Torque Increase This is a chart of MAX_TORQ in summary log file.
Unit:%
Min Torque Increase This is a chart of MIN_TORQ in summary log file.
Unit:%
Free Torque This is a chart of FREE_TORQ in summary log file.
Unit:%
Tip Advance This is a chart of TIP_DIST in summary log file.
Unit:mm
Tip Contact Pos. This is a chart of TIPCNTC_DIST in summary log file.
Unit:mm
Gun Pressure This is a chart of PRESS_VAL in summary log file.
Unit:kgf
Tot. Tip Wear This is a chart of TOTAL_TIP_WEAR in summary log file.
Unit:mm
End Torque This is not being used now.

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Operation
ITEM DESCRIPTION
F2 GUN# This changes the gun number.

F3 CLEAR This deletes contents of summary log file.

F4 SCHED# This changes the tip dress schedule.
F5 [DISPLAY] This can be used to toggle on/off each of the (8) display items.

22.5.3 Servo Tip Dresser Drive Program

The following KAREL program to drive tip dress servo motor is prepared beforehand.

TURNDRES (Dresser number, Cutter head speed[rpm], Driving time[ms])

This KAREL program can drive tip dress servo motor without the execution of the TIPDRESS instruction.

Step
1. Make a suitable TP program.
2. Call TURNDRES.PC in the TP program. Specify dresser number, cutter head speed and driving time
to the argument.

DRESS_ON LINE 0 T2 ABORTED G1 JOINT 100%

1: CALL TURNDRES(1,100,2000)

[End]

POINT SPOT TOUCHUP

3. Execute the TP program. Tip dress servo motor drives according to the specified argument.
4. Specify a negative value as follows for a cutter head speed if you want to make the tip dress servo
motor reverse-driven.

DRESS_ON LINE 0 T2 ABORTED G1 JOINT 100%

1: CALL TURNDRES(1,(-100),2000)

[End]

POINT SPOT TOUCHUP

22.6 ALARM
Refer to OPERATOR’S MANUAL (Alarm Code List) (B-83284EN-1).

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23 WELDTIP INSPECTION
23.1 OVERVIEW
The Weld Tip Inspection is designed to visually inspect and error proof the condition of spot welding tips.
This function requires Weld Tip Inspection (A05B-2500-J847)
- Verification of proper Cap Replacement
- Verification of successful Tip Dress Operation
- Measure Gun and Robot tip wear to determine if threshold is exceeded
- Adjust welding tip gap from tip wear
- Check Alignment of weld tip angles

23.1.1 WeldTip Vision Model

iRVision camera takes and saves the figure of new tip. WeldTip inspection compares the figure of tip at
the inspection with that of new tip.

Image of Weld Tip

23.1.2 Composition of Tip Inspection

Inspection box is composed as following. Camera and LED light are located. Move robot into the station's
view position. Robot moves accurately every times and it leads correct inspection.

Blush

Cover

LED

Relay

Diffusion Plate
Calibration Plate
Camera cover
Camera
Composition of inspection

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CAUTION
1 The direction of the installation is only for the horizontal or wall hanging. Please
do not set it up in the vertical direction for dustproof. （Following chart）
2 Please clean the camera cover and diffusion plate in the main body periodically.
3 Please down the power supply immediately when water splashes. Then take off
the main body cover, and wipe moisture in the main body off.
4 Please do not step the body.
5 Please light the LED only during inspection of the tip.

Horizontal Wall hanging Ceiling hanging Vertical

installation installation installation installation

23.1.3 Related Function

iRVision
iRVision is a visual sensor system designed to provide robot guidance and error proofing capabilities by
inspecting a work piece using cameras. It can perform various measurements as well as adjust the robot
motion so that the robot can manipulate the work piece in the same way as programmed. For full details
on the setup and use of iRVision, please refer to the iRVision Addendum and iRVision Operator
manuals.

23.2 HARDWARE SETUP

It explains the setup method of Weld tip inspection (A05B-1409-B101) as follows.

23.2.1 Inspection Box

Specifications

Item description
Tip inspection The main function Weld tip inspection, Shank relative angle inspection
Cutting amount check of tip
Method Picture processing by iRVison
Camera, Lens, LED Built-in
LED power supply DC24V supply necessity, It is possible to turn it on and off
by relay (built-in).
Size 470 x 190 x 152（refer to the overall dimensions）
Mass 4.2kg
Sensor control part Picture processing R-30iB main board
Number of pixels 512 x 480
Operational environment PC ( It can be detached except teaching )
Image display iPendant ( or PC connected with Ethernet )

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Overall dimensions
Installation dimensions

Camera cable
connection

LED power-signal
cable connection
Conformity
diameter φ 5 − φ 9

23.2.2 Routing Method of Main Body Connection Cables（Camera,

LED）
Please do the connection and detaching the camera cable after turning off robot controller's power supply
without fail. There is a possibility that the hardware or the robot controller breaks down when the cable is
connected or detached at power supply ON.
Please loosen the cable clamp completely and detach the plate in the back when you connect the camera
cable.

Cable clamp
Please loosen it
completely.

Method of camera cable connection

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R-30iB

Main bord
Camera cables (A-cabinet) Camera cables (B-cabinet)
A05B-2253-J300 (7m) A05B-2253-J001 (7m)
A05B-2253-J301 (14m) A05B-2253-J002 (14m)
A05B-2253-J302 (20m) A05B-2253-J003 (20m) Tip inspection
A05B-2253-J303 (25m) A05B-2253-J004 (25m)

JRL6 camera

LED
Relay
LED power, signal cable
LED Power (Customer arrangements)
Supply signal cable diameter φ5-φ9mm ※ The size of the relay terminal is M3,
DC 24V overall dimensions is φ5.9 or less
(Customer
arrangements) Method of relay terminal connection

5:power 0V
8:power +24V
13:signal 0V
14:signal +24V

When lighting directly

with the signal cable
1:power 0V
4:power +24V

Connection of camera and LED

Transit unit • If a customer doesn’t prepare the LED

power and cable, this option can turn
A05B-2527-J497 ON/OFF LED.
• Please order with the transit unit
A05B-2527-J497.
• Please refer to the left figure for the
cable path in the controller.
• This option makes the RO1 signal a
special power supply of LED.
Therefore, the RO1 signal in the EE
connector of the robot cannot be used.
• This option can’t be used in A-cabinet
Tip inspection

Camera
LED

Relay
LED ON/OFF cable （option）
A05B-1409-K001 (7m)
A05B-1409-K002 (14m) The size of the relay
Please replace of the jumper A05B-1409-K003 (20m) terminal is M3,
connectors CRP28 and CRMA41 A05B-1409-K004 (25m) overall dimensions is
with connectors of this option φ5.9 or less

Please fix with the cable clamp Method of relay

terminal connection

1:power 0V
4:power +24V

LED ON/OFF cable (option)

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23.2.3 Installation of Calibration Plate

Please install Calibration plate (A05B-1409-J901) horizontally with main body. And confirm whether the
bulge of under Plate is accurately in a square hole of main body. And tightens a bolt. Because the lock
washer is broken Please do not pull the bolt forcibly. Please take care not to place the cable.

Please confirm whether the bulge

of Plate is in a square hole of
main body.
Please do not place the cable.

Please do not pull the bolt

forcibly.

23.2.4 Periodic Maintenance

Please clean up when you can confirm dirt to the surface of lens, camera cover, and diffusion plate. Please
exchange the parts when dirt can’t be washed or there is a crack in parts.
Please clean up it according to the following procedures.
1. Please blow off the dirt of parts in a clean dry air.
2. Please wipe the parts by lens cleaning paper that soaked alcohol until dirt is washed off. If the dirt is
not washed, please exchange the parts.

23.2.5 Spare Parts List

Overall dimensions

22
1
1

6 55
6
33

99
88
77
44

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Specification / name

Specification Name Quantity

1 A290-7409-X002 Main body cover 1
2 A290-7409-X004 Blushes 4
3 A97L-0218-0683/XC56 Camera 1
4 A97L-0218-0774 Lens 1
5 A290-7409-X006 Camera cover 1
6 A58L-0001-0015/ADC24 Relay ( contact part ) 1
7 A05B-1409-J901 Calibration jig ( option ) 1
8 A290-7409-X007 Diffusion plate 1
9 A290-7409-V001 LED unit 1

23.2.6 Connecting a Setup PC

A PC is used to setup vision data.
For details, please refer to Section 6, "SETUP" in " R-30iB CONTROLLER Sensor Mechanical Unit /
Control Unit OPERATOR'S MANUAL (B-83434EN)"

- Connect Robot controller and PC with Ethernet cable

- Set IP address to be assigned to Robot Controller and PC
- Install the Vision UIF Control on PC

23.3 CREATING VISION DATA

23.3.1 Robot Homepage

You can set up iRVision by vision setup screen by pressing [MENU] on iPendant and selecting
[8.iRVision], or using a PC connected to the robot controller over an Ethernet network. Following is the
procedure by using PC connected to the robot. For details, see Section A, “TEACHING FROM PC” in
"iRVision OPERATOR'S MANUAL (Reference) (B-83304EN)".

To setup by iPendant, see Section 3.1, “VISION SETUP” in "iRVision OPERATOR'S MANUAL
(Reference) (B-83304EN)".

Procedure
1. Click the [Start] button on the PC screen, and start Internet Explorer.
2. Enter the IP address or the host name of the robot controller in [Address] and Robot Homepage
appears.
3. Click “Vision Setup” on the screen.

The robot homepage is not dedicated to iRVision but also is provided for every robot controller. When
the robot controller has the iRVision option, the following three links for iRVision appear on the
homepage of the robot:

- Vision Setup
Performs iRVision setup and testing.
For details, see Section 3.1, “VISION SEUTP” in "iRVision OPERATOR'S MANUAL (Reference)
(B-83304EN)".

- Vision Log
Displays the execution log of iRVision.

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For details, see Section 3.3, “VISION LOG” in "iRVision OPERATOR'S MANUAL (Reference)
(B-83304EN)".

- Vision Runtime
Displays the run-time monitor of iRVision.
For details, see Section 3.2, “VISION RUN-TIME” in "iRVision OPERATOR'S MANUAL (Reference)
(B-83304EN)".

23.3.2 Vision Setup

This is the Main Setup Page for performing iRVision setup and testing.
For details, see Section 3.1, “VISION SEUTP” in "iRVision OPERATOR'S MANUAL (Reference)
(B-83304EN)".

23.3.3 Camera Setup Tool

Default camera data is “WTWCAM” for this function. Please it as it is for following vision setup.

To reset or add vision data for camera setup, please refer to Section 4, "CAMERA" in "iRVision
OPERATOR'S MANUAL (Reference) (B-83304EN)".

23.3.4 Camera Calibration

Default camera data is “WTICALB” for this function. Please reset Camera Calibration vision data with
your inspection station. It adjust frame based on calibration grid and leads accurate measurement of weld
tip. Use this vision data for following vision setup.

Procedure
1. Fix calibration grid on inspection station.
2. Supply LED power.
3. Perform camera calibration with either of following two procedures.
(a) With robot controller:
(i) Press [SELECT] key on TP and Program select screen appears.
(ii) Select KAREL program "WTICALB" and execute it.

(b) With Setup PC

(i) Select "WTICALB" from vision data list of camera calibration and Camera Calibration
setup window appears.
(ii) Click [Find] button at lower right hand of the screen.
(iii) Click [OK] button and [Close] button at lower right hand of the screen.

4. Take off the calibration grid.

23.3.5 Vision Process Tools

Weldtip inspection works when vision processes are performed from TP program. Vision process setups
need new weld tip.

Vision Setup screen shows the list of vision process.

Set up following three vision processes.

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Process Name Contents

WTINEW Inspects new tip figure.
WTIWEAR Inspects tip wear, length and alignment.
WTIDRESS Inspects dressed tip figure.

23.3.5.1 New tip inspection

Set up vision process with new weld tip. Vision process is constituted of command tools.

Procedure
1. Set new weld tip to spot welding gun.
2. Move robot into view position. Locate weld tip in front of camera and on the plane where calibration
grid is located at camera calibration.
3. Teach view position to robot.

NOTE
Please the location of robot and inspection station at the same time every time.
Accurate inspection is performed when welding tip is located on calibration grid
plane.

4. Turn on LED.
5. Click "WTINEW" on the list of vision process.

Vision process setup window

A model is taught in WTINEW so modify it. Gun tip is located in left and Robot tip is located in right in
the screen of the model. Please change the location if needed. Model ID of vision process defines which
tip is gun tip or robot tip.

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Model ID Vision tool name

Gun tip 1 GunNew
Robot tip 2 RobotNew
They can change the name of vision tools.

6. Confirm calibration data is selected in the screen.

7. To teach gun tip model pattern, select "GunNew" in vision tools tree view and setup page appears.
8. Click [Teach Pattern] button. Enclose the work piece within the red rectangle that appears, and
click the [OK] button. For detailed information about the operation method, see Subsection 3.7.9,
“Window Setup” in "iRVision OPERATOR'S MANUAL (Reference) (B-83304EN)".

Teaching tip model

9. Specify the range of the area of the image to be searched. To change the search window, click the
[Set Search Win.] button. When a rectangle appears on the image, adjust its geometry a little
larger than teaching a model. If teaching model is located out of search window, it causes error.

Setting search window

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10. To teach Robot tip model pattern, select "RobotNew" in vision tools tree view and set up as same
as procedure 7~10.
11. After teaching two tip model, select "WTINEW" in vision tools tree view and [click Continuous
S+F button]. If there is no problem, please click [Stop S+F button].
12. Click [Save] button and exit the window.

For details, see Section 23.3.6, "Note for teaching vision process" in this manual and Section 8,
“COMMAND TOOLS” in "iRVision OPERATOR'S MANUAL (Reference) (B-83304EN)".

23.3.5.2 Dressed tip inspection

Set up vision process with new weld tip or dressed weld tip. Vision process is constituted of command
tools as followings.

Procedure
1. Set new weld tip or dressed tip to spot welding gun.
2. Move robot into view position. Locate weld tip in front of camera and on the plane where calibration
grid is located at camera calibration.
3. Teach view position to robot.

NOTE
Please the location of robot and inspection station at the same time every time.
Accurate inspection is performed when welding tip is located on calibration grid
plane.

4. Turn on LED.
5. Click "WTIDRESS" on the list of vision process.

Vision process setup window

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A model is taught in WTIDRESS so modify it. Gun tip is located in left and Robot tip is located in right
in the screen of the model. Please change the location if needed. Model ID of vision process defines
which tip is gun tip or robot tip.

Model ID Vision tool name

Gun tip face 1 GunDress
Robot tip face 2 RobotDress
They can change the name of vision tools.

6. Confirm calibration data is selected in the screen.

7. To teach gun tip face model pattern, select "GunDress" in vision tools tree view and setup page
appears.
8. Click [Teach Pattern] button. Enclose the work piece within the red rectangle that appears, and
click the [OK] button. For detailed information about the operation method, see Subsection 3.7.9,
“Setting Window” in "iRVision OPERATOR'S MANUAL (Reference) (B-83304EN)".

Teaching tip face model

9. Specify the range of the area of the image to be searched. To change the search window, click the
[Set Search Win.] button. When a rectangle appears on the image, adjust its geometry. Please
consider the tip face shifts by tip dress. If teaching model is located out of search window, it causes
error.

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Setting search window

10. To teach Robot tip model pattern, select "RobotDress" in vision tools tree view and set up as same
as procedure 7~10.
11. After teaching two tip model, select "WTIDRESS" in vision tools tree view and [click
Continuous S+F button]. If there is no problem, please click [Stop S+F button].
12. Click [Save] button and exit the window.

For details, see Section 23.3.6, "Note for teaching vision process" in this manual and Section 7,
“COMMAND TOOLS” in "iRVision OPERATOR'S MANUAL (Reference) (B-83304EN)".

23.3.5.3 Tip wear inspection

This process inspects tip wear, tip length, dressed amount and alignment.
Set up gun axis mastering, vision process and nominal value for measurements.

Gun axis mastering

Procedure
1. Complete gun axis mastering with new weld tip.
2. Set up Tip wear down compensation of servogun function. It is no matter the method is ONE-STEP
or TWO-STEP. For details, see "Servo Gun Function OPERATOR'S MANUAL (B-83264EN)". It
works when vision data for tip wear inspection is lost by any accident. For details about vision data
recovery, see Section 23.9, "Vision Data Recovery".

Create Vision Process

Procedure
1. Set new weld tip to spot welding gun.
2. Move robot into view position. Locate weld tip in front of camera and on the plane where calibration
grid is located at camera calibration.
3. Teach view position to robot.

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NOTE
Please the location of robot and inspection station at the same time every time.
Accurate inspection is performed when welding tip is located on calibration grid
plane.

4. Turn on LED.
5. Click "WTIWEAR" on the list of vision process.

Vision process setup window

Tip wear measurement detects tip face as a line not a figure because the figure can changes from welding.
So search window of tip face must be located accurately. Firstly shank or gun base is detected and the
search window of tip face is shifted as the location of gun shank. They can use any part to detect for
searching location if the figure does not change with welding.

A model is taught in WTIWEAR so modify it. Gun tip is located in left and Robot tip is located in right
in the screen of the model. Please change the location if needed. Model ID of vision Tools defines which
tip is gun tip or robot tip.

Model ID Vision tool name

Gun tip base 1 GunBase
Gun tip face 2 GunTip
Robot tip face 3 RobotTip
Robot tip base 4 RobotBase

They can change the name of vision tools.

CAUTION
Wrong setting about Gun tip and Robot tip cause incorrect movement.
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6. Confirm calibration data is selected in the screen.

- Shank model
7. To teach gun shank model pattern, select "GunLocate" in vision tools tree view and set up page
appears.
8. Click [Teach Pattern] button.
9. Enclose the workpiece within the red rectangle that appears, and click the [OK] button. For detailed
information about the operation method, see Subsection 3.7.9, “Setting Window” in "iRVision
OPERATOR'S MANUAL (Reference) (B-83304EN)".
10. Specify the range of the area of the image to be searched. To change the search window, click the
[Set Search Win.] button. When a rectangle appears on the image, adjust its geometry a little
larger than teaching a model.

Teaching shank model

- Tip base model

11. To teach Tip base model pattern, select "GunBase" in vision tools tree view and set up page
appears.
12. Click [Teach Pattern] button.
13. Enclose the workpiece within the red rectangle that appears, and click the [OK] button.
14. Specify the range of the area of the image to be searched. To change the search window, click the
[Set Search Win.] button. When a rectangle appears on the image, adjust its geometry a little
larger than teaching a model. if teaching model is located out of search window, it cause error.

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Teaching tip base model

- Tip face model

15. To teach gun tip face model pattern, select "GunTip" in vision tools tree view and set up page
appears.
16. Click [Teach Pattern] button.
17. Enclose the tip face within the red rectangle that appears, and click the [OK] button. Larger model
within tip face makes more accurate measurements.

Teaching Tip face model

18. Specify the range of the area of the image to be searched. To change the search window, click the
[Set Search Win.] button. When a rectangle appears on the image, adjust its geometry. Please
consider the tip face shifts by tip dress. Notify the search window of gun tip does not overlap with
robot tip.

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Setting search window

19. To teach Robot tip model pattern, select "RobLocate"(shank), "RobotTip"(gun base) and
"RobotBase"(gun face) in vision tools tree view and set up as same as procedure 7~18.
20. After teaching two tip model, select "WTIWEAR" in vision tools tree view and [click Continuous
S+F button]. If there is no problem, please click [Stop S+F button]. Click [Save] button and
exit the window.

For details, see Section 23.3.6, "Note for teaching vision process" in this manual and Section 7,
“COMMAND TOOLS” in "iRVision OPERATOR'S MANUAL (Reference) (B-83304EN)".

Setup nominal value

Just after vision process setup, set nominal value for tip wear inspection.
Procedure
1. Press [Menu] key on TP.
2. Select [Setup] -> [WTW Setup] and enable "Tip Wear Test" or "Tip Alignment Verify". For details
of setups, see Section 23.5, "Setup".
3. Move robot into view position.
4. Perform vision program from TP Program as following.

CALL WTIWEAR (WTIWEAR, 1, 1, 20)

Regster No.

Vision process name Gun No. 1:Set norminal / 0:Usual

After Inspection finished successfully, value of assigned register is set to 1.

As for multi gun system, see Section 23.7, "Setup Multi Gun System".

CAUTION
Set up Vision process and Nominal value just after complete gun axis mastering.

It is recommended that Tip wear down compensation of servogun function. It works when vision data
for tip wear inspection is lost by any accident. For details about vision data recovery, see Section 23.9,
"Vision Data Recovery".

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23.3.6 Note for Teaching Vision Process

- At teaching vision process, set mask in the measurement area if needed. If there is reflex or water
drop along the vision model, it is recommended to mask the area and it prevents detection error.

- The attachment of tip and shank may shift gradually by pressure. At setting search window for tip,
consider its shift and set the window a little larger.

- When vision program is performed but any of vision tools in the process is not detected, "Delete
Duplicate Results If" may be large. Please adjust it.

For details, see "iRVision OPERATOR'S MANUAL (Reference) (B-83304EN)".

23.4 INSPECTION PROCEDURE

23.4.1 New Tip Inspection

Procedure
1. Complete vision process tools setup.
2. Press [Menu] on TP.
3. Select [SETUP] -> [WTW Setup], and setup menu appears.
4. Enable "Cap Change Verify" on setup menu. For details of setup menu, see Section 23.5.1, "Setup
Menu".
5. Move robot into view position to perform vision process.
6. Perform vision program from TP Program as following. Assign vision process that is created in
Section 23.3, “Creating Vision Data”.

CALL WTINEW (WTINEW, 1, 20)

Vision process name Gun No. Regster No.

After Inspection finished successfully, value of assigned register is set to 1.

As for multi gun system, see Section 23,7, " Setup Multi Gun System ".

23.4.2 Dressed Tip Inspection

Procedure
1. Complete vision process tools setup.
2. Press [Menu] on TP.
3. Select [SETUP] -> [WTW Setup], and setup menu appears.
4. Enable "Dressed Shape Verify" on setup menu. For details of setup menu, see Section 23.5.1, "Setup
Menu".
5. Move robot into view position to perform vision process.
6. Perform vision program from TP Program as following. Assign vision process that is created in
Section 23.3, “Creating Vision Data”.

CALL WTIDRESS (WTIDRESS, 1, 20)

Vision process name Gun No. Regster No.

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After Inspection finished successfully, value of assigned register is set to 1.
As for multi gun system, see Section 23,7, " Setup Multi Gun System ".

23.4.3 Tip Wear Inspection

- Shank model
Tip Wear is measured by comparing tip face displacement values. The Nominal position of the Tip model
is compared with the current position of the Tip model. This displacement is projected on the servo gun
axis and robot movement. These values are used by the servo gun function for the Tip Wear
Compensation feature. Even if tip wear test is disabled, tip wear is compensated at measurement.

Gun Tip Wear Robot Tip Wear

- Tip changed length

The Changed Length value is used to indicate when the tip is getting worn.

Gun Tip Changed Length Robot Tip Changed Length

- Tip alignment

The Alignment is the measured angle difference between the Gun Tip vector (formed by the Tip base to
tip face model origins) and the Robot Tip vector.
The difference between the Nominal Angle and the Measured Angle is the Changed Angle. If the absolute
value of the Changed Angle is greater than the Max Alignment Threshold (setup screen) an error is posted
indicating that a mechanical change has occurred and should be addressed.

Tip Alignment

Procedure
1. Complete vision process tools setup.
2. Press [Menu] on TP.
3. Select [SETUP] -> [WTW Setup], and setup menu appears.

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4. Enable "Tip Wear Test", "Cap change verify" or "Tip Alignment Verify" on setup menu. For details
of setup menu, see Section 23.5.1, "Setup Menu".
5. Reset tip wear compensation as following. As for details of register number with WDNRST macro,
please refer to section 6.9.2,”Recovery from lost of tip”.

CALL WDNRST(1, 10)

Gun No. register No.

NOTE
Tip wear compensation also works at tip inspection. So the view position shifts
by the tip wear measurement. Reset the compensation value just before the
inspection. Following program works for reset tip wear measurement.

6. Move robot into view position to perform vision process.

7. Perform vision program from TP Program as following. Assign vision process that is created in
Section 23.3, “Creating Vision Data”.

CALL WTIWEAR (WTIWEAR, 1, 0, 20)

Regster No.

Vision process name Gun No. 1:Set nominal / 0:Usual

After Inspection finished successfully, value of assigned register is set to 1.

As for multi gun system, see Section 23,7, " Setup Multi Gun System ".

23.4.4 Dressed Length Inspection

They can compare the tip length after the dress to the length before the dress and measure tip dress
amount.

Procedure
1. Complete Tip wear test setup.
2. Press [Menu] on TP.
3. Select [SETUP] -> [WTW Setup], and setup menu appears.
4. Enable "Dressed length Verify " on setup menu. For details of setup menu, see Section 23.5.1,
"Setup Menu".
5. Call "WTILEN" and perform vision process to measure tip length before tip dress as following.

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CALL WDNRST (1, 10)

Gun No. Register No.

( Move to view point )

CALL WTILEN (WTIWEAR, 1, 20)

Vision process name Gun No. Register No.

( Tip dress )

( Move to view point )

CALL WTIWEAR (WTIWEAR, 1, 0, 20)

Register No.

Vision process name Gun No. 1:Set nominal / 0:Usual

If "Dressed length Verify" is enabled but tip length measurement before tip dress(WTWLEN) is skipped,
tip length is compared to the length at last measurement.
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23.4.5 Examples
Following is an example of inspection.

New tip Inspection

CALL WDNRST (1, 10)

Gun No. Register No.

( Move to view point )

CALL WTINEW (WTINEW, 1, 20)

Vision process name Gun No. Register No.

Tip Dress and wear Inspection

Following is an example to inspect tip dress figure, tip dress amount and tip wear at tip dress.

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CALL WDNRST (1, 10)

Gun No. Register No.

( Move to view point )

CALL WTILEN (WTIWEAR, 1, 20)

Vision process name Gun No. Register No.

( Tip dress )

( Move to view point )

CALL WTIDRESS (WTIDRESS, 1, 20)

Vision process name Gun No. Register No.

CALL WTIWEAR (WTIWEAR, 1, 0, 20)

Register No.

Vision process name Gun No. 1:Set nominal / 0:Usual

Approach movement to view position

Less mechanical vibration makes better accuracy of measurement at inspection. Make the approach
movement to the view position as following for less vibration.

- Reduce velocity to the view position gradually.

- Reduce acceleration.
- Wait at the view position before inspection.

(Example)
L P[1: Approach] 2000mm/sec CNT100
L P[2] 400mm/sec CNT100 ACC50
L P[3: Inspection] 100mm/sec FINE ACC20
WAIT 0.5sec

CALL WTIWEAR(WTIWEAR,1,0,20)

L P[1: Approach] 2000mm/sec CNT100

23.5 SETUP

23.5.1 Setup Menu

Tip Inspection Setup

Each test is enabled/disabled on this screen.

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Procedure
1. Press [MENU] key.
2. Select [Setup] -> [WTW Setup] and following items appear.

Click check box for enabled/disabled and the status turns to each other.

Item Description
Servo Gun# Displayed data is for a specific servo gun.
Gun Tip Wear Test Enables/Disables Gun Tip Wear inspection.
Enable/Disable
Robot Tip Wear Test Enables/Disables Robot Tip Wear inspection.
Enable/Disable
Tip Alignment Verify Enables/Disables Tip Alignment inspection.
Enable/Disable
Cap Change Verify Enables/Disables New Tip inspection.
Enable/Disable
Dressed Shape Verify Enables/Disables Dressed Tip inspection.
Enable/Disable
Dressed length Verify Enables/Disables Tip dress length Inspection. It requires that tip wear test is enabled.
Enable/Disable
Gun Trend Test Enables/Disables Gun Tip wear trend screen.
Enable/Disable
Robot Trend Test Enables/Disables Robot Tip wear trend screen.
Enable/Disable
Spot Count Indicates spot welding count. It requires spot count setup in SpotTool menu.
Tip Dress Count Indicates tip dress count. It requires tip dress count setup in SpotTool menu.
These setups are to enable/disable alarm. Even if no item is enabled, tip wear is compensated when
inspection is performed.

Gun Tip Wear Setup

Setup Gun tip inspection in this screen.

Procedure
1. Display either of Tip Inspection Setup screen.
2. Press F3[SETUP] and select [Gun Tip Setup]. Following screen appears.

Item Description
Servo Gun# Displayed data is for a specific servo gun.
Tip Wear Max When Gun tip Wear inspection is enabled and tip wear exceeds this value, tip wear
(mm) exceeded DO turns on and alarm occurs
Changed Length Max When Gun tip Wear inspection is enabled and changed tip length exceeds this value,
(mm) tip wear exceeded DO turns on and alarm occurs.
Tip Wear Exceeded When Gun tip Wear inspection is enabled and tip wear or changed tip length exceeds
DO[n] the threshold, This DO turns on.
Tip Increase Max When Gun tip Wear inspection is enabled and tip increase exceeds this value,
(mm) Tip/Shank Increase Exceeded DO turns on and alarm occurs.
Shank Displace Max When Gun tip Wear inspection is enabled and shank displace exceeds this value,
(mm) Tip/Shank Increase Exceeded DO turns on and alarm occurs.
Tip/Shank Increase When Gun tip Wear inspection is enabled and Tip Increase or Shank Displace
Exceeded DO[n] exceeds the threshold, This DO turns on.

Tip Change Failure When New Tip Inspection and test status is NG, This DO turns on and alarm occurs.
DO[n]

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Item Description
Tip Dress Min When Dressed Length Inspection is on and dressed length runs short this value, Tip
(mm) Dress Failure DO turns on and alarm occurs.
Tip Dress Failure When Dressed Length Inspection or Dressed tip inspection is on and test status is NG,
DO[n] This DO turns on and alarm occurs.
Tip Dress Max When Dressed Length Inspection is on and dressed length exceeds this value,
(mm) warning is displayed.

Robot Tip Wear Setup

Setup Robot tip inspection in this screen. The contents are same as that of Gun Tip Inspection.

Procedure
1. Display either of Tip Inspection Setup screen.
2. Press F3[SETUP] and select [Robot Tip Setup].

Alignment Setup
Setup Tip Alignment inspection in this screen.

Procedure
1. Display either of Tip Inspection Setup screen.
2. Press F3[SETUP] and select [Alignment Setup]. Following screen appears.

Item Description
Servo Gun# Displayed data is for a specific servo gun.
Max Alignment Threshold When Tip Alignment inspection is enabled and Tip Alignment exceeds this value,
(deg) Alignment Exceeded DO turns on and alarm occurs.
Off Axis Threshold When Tip Alignment inspection is enabled and Tip Distance exceeds this value,
(mm) Alignment Exceeded DO turns on and alarm occurs.
Alignment Exceeded
DO[n] When Tip Alignment inspection is enabled and test status is NG, this DO turns on.

23.5.2 Status Menu

Weld Tip Status
This screen displays the status of all tests.

Procedure
1. Press [Menu] key.
2. Select [Status] -> [WTW Status]

Gun Wear Trend

This screen is used to display a trend in gun tip wear as a function of spot weld count.

Procedure
1. Display either of Tip Inspection Status screen.
2. Press F4[STATUS] and select [Gun Wear Trend].

Robot Wear Trend

This screen is used to display a trend in robot tip wear as a function of spot weld count.

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Procedure
1. Display either of Tip Inspection Status screen.
2. Press F4[STATUS] and select [Robot Wear Trend].

Runtime
Latest Execution of a vision process can be monitored iPendant during production operation.

Procedure
1. Display either of Tip Inspection Status screen.
2. Press F4[STATUS] and select [Runtime].

23.6 ERROR CODES

When tip inspection is enabled and an error occurs, following alarms are posted.

Which
Item Description Inspection Alarm DO
alarms
SPOT-306 Found duplicate model All
PAUSE Verify vision process.
SPOT-307 Gun Tip Test missing model All
PAUSE Verify vision process.
SPOT-308 Robot Tip Test missing model All
PAUSE Verify vision process.
SPOT-309 Tip Alignment missing model Alignment
PAUSE Verify vision process. Inspection
SPOT-310 Gun Tip Wear exceeded Tip wear Gun Tip Wear
WARN Tip wear amount exceeds threshold. Inspection Exceeded DO
SPOT-311 Gun Cap Changed Length Exceeded Tip wear Gun Tip Wear
WARN Tip changed length exceeds threshold. Inspection Exceeded DO
SPOT-312 Gun Shank Displaced Tip wear Gun Tip/Shank
PAUSE Shank displacement exceeds threshold. Inspection Increase Exceeded
DO
SPOT-313 Gun Tip Increase Error Tip wear Gun Tip/Shank
PAUSE Tip length increases over threshold. Inspection Increase Exceeded
DO
SPOT-314 Robot Tip Wear exceeded Tip wear Robot Tip Wear
WARN Tip wear amount exceeds threshold. Inspection Exceeded DO
SPOT-315 Robot Cap Changed Length Exceeded Tip wear Robot Tip Wear
WARN Tip changed length exceeds threshold. Inspection Exceeded DO
SPOT-316 Robot Shank Displaced Tip wear Robot Tip/Shank
PAUSE Shank displacement exceeds threshold. Inspection Increase Exceeded
DO
SPOT-317 Robot Tip Increase Error Tip wear Robot Tip/Shank
PAUSE Tip length increases over threshold. Inspection Increase Exceeded
DO
SPOT-318 Tip Alignment exceeds Threshold Alignment Alignment Exceeded
WARN The gap of angle between two tips exceeds threshold. Inspection DO
SPOT-319 Gun Tip Dress failed Dressed tip Gun Tip Dress Failure
WARN Test status of dressed tip inspection is NG. inspection DO
SPOT-320 Robot Tip Dress failed Dressed tip Robot Tip Dress
WARN Test status of dressed tip inspection is NG. inspection Failure DO
SPOT-321 Gun Cap Change/Type failed New tip Gun Tip Change
WARN Test status of dressed new tip inspection is NG. inspection Failure DO

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Which
Item Description Inspection Alarm DO
alarms
SPOT-322 Robot Cap Change/Type failed Dressed tip Robot Tip Change
WARN Test status of dressed new tip inspection is NG. inspection Failure DO
SPOT-328 Gun Tip Dress shortage Dressed length Gun Tip Dress Failure
WARN Tip dress amount runs short the threshold. inspection DO
SPOT-329 Robot Tip Dress shortage Dressed length Robot Tip Dress
WARN Tip dress amount runs short the threshold. inspection Failure DO
SPOT-330 Gun Tip Dress exceeds Dressed length
WARN Tip dress amount exceeds the threshold. inspection
SPOT-331 Robot Tip Dress exceeds Dressed length
WARN Tip dress amount exceeds the threshold. inspection
SPOT-332 Missing Nominal Length Dressed length
WARN Nominal tip length before dress is not measured. inspection
SPOT-333 Dress Length Test ignored Dressed length
WARN Dress length inspection is skipped. inspection

23.7 SETUP MULTI GUN SYSTEM

Tip figures are different for each gun in the multi gun system. So vision process needs to be prepared for
each gun.

Create vision process

Move each gun to view point. Connect Setup PC to master robot and copy or re-create vision process for
each gun. The name of vision process needs to be different for each gun. Other restriction for the name
does not exist.

(Example)
Original Copy
WTINEW WTINEW2
WTIDRESS WTIDRESS2
WTIWEAR WTIWEAR2

Perform vision process

To perform vision process, assign proper Vision Process name and Gun No.

(Example)
CALL WTINEW (WTINEW2, 2, 20)

Vision process name Gun No. Register No.

CALL WTIDRESS (WTIDRESS2, 2, 20)

Vision process name Gun No. Register No.

CALL WTIWEAR (WTIWEAR2, 2, 0, 20)

Register No.

Vision process name Gun No. 1:Set nominal / 0:Usual

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23.8 SHARE ONE LNSPECTION STATION WITH MULTI ROBOT

Constitution
To share one inspection station with multi robot, one of robots mounts the inspection box and robot ring
connect all robots via Ethernet. Inspection box is in the area of all robots and inspects the guns each other.
There is no restriction about the number of guns and robot.

Vision data of ROBOT1

Vision data of ROBOT2 Gun
ROBOT1

Camera cable
Inspection
Setup PC ROBOT2 Ethernet
station

Gun
The robot that connects to camera is defined as master robot and the other robots are defined slave robots
in this section.
Vision processes are taught to master robot and stored in it. Slave robot sends commands to master robot
at inspection.

Connect Robot And Setup PC

Connect all robots via Ethernet and connect Setup PC to Master robot. Select "Robot Ring" on Vision
Setup menu on iRVision. For details, see Section 6, "SETUP" in " R-30iB CONTROLLER Sensor
Mechanical Unit / Control Unit OPERATOR'S MANUAL (B-83434EN)".

Create Vision Process For Slave Robot

Move gun of slave robot to view point. Connect setup PC to master robot and copy or re-create vision
process for slave robot. The name of vision process needs to be different for each gun. Other restriction
for the name does not exist.
(Example)
Original Copy
WTINEW WTINEW2
WTIDRESS WTIDRESS2
WTIWEAR WTIWEAR2

Perform Inspection For Slave Robot

Move gun to view point and perform vision process from slave robot. To perform vision process of each
robot, assign robot name that has vision process, vision process name and gun No.

Assign vision process as following. Robot name is same as the name assigned at robot ring setup.
Robot Name. Vision Process Name

Dot

Gun No is the number in the slave robot.

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(Example)
CALL WTINEW (ROBOT1.WTINEW2, 1, 20)

Robot Name + Gun No. Register No.

Vision process name

CALL WTIDRESS (ROBOT1.WTIDRESS2, 1, 20)

Robot Name + Gun No. Register No.

Vision process name

CALL WTIWEAR (ROBOT1.WTIWEAR2, 2, 0, 20)

Register No.
Robot Name + Gun No.
1:Set nominal / 0:Usual
Vision process name

23.9 RECOVER VISION DATA

When vision data is lost, recover the data as following.

New Tip Inspection

Procedure
Start Section 23.3.5.1, ”New Tip Inspection” over again.

Dressed Tip Inspection

Procedure
Start Section 23.3.5.2, “Dressed Tip Inspection” over again.

Tip Wear Inspection

Even if new tip is replaced, the attachment of tip and shank may be shifted by pressure. Use servogun tip
wear compensation together with iRVision Tip Inspection and it reduce the effect of attachment shift. Tip
wear amount is calculated as below.

Compensation Amount = Attachment shift ＋ Tip wear

Servogun Tip Wear iRVision Tip Inspection

Compensation calculate Calculate

Procedure
1. Set new weld tip to spot welding gun.
2. Set up Tip wear down compensation of servogun function. It is no matter the method is ONE-STEP
or TWO-STEP. For details, Section 6, ”Tip Wear Compensation”.
3. Retry the Section “Create Vision Process” and “Setup Nominal Value” in 23.3.5.3 ”Tip Wear
Inspection”. Skip the section “Gun Axis Mastering” in it

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24 SERVOGUN DIAGNOSIS FUNCTION

24.1 OVERVIEW
Increase of the friction from the weariness of servogun decreases its pressure force. This function
diagnoses the decrease of pressure force of servogun and urges the adjustment of it.

24.2 SPECIFICATION

24.2.1 Parameters for Monitoring

This function monitors and diagnoses the output torque and disturbance torque during servogun stroke
motion. It outputs the result of diagnosis for external memory devices and they can observe the transition
of values with csv format. iPendant can also display the chart of values graphically.

24.2.2 Servogun Motion for Monitoring and Diagnosis

This function records a series of gun stroke motion. If gun presses and open after closing, each motion is
recorded.

24.2.3 Condition for Diagnosis

If closing motion of a gun starts while diagnosis program runs, this function automatically starts to record
the motion. The standard diagnosis program is TWZRCLB2.TP (the internal program of tip weariness
detection). The diagnosis program is arbitrarily made and set by user.

- If diagnosis program runs as sub program and gun closes during it, pressing and opening motion is
recorded if they act during the main program runs.
- The span for monitoring a stroke motion is 3200msec at maximum as default. It is changeable by
$sgdiagcfg.$rec_size (Unit: 8msec).
- As for multi guns system, all guns can be recorded together.

After a series of gun motion, the record is diagnosed and outputted to files on following condition.

- The gun finishes a stroke (close and open motion) and diagnosis program finishes. If only close
motion acts by sub program, it diagnosed after the main program finishes.
- (For multi gun system) No other gun is under monitoring.
- (For multi gun system) No diagnosis program for other gun is running.

24.2.4 The Result of Diagnosis

This function calculates the maximum, average and minimum disturbance torque during each servogun
motion, and records it. When disturbance torque exceeds the limit, it posts warning and output signal by
I/O.
The base disturbance torque values are that of first diagnosis after the reset of record, they are
automatically set.

Some or all of following values can be observed.

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For closing motion, pressing and opening motion

Item Description
Maximum disturbance torque The maximum disturbance torque [%]
Average disturbance torque The Average disturbance torque [%]
Minimum disturbance torque The minimum disturbance torque [%]

For all motions in the diagnosis program

Item Description
Maximum disturbance torque The maximum disturbance torque [%]
Minimum disturbance torque The minimum disturbance torque [%]

24.2.5 Save Diagnosis Records

Diagnosis records are following.

- The details
- Summary of diagnosis

24.2.5.1 The details

This is composed of the chart of output torque, disturbance torque and position of a gun sampled every
8msec during servogun motion. Data files are created every diagnosis and saved in FROM as followings.
They can copy these files to device automatically in each time or manually in status menu.

Detailed data is created in following format.

Time/date 2009/3/11 11:29

Recorded times 7
Tuned times 1
From count 8 to count 50
Max disturbance[%] 1.304587
Min disturbance[%] -2.156001
Average disturbance[%] -0.17469
From count 53 to count 260
Max disturbance[%] 11.727548
Min disturbance[%] -1.414447
Average disturbance[%] 0.126959
From count 260 to count 303
Max disturbance[%] 0.068662
Min disturbance[%] -3.433123
Average disturbance[%] -1.006841
Max disturbance in program[%] 12.263115
Min disturbance in program[%] -3.47432
Number GUNDST GUNPLS GUNPOS GUNTRQ
1 -1.043669 -294.546692 -293.971222 -1.071134
2 -1.043669 -294.546783 -292.243347 -1.071134
3 -1.016204 -294.540558 -288.787598 0.549299

Parameters
- Total time the gun is diagnosed since the record is reset
- Total time of auto tuning for the gun since the record is cleared
- The span disturbance torque is checked in the chart of each motion.
- Maximum disturbance torque in the span
- Average disturbance torque in the span
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- Minimum disturbance torque in the spans
- Chart of following value

GUNDST Disturbance torque [%]

GUNPLS Current position [mm]
GUNPOS Target position [mm]
GUNTRQ Motor torque [%]

Without pressing or opening motion, all values for it are 0.

Sign of disturbance torque

The sign of disturbance torque is defined in detailed data as follows.

+ opposite to gun closing direction

- opposite to gun opening direction

Save detailed data

The files of detailed data are saved in FROM as followings.

- Recent records
The latest 5 records are saved in controller automatically.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Recent 5 records

- Historical records
Beside the resent records as above, the records since the start of diagnosis are saved automatically.
If the number of saved records reaches 10, records of even number period are cleared. Then the record
cycle becomes twice time.

1 2 3 4 5 6 7 8 9 10

1 3 5 7 9 11 13 15 17 19

Recorded in last period Recorded in current period

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24.2.5.2 Summary of diagnosis records

The summaries of records from all diagnosis are written in a file with csv format.

Number Date Tuned time Pos at Peak Max dst1 Ave dst1
1 09/03/11 11:25 1 -46.216011 1.441912 -.097467
2 09/03/11 11:25 1 -46.212273 1.386982 -.106985
3 09/03/11 11:28 1 -46.205978 1.455644 -.111199
4 09/03/11 11:29 1 -46.208038 1.414447 -.159999
5 09/03/11 11:29 1 -46.203880 1.414447 -.157764
6 09/03/11 11:29 1 -46.209717 1.386982 -.194264
7 09/03/11 11:29 1 -46.204224 1.304587 -.174690

Item Description
Number Total time the gun is diagnosed since the record is reset
Date Day and time
Tuned time Total time of auto tuning for the gun since the record is cleared
Pos at Peak The position max disturbance torque is recorded during gun closing motion
Max dst The maximum disturbance torque in close motion [%]
Ave dst The average disturbance torque in close motion [%]

24.2.6 Save and Clear Diagnosis Data

Save records in external devices
They can record diagnosis records in external memory devices such as Flash ATA and observe the
transition of values with csv format.

Reset diagnosis data

This is recommended at servogun retuning

(a) The detailed data are cleared and the limit value is reset
(b) The summary remains.

Clear diagnosis data

It is recommended for the change of diagnosis program or servogun

(a) The detailed data are cleared and the limit value is reset
(b) The summary is cleared.

The summary

The detailed

Start Clear Reset Current

(Change of gun)(Retuning)

(Change diagnosis program)

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24.2.7 The Schedule of Diagnosis

They can set diagnosis time. At the start of a day the temperature of mechanical unit is colder than it on
stream. It restrains the errors that occur from dispersion of the temperature.

24.2.8 Multi Servogun

For multi servogun system, this function diagnoses each servogun and the results are saved individually.

24.3 USER INTERFACE

24.3.1 Diagnosis Setup Screen

This menu is for setting of this function.

Step
1. Press [MENU] key.
2. Select [SETUP] Æ [Servo Gun].
3. Select [General Setup] on the screen.
4. Select [Servogun diagnosis] on the screen.

Following screen appears.

Servogun diagnosis setup screen

SETUP Servo Gun Diagnosis
SERVOGUN DIAGNOSIS / EQ:1 Gun:1 1/12

1 Diagnosis enable/disable: ENABLE

2 OVR CHECK: ENABLE

3 Max Torque check: ENABLE

4 Max Torque tolerance: 0.0%
5 Average Torque check: ENABLE
6 Average Torque tolerance: 0.0%

Program Name:
7 BB01
8 Diagnosis interval: 0DAYS
9 Diagnosis Time: 10:00
10 Torque check Alarm DO[ 0]
11 Alarm clear DI[ 0]
12 Consecutive number 1times

[ TYPE ] EQUIP GUN ENABLE DISABLE >

Expansion
They can also check the disturbance torque during pressing and opening motion, not only that of closing
motion.
Servogun diagnosis setup menu turns as blow with $SGDIAGCFG.$CUSTOM = 1

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Servogun diagnosis setup screen (Extended version)

SETUP Servo Gun Diagnosis
SERVOGUN DIAGNOSIS / EQ:1 Gun:1 1/30

1 Diagnosis enable/disable: ENABLE

2 OVR CHECK: ENABLE

Closing motion

3 Max Torque check: ENABLE

4 Max Torque tolerance: 0.0%
5 Average Torque check: ENABLE
6 Average Torque tolerance: 0.0%
7 Min Torque check: ENABLE
8 Min Torque tolerance: 0.0%

Pressing motion

9 Max Torque check: ENABLE

10 Max Torque tolerance: 0.0%
11 Average Torque check: ENABLE
12 Average Torque tolerance: 0.0%
13 Min Torque check: ENABLE
14 Min Torque tolerance: 0.0%

Opening motion

15 Max Torque check: ENABLE

16 Max Torque tolerance: 0.0%
17 Average Torque check: ENABLE
18 Average Torque tolerance: 0.0%
19 Min Torque check: ENABLE
20 Min Torque tolerance: 0.0%

All motion in program

21 Max Torque check: ENABLE

22 Max Torque tolerance: 0.0%
23 Min Torque check: ENABLE
24 Min Torque tolerance: 0.0%

Program Name:
25 BB01
26 Diagnosis interval: 0DAYS
27 Diagnosis Time: 10:00
28 Torque check Alarm DO[ 0]
29 Alarm clear DI[ 0]
30 Consecutive number 1times

[ TYPE ] EQUIP GUN ENABLE DISABLE >

24.3.1.1 Gun No.

If the system has multi servogun, this function can diagnose each servogun individually. To change the
gun that displayed on this screen, change Gun No pressing F3[GUN]

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Gun 1 Gun 2

[Setup menu] [Setup menu]

Set limit value Set limit value
Set Program name Set Program name

Program Program
execution execution

Diagnosis Diagnosis
[Status menu] [Status menu]

Set limit value Set limit value

Set Program name Set Program name
(SGDIAG1.DT, etc) (SGDIAG2.DT, etc)

24.3.1.2 Enable/Disable diagnosis

Usually this item is enabled. If it is turned to enable from disable, cycle power is necessary.

24.3.1.3 Override check

If this item is enable and override during the diagnosis get different from
$SGDIAGn.$SETUP.$DEF_OVR( standard value is 100 ), diagnosis is interrupted.

24.3.1.4 Torque check

If the disturbance torque value of each sort exceeds the limit, it posts warning.
The definition of each value is as below. The positive value of disturbance torque is opposite to gun
closing direction.

Closing motion, pressing

Item Condition for alarm
Maximum torque check Maximum disturbance torque comes over[base value] + [tolerance value]
Average torque check Average disturbance torque comes over[base value] + [tolerance value]
( Average disturbance torque comes under[base value] - [tolerance value] ) *
Minimum torque check Minimum disturbance torque comes under[base value] - [tolerance value]

Opening motion
Item Condition for alarm
Maximum torque check Minimum disturbance torque comes under[base value] - [tolerance value]
Average torque check Average disturbance torque comes under[base value] - [tolerance value]
( Average disturbance torque comes over[base value] + [tolerance value] ) *
Minimum torque check Maximum disturbance torque comes over[base value] + [tolerance value]

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All motion in diagnosis program

Item Condition for alarm
Maximum torque check Maximum disturbance torque comes over(base value) + (tolerance value)
Minimum torque check Minimum disturbance torque comes under(base value) - (tolerance value)

* Enabled if bit1(2) of $SGDIAGCFG.$CUSTOM is on.

24.3.1.5 Diagnosis Program

Set program name
Program name for diagnosis is set. Servogun motion during the program leads diagnosis.

Start by system variables

They can also monitor and diagnose a gun by system variables setting, not by registration of diagnosis
program.

$SGDIAGn.$MON_START = 1 (Start monitoring)

$SGDIAGn.$DIAG_START = 1 (Start diagnosis)
Each variable turns off after execution.

Following is an example of diagnosis program.

1: $SGDIAG1.$MON_START = 1
2: CALL <program for close motion>
3: CALL <program for open motion>
4: $SGDIAG1.$DIAG_START = 1

24.3.1.6 Diagnosis schedule

They can define the time and cycle for diagnosis.

Diagnosis time
This function diagnoses a gun after specified time in a day.

Diagnosis cycle
WEEK A gun is diagnosed at the first time from Sunday to Saturday with specified cycle.
DAY A gun is diagnosed at the first time after specified days passed from the last day.
HOUR For example, if diagnosis time is 7:00 and the cycle is 8 hours, it diagnoses a gun at first time
after 7:00, 15:00 and 23:00.

Consecutive number
To avoid accidental alarm, they can specify a number of consecutive diagnosis measurements which must
be over the limit before alarm.

24.3.2 Diagnosis Status Screen

Step
1. Press [MENU] key.
2. Select [Status] Æ [Gun diag]
3. Select [Servogun diagnosis] on the screen.

History
Press F2[HIST] and the chart of summary of data is shown in chart menu.
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Gun No
Press F3[GUN] and select the gun number which is displayed on the screen.

Chart screen for detailed data

Move cursor at each record and press F4[CHART], the chart of detailed data is shown in chart menu.

Save the records

Press F5[SAVE] and all records are saved in default device set in file menu. They can create charts with
Excel.

Saved files are followings. ( n : Gun number )

File name Description
SGDIAn01.DT～SGDIAn05.DT Last 5 records are saved.
SGDIAn11.DT～SGDIAn19.DT Historical records are saved.
SGDIAGn.DT The summary, time, date and results for all saved records are written.

Save all records in external device

If $SGDIAGCFG.$REC_DEVICE > 0, all detailed data and summary data is recorded to the device
defined in $DEVICE each time.

File name of detailed data are as below

SGDIAnaabbcceeee.DT
(n: gun_num, aabbcc: Date, eeee: Time)

Reset the records

Press F-> key and F4[RESET], then all detail records except summary are cleared after prompt.

If Bit0(1) of $SGDIAGCFG.$AUTORESET is on, it will reset data at next diagnosis and then bit0 turns
off.
If Bit1(2) of $SGDIAGCFG.$AUTORESET is on, it will reset data after auto tuning.

Clear the records

Press NEXT key and F5[CLEAR], then all records are cleared after prompt.

24.3.3 Chart Menu

When F2[HIST] or F4[CHART] is selected in Servogun Diagnosis status menu, following screen appears
and transition of each value is shown graphically.

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Limit values of disturbance torque during gun closing motion are also displayed.

24.3.4 Alarm
If some disturbance torque check is valid and it excesses the tolerance at diagnosis, this function
following warns it with followings.

DO
Specified DO turns on at alarm, It turns off when specified DI is on.

Warning
Warning is posted with following message.

Item Description
SVGN-223Max disturbance torque excess (Gun: i) Status of max disturbance torque is NG.
SVGN-224Average disturbance torque excess (Gun: i) Status of average disturbance torque is NG.
SVGN-225Min disturbance torque excess (Gun: i) Status of min disturbance torque is NG.

24.4 SYSTEM VARIABLE

In this section, it describes system variables related to servogun diagnosis function.

$SGDIAGn.$SETUP(n:Gun number)
Item Default Description
value
For one cycle motion
i = 1 : closing motion
i = 2 : pressing
i = 3 : opening motion
$AVE_CHKi FALSE Enable / Disable average disturbance torque check
$AVE_LMTi 0 Tolerance value from base value for alarm
$AVE_BASEi 0 Base value of average disturbance torque
$MAX_CHKi FALSE Enable / Disable maximum disturbance torque check
$MAX_LMTi 0 Tolerance value from base value for alarm
$MAX_BASEi 0 Base value of maximum disturbance torque
$MIN_CHKi FALSE Enable / Disable minimum disturbance torque check
$MIN_LMTi 0 Tolerance value from base value for alarm
$MIN_BASEi 0 Base value of minimum disturbance torque
$STRT_CNTi 0 First count for checking disturbance torque
$END_CNTi 0 Last count for checking disturbance torque
For all motion in program
$PRG_MAXCHK FALSE Enable / Disable maximum disturbance torque check
$PRG_MAXLMT 0 Tolerance value from base value for alarm
$PRG_MAXBASE 0 Base value of maximum disturbance torque
$PRG_MINCHK FALSE Enable / Disable minimum disturbance torque check
$PRG_MINLMT 0 Tolerance value from base value for alarm
$PRG_MINBASE 0 Base value of minimum disturbance torque
Others
$COUNT_LOCK 2 Change the span of disturbance torque check for each motion in the chart
as following.0: From first peak to last peak of motor torque in each motion
(exclude the start and the end of motion)1: Specified span by user
($STRT_CNTn to $END_CNTn)2: All of each motion (include the start the
end of motion)"
$PROG_NAME TWZRCLB2 Diagnosis program name
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Item Default Description

value
$ALM_DO_NO 0 Number of Alarm DO
$ALM_DI_NO 0 Number of Alarm clear DI
$CNSCTV_NUM 1 Consecutive number of disturbance excesses for posting alarm
$CONSECTIVED 1 Consecutive number that disturbance has exceeded the limit
$DEF_OVR 100 Override value is checked in monitoring with this value
$OVR_CHECK TRUE Enable / Disable override check
$RETUNED TRUE Turns TRUE at Auto tuning and FALSE at diagnosis
$TUNED_TIME 0 Total number of auto tuning since diagnosis started
$REC_TIME 0 Total recorded number of diagnosis since diagnosis started
$INTVL_NUM 1 Number of interval
$INTVL_TYP 1 Type of interval
$DIAG_HOUR 10 Diagnosis hour/min (hour)
$DIAG_MIN 0 Diagnosis hour/min (minute)
$DIAG_AMPM 1 24 hour or AM/PM indication
$LAST_YEAR 0 Day and time of latest record (year)
$LAST_MON 1 Day and time of latest record (month)
$LAST_DAY 1 Day and time of latest record (day)
$LAST_HOUR 0 Day and time of latest record (hour)
$LAST_MIN 0 Day and time of latest record (minute)

$SGDIAGn(n:Gun number)
Item Default Description
value
$MON_START 0 Monitoring the gun starts if this value > 0
$DIAG_START 0 Output the record and diagnose about the monitored gun if this value > 0

$SGDIAGCFG
Item Default Description
value
$REC_DEVICE 0 Output the detailed data for external device if this value > 0
$AUTORESET 0 Automatically resets the record if following bit is onbit0(1): At the recording
of next time(automatically turns off after auto reset)bit1(2): At auto tuning
$REC_SIZE 400 Maximum number of one record (Unit: 8msec)
$CUSTOM 0 The condition about checking the torque varies if following bit is on.bit0(1):
Display servogun diagnosis setup menu with expansion.bit1(2): Not only
increase of average disturbance torque , but also decrease is checked
$CHK_MAINPRG 3 Check the status of diagnosis program if following bit is on.(bit1- 3 is valid if
a sub program is diagnosis program)bit0(1): Check the diagnosis program
starts from line 1.bit1(2): If Only closing motion has finished during
diagnosis task runs, diagnosis starts after the main program
finishes.bit2(4): Diagnosis starts when the main program finishes.bit3(8): If
diagnosis task runs for another gun, diagnosis of itself starts after the main
program for another gun finishes.

24.5 PRESSURE CHECK FUNCTION

24.5.1 Overview
This function provides pressure estimation and compensation (pressure calibration adjustment) based on
the diagnosis.

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NOTE
This function is an option to Servogun Diagnosis (A05B-2***-J950). If you want to
use this function, please order Pressure Check (A05B-2***-J948) with Servogun
Diagnosis (A05B-2***-J950).

NOTE
This function estimates pressure based on position of servogun axis. So if servogun
has large friction, it will be low accuracy for estimated pressure.

NOTE
This function estimates pressure based on position of servogun axis. So if servogun
has crack or some damage, estimated pressure will be incorrect. Please confirm
servogun if estimated pressure is large different from original pressure. You can
post warning if estimated pressure is large different from original pressure by
enabling pressure check on setup screen.

NOTE
Servogun Diagnosis (A05B-2***-J950) can detect symptom for incorrect estimation
like increase of mechanical friction by using torque check. Please refer to “24.1
OVERVIEW” ~ “24.4 SYSTEM VARIABLE” for more details.

24.5.2 Pressure Check/Adjustment Procedure

24.5.2.1 Pressure Check Calibration
You should complete pressure check calibration previously to perform pressure check/adjustment. Please
perform either method of the following two and complete pressure check calibration.
1. Perform pressure check calibration from pressure calibration screen:
You can perform pressure check calibration after completing pressure calibration. If you don’t
perform pressure check calibration at completing pressure calibration, please perform pressure check
calibration in accordance with the following procedure.
2. Perform pressure check calibration by calling KAREL program:
Please create a TP program which calls KAREL program SGPRSCHK as below and perform it.
Argument for SGPRSCHK is gun number. Please specify 2 if you perform pressure check calibration
with servogun whose gun number is 2.

TEST
1/1
1: CALL SGPRSCHK(1)
[END]

POINT SPOT TOUCHUP >

WARNING
The servogun axis moves during pressure check calibration. Note the following.
- Remove force/pressure gage
- Reset Faults
- Disable STEP mode
- Set override to 100%
- Set AUTO or T2 mode
- (T2 mode) Don’t release both of dead man switch and shift key
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NOTE
The following warnings are posted during pressure check calibration.
SVGN-413 Pressure Check Init Start
SVGN-414 Pressure Check Init Complete

NOTE
SGPRSCHK after completing pressure check calibration perform pressure
check/adjustment. If you want to re-perform pressure check calibration, press F9
“CLEAR” or F10 “RESET” on status screen.

NOTE
If you change pressure calibration value after completing pressure check
calibration, you have to re-perform pressure check calibration. Please perform
pressure check calibration after changing pressure calibration value.

24.5.2.2 Pressure Check

You can perform pressure check by calling a program for diagnosis after completing pressure check
calibration. Please create a TP program which calls KAREL program SGPRSCHK as below and perform
it. The first parameter is gun number. Please specify 2 if you want to perform pressure check with
servogun whose gun number is 2.
If pressure check completes without any problem, you can see pressure errors (which is deviation from
values at pressure check calibration) on status screen. For more details on pressure check result, please
refer to “24.5.4 Status Screen”.

TEST
1/1
1: CALL SGPRSCHK(1)
[END]

POINT SPOT TOUCHUP >

WARNING
The servogun axis moves during pressure check. Note the following.
- Remove force/pressure gage
- Reset Faults
- Disable STEP mode
- Set override to 100%
- Set AUTO or T2 mode
- (T2 mode) Don’t release both of dead man switch and shift key

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NOTE
Pressures for diagnosis are values at pressure calibration result. If the following is
pressure calibration result, pressures for diagnosis are 1000N, 2000N, 3000N and
4000N.

SETUP Servogun
1/5
Pressure Calibration
Equipment number:1 Gun: 1

Calibration Status: COMP

Point Torque Speed Pressure

1 5.0% 25mm/sec 1000.0 N
2 10.0% 50mm/sec 2000.0 N
3 15.0% 75mm/sec 3000.0 N
4 20.0% 100mm/sec 4000.0 N

[ TYPE ] END COMP INCOMP

NOTE
Pressure check is not performed for pressures which is less than
$SGDIAG#.$SETUP.$PRSCHK_LOW (pressure unit : kgf). The default value is
100kgf, so please change $SGDIAG#.$SETUP.$PRSCHK_LOW if you want to
perform pressure check for pressures which is less than 100kgf.

You can post “SVGN-415 Pressure Check Tolerance Exceed” and turn on specified DO by enabling
“Pressure Check” on setup screen. For more details, please refer to “24.5.3 Setup Screen”.

NOTE
This function estimates pressure based on position of servogun axis. So if servogun
has crack or some damage, estimated pressure will be incorrect. You can detect
crack or some damage for servogun by using pressure check alarm (SVGN-415).

24.5.2.3 Pressure Adjustment

Pressure torque is automatically adjusted at pressuring after pressure check by enabling “Pressure Auto
Adjust” on setup screen. Generally, pressure error becomes compensation value. But if pressure error
exceeds “Pressure Adjust Tol”, “SVGN-416 Pressure Adjustment Tol Exceed” occurs and compensation
value is clamped to “Pressure Adjust Tol” value. For more details, please refer to “24.5.3 Setup Screen”.

24.5.3 Setup Screen

Please display setup screen by the following procedure.
1. Press MENU key
2. Select “SETUP” -> “Servo Gun” -> “General Setup”
3. Select “Servogun diagnosis”
4. Select “Pressure check/adjust”

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SETUP Servo Gun Diagnosis
PRESSURE CHECK / EQ:1 Gun:1 1/9

Pressure Check: ENABLE

Pressure Check Tol: 10%
Pressure Check Alarm: DO[ 0]
Consective number: 1times
Pressure Auto Adjust: ENABLE
Pressure Adjust Tol: 5%
Pressure Adjust Alarm: DO[ 0]
Alarm Clear: DI[ 0]
Override Check Severity: ERROR

[ TYPE ] EQUIP GUN ENABLE DISABLE

Configurations
Item Description
Pressure Check If this item is enabled, “SVGN-415 Pressure Check Tolerance Exceed”
occurs and specified DO becomes ON when pressure error exceeds
Pressure Check Tol.
NOTE: This function estimates pressure based on servogun axis position.
So if servogun has crack or some damage, estimated pressure will be
incorrect. You can detect crack or some damage for servogun by using this
item.
Pressure Check Tol Specify a tolerance for pressure check.
“SVGN-415 Pressure Check Tolerance Exceed” occurs and specified DO
becomes ON if pressure error exceeds the specified value.
You can choice unit for tolerance, “%” or “kgf/lbf/nwt”(depending on current
force unit). The followings show how to calculate pressure error.
case “%”:
error [%] = (diag pressure – base pressure) / (base pressure)
case “kgf/lbf/nwt”:
error [kgf/lbf/nwt] = diag pressure – base pressure
NOTE: The probability of occurrence for SVGN-415 will increase if you set
“%” and low pressure is diagnosed.
Pressure Check Alarm You can turn on a specified DO when pressure error exceeds Pressure
Check Tol. If you specify 0, any DO does not become ON. If Alarm Clear
signal is ON, the specified DO becomes OFF.
Consecutive number You can specify a number of consecutive pressure check exceeding that
must be over the limit before alarm. This is for avoiding accidental alarm.
Pressure Auto Adjust Enable/Disable pressure auto adjustment.
If pressure auto adjustment is enabled, pressure torque is automatically
adjusted at pressuring after pressure check. Generally, pressure error
becomes compensation value. But if pressure error exceeds “Pressure
Adjust Tol”, compensation value is clamped to “Pressure Adjust Tol” value.
Pressure Adjust Tol Specify a tolerance for pressure auto adjustment.
“SVGN-416 Pressure Adjustment Tol Exceed” occurs and specified DO
becomes ON if pressure error exceeds the specified value.
You can choice unit for tolerance, “%” or “kgf/lbf/nwt”(depending on current
force unit). The followings show how to calculate pressure error.
case “%”:
error [%] = (diag pressure – base pressure) / (base pressure)
case “kgf/lbf/nwt”:
error [kgf/lbf/nwt] = diag pressure – base pressure
NOTE: The probability of occurrence for SVGN-416 will increase if you set
“%” and low pressure is diagnosed.
Pressure Adjust Alarm You can turn on a specified DO when pressure error exceeds Pressure
Adjust Tol. If you specify 0, any DO does not become ON. If Alarm Clear
signal is ON, the specified DO becomes OFF.
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Alarm Clear Clear the above two DO for alarm. If you specify 0, you can’t clear DO.
Override Check Severity Specify behavior when override is not 100%.
ERROR: alarm occurs, and pressure check stops
WARN: warninig occurs, and pressure check does not stop
NONE: alarm/warning does not occur, and pressure check does not stop
NOTE: override affects diagnosis accuracy. Please perform pressure check
with override 100%.

Function keys
Item Description
F2 “EQUIP” Switch to a specified equipment
F3 “GUN” Switch to a specified gun

24.5.4 Status Screen

24.5.4.1 General Status Screen

Please display general status screen by the following procedure.
1. Press MENU key
2. Select “-- NEXT --“ -> “STATUS” -> “Gun Diag”
3. Select “Pressure check/adjust”

Servogun diagnosis
Pressure check/adjust 1/15
Gun number: 1

Last 5 Diagnosis Records

Time/Date Times MaxErr[%]
1 09/25 10:27 10 10.2 <*DETAIL*>
2 09/24 19:09 9 2.2 <* DETAIL *>
3 09/22 10:56 8 2.2 <* DETAIL *>
4 09/21 10:44 7 2.3 <* DETAIL *>
5 09/20 10:30 6 1.4 <* DETAIL *>

Historical Records - Summary

Time/Date Times MaxErr[%]
10 09/14 10:30 1 1.0 <* DETAIL *>
9 09/15 10:44 2 1.0 <* DETAIL *>
8 09/17 10:56 3 1.0 <* DETAIL *>
7 09/18 19:09 4 1.4 <* DETAIL *>
6 09/19 10:27 5 1.3 <* DETAIL *>
5 09/20 10:30 6 1.4 <* DETAIL *>
4 09/21 10:44 7 2.3 <* DETAIL *>
3 09/22 10:56 8 2.2 <* DETAIL *>
2 09/24 19:09 9 2.2 <* DETAIL *>
1 09/25 10:27 10 10.2 <* DETAIL *>

[ TYPE ] HIST GUN SAVE

GUN CLEAR RESET

Displayed Items
Item Description
Time/Date Time and Date the gun is diagnosed
Times Total times the gun is diagnosed
MaxErr Max value of pressure error for the diagnosis.
For more details on pressure error, move cursor on “<* DETAIL *>” and
press ENTER key. Detail status screen will be displayed.

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Function keys
Item Description
F2 “EQUIP” Switch to a specified equipment
F3, F8 “GUN” Switch to a specified gun
F5 “SAVE” Save diagnosis records to current specified device.
F9 “CLEAR” Clear all diagnosis records.
Summary of records is not cleared.
And clear pressure check calibration data. So pressure check calibration is
performed when you call SGPRSCHK after this operation.
F10 “RESET” Clear all diagnosis records.
Summary of records is cleared.
And clear pressure check calibration data. So pressure check calibration is
performed when you call SGPRSCHK after this operation.

Last 5 and historical (extracted up to now) diagnosis records are displayed on status screen.
Please refer to “24.2.5.1 The details” for more details on historical records.

24.5.4.2 Detail Status Screen

You can display details status screen by the following procedure.
1. Display general status screen
2. Move cursor on “<* DETAIL *>” of the item you want to display
3. Press ENTER key and the following screen will be displayed
Servogun diagnosis
Pressure check/adjust(detail) 1/10
Gun number: 1
Time/Date: 09/25 10:27
Times: 2
Max Error[%]: 10.2
Base[nwt] Diag[N] Err[ % ] CHK ADJ
1 1004.2 1003.1 1.1 OK OK
2 2002.7 2000.1 2.6 OK OK
3 3000.2 2988.2 12.0 OK OK
4 3998.0 4056.0 -58.0 OK OK
5 5004.2 5263.1 -259.9 OK NG
6 6000.0 5390.0 610.0 NG NG
7 0.0 0.0 0.0 ** **
8 0.0 0.0 0.0 ** **
9 0.0 0.0 0.0 ** **
10 0.0 0.0 0.0 ** **

[ TYPE ] UNIT >

Displayed Items
Item Description
Time/Date Time and Date the gun is diagnosed
Times Total times the gun is diagnosed
MaxErr Max value of pressure error for the diagnosis.
Base Pressure values at pressure check calibration.
These values are determined from pressure calibration.
Diag Estimated pressure values by pressure check (diagnosis).
Err = Base value – Diag value
You can change unit of pressure error by F3 “UNIT”
CHK OK : pressure error does not exceed pressure check tol.
NG : pressure error exceeds pressure check tol.
ADJ OK : pressure error does not exceed pressure adjust tol.
NG : pressure error exceeds pressure adjust tol.

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Function keys
Item Description
F3 “UNIT” Change pressure error unit

24.5.4.3 History Screen

You can see max error history with graphical view by pressing F2 “HIST” on general status screen. Red
lines are displayed if pressure check / adjustment are enabled.

24.5.5 Log File

Summary/detail of record will be saved to selected device if F5 “SAVE” is pressed on general status
screen. The file can be browsed on PC and so on.

24.5.5.1 Summary of Record

Summary of all records is saved.
The record file name is SGDGPRSn.DT. (n : gun number)

Record Format
Number Date Prs Check Prs Adjust Max Error[%] Max Error[kgf]
1 06/24 10:30 OK OK 3.74857E-01 1.14674E+00
2 06/25 10:31 OK OK 3.26709E-01 9.99452E-01
3 06/26 10:30 OK OK 4.70431E-01 1.43912E+00
4 06/27 10:30 OK OK 6.88984E-01 2.10771E+00
5 06/28 10:31 OK OK 9.09005E-01 2.78078E+00
6 06/29 10:30 OK OK 6.83054E-01 2.08956E+00

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B-83264EN/03 24.SERVOGUN DIAGNOSIS FUNCTION
Record Item
Item Description
Number Total times the gun is diagnosed.
Date Time and Date the gun is diagnosed.
Prs Check OK : pressure error does not exceed pressure check tol.
NG : pressure error exceeds pressure check tol.
Prs Adjust OK : pressure error does not exceed pressure adjust tol.
NG : pressure error exceeds pressure adjust tol.
Max error [%] Max value of pressure error [%] for the diagnosis.
Max error [kgf] Max value of pressure error [kgf] for the diagnosis.

24.5.5.2 Detail of Record

Detail of record is saved as follow format.
The record file names are as follow. (n : gun number)
- SGDGPn01.DT ~ SGDGPn05.DT : Last 5 diagnosis records
- SGDGPn11.DT ~ SGDGPn20.DT : Historical records displayed on status screen

Record Format
Time/date 06/29 10:30
Recorded times 6
Max error [%] 1.27021E+00
Press check tolerance [%] 1.00000E+01
Press adjust tolerance [%] 5.00000E+00
Spring rate(approx.)[kgf/mm] 2.04291E+02
Number Trq Err[kgf] Err[%] Chk Adj Diag Pos Diag Prs Base Pos Base Prs SoloUpdt
0 1.0 -- -- -- -- 0.01 -- 0.01 --
1 5.0 1.1 0.1 OK OK 1.02 1003.1 1.03 1004.2
2 10.0 2.6 0.1 OK OK 2.02 2000.1 2.03 2002.7
3 15.0 12.0 0.4 OK OK 3.01 2988.2 3.04 3000.2
4 20.0 58.0 1.5 OK OK 4.06 4056.0 4.00 3998.0
5 -- -- -- -- -- -- -- -- --
6 -- -- -- -- -- -- -- -- --
7 -- -- -- -- -- -- -- -- --
8 -- -- -- -- -- -- -- -- --
9 -- -- -- -- -- -- -- -- --
10 -- -- -- -- -- -- -- -- --

Record Item
Item Description
Time/date Time and Date the gun is diagnosed.
Recorded Times Total times the gun is diagnosed.
Max error [%] Max value of pressure error for the diagnosis.
Spring rate(approx.)[kgf/mm] Estimated spring rate (approximate value)
Press check tolerance Tolerance for pressure check
Press adjust tolerance Tolerance for pressure auto adjustment
Number Point number (corresponding to pressure calibration)
Trq Torques at diagnosis
Err [kgf] Pressure error [kgf]
Err [%] Pressure error [%]
Chk OK : pressure error does not exceed pressure check tol.
NG : pressure error exceeds pressure check tol.
Adj OK : pressure error does not exceed pressure adjust tol.
NG : pressure error exceeds pressure adjust tol.
Diag Pos Pressure position at diagnosis

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24.SERVOGUN DIAGNOSIS FUNCTION B-83264EN/03

Item Description
Diag Prs Estimated pressure value at diagnosis
Base Pos Pressure position at pressure check calibration
Base Prs Estimated pressure value at pressure check calibration
SoloUpdt “*” shows which pressure is updated when pressure check is performed
individually.

24.5.5.3 Automatic Save to External Device

Detail of record is saved to selected device every diagnoses if $SGDIAGCFG.$REC_DEVICE > 0.
The record file name is SGDGPn_aabbccdd.DT. (n : gun number, aa : month, bb : day, cc : hour, dd :
minute)

24.5.6 Pressure Check/Adjustment Individually

Normally, diagnosis is performed for all pressures corresponding to pressure calibration.
But it might take time and it is difficult to perform it with robot motion.
This section describes how to diagnose for specified pressure.

NOTE
Pressures that can be specified are values at pressure calibration result. If the
following is pressure calibration result, you can specify 1000N(point number 1),
2000N(point number 2), 3000N(point number 3) and 4000N(point number 4).

SETUP Servogun
1/5
Pressure Calibration
Equipment number:1 Gun: 1

Calibration Status: COMP

Point Torque Speed Pressure

1 5.0% 25mm/sec 1000.0 N
2 10.0% 50mm/sec 2000.0 N
3 15.0% 75mm/sec 3000.0 N
4 20.0% 100mm/sec 4000.0 N

[ TYPE ] END COMP INCOMP

24.5.6.1 Pressure Check Procedure

The first parameter for SGPRSCHK is gun number and the second parameter for SGPRSCHK is point
number (on pressure calibration). The following TP program will diagnose gun1’s point number 3 (if the
above is pressure calibration result, it’s pressure is 3000N).

TEST
1/1
1: CALL SGPRSCHK(1, 3)
[END]

POINT SPOT TOUCHUP >

Pressure for diagnosis will be changed every SGPRSCHK by specifying 0 for point number. For example,
if the above is pressure calibration, point number will be changed 1 -> 2 -> 3 -> 4 -> 1 -> … (pressure
will be changed 1000N -> 2000N -> 3000N -> 4000N -> 1000N -> …).

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TEST
1/1
1: CALL SGPRSCHK(1, 0)
[END]

POINT SPOT TOUCHUP >

24.5.6.2 Pressure Check Result / Status Screen

Pressure check result will be overwritten to the previous result.
“ * “ shows which pressure check result is updated by displaying detail status screen.

Servogun diagnosis
Pressure check/adjust(detail) 1/10
Gun number: 1
Time/Date: 09/25 10:27
Times: 2
Max Error[%]: 10.2
Base[nwt] Diag[N] Err[ % ] CHK ADJ
1 1004.2 1003.1 1.1 OK OK
2 2002.7 2000.1 2.6 OK OK
3 3000.2 2988.2 12.0 OK OK
4 3998.0 4056.0 -58.0 OK OK
*5 5004.2 5263.1 -259.9 OK NG
6 6000.0 5390.0 610.0 NG NG
7 0.0 0.0 0.0 ** **
8 0.0 0.0 0.0 ** **
9 0.0 0.0 0.0 ** **
10 0.0 0.0 0.0 ** **

[ TYPE ] UNIT >

24.5.6.3 Pressure Check by Multi Task

During performing pressure check individually, only gun axis moves and it might not take a long time.
Using multi task, pressure check can be executed together robot motion. For example, during robot
returns to home position after tip dress, pressure check can be executed. Please refer to the following
sample.

TEST.TP : Call a program that robot moves to home position (GO_HOME) after running diagnosis
program (DO_PRSCHK).
TEST
1/2
1: RUN DO_PRSCHK
2: CALL GO_HOME
[ｵﾜﾘ]

POINT SPOT TOUCHUP >

DO_PRSCHK.TP : Call diagnosis (SGPRSCHK).

DO_PRSCHK
1/2
1: CALL SGPRSCHK(1, 0)
2: R[1:DIAG END] = 1
[END]

POINT SPOT TOUCHUP >

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24.SERVOGUN DIAGNOSIS FUNCTION B-83264EN/03

GO_HOME : Robot moves to home position.

GO_HOME
1/2
1: L P[1] 1500mm/s FINE
2: WAIT R[1:DIAG END] = 1
[END]

POINT SPOT TOUCHUP >

WARNING
In case using multi task, do not specify group mask of gun to robot motion program
(GO_HOME.TP in the above sample).

WARNING
During pressure check using multi task, do not change servo gun posture largely
with robot motion. Large changing posture would cause incorrect pressure
check/adjustment.

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B-83264EN/03 25.EARLY WELD INIT FUNCTION

25 EARLY WELD INIT FUNCTION

25.1 OVERVIEW
In SPOT welding sequence, weld init signal is output to weld timer when gun reaches target pressure.
Ideally, weld current flows immediately. However, communication delay and/or internal process time of
weld timer can cause current flow to lag (current flows some time after target pressure is reached).
Early weld init function asserts weld init signal prior to gun reaching target pressure, to compensate for
this delay. Therefore, early weld init can reduce cycle time.

Pressure reached Pressure reached

Weld delay time

Pressure Pressure

Early output
Weld init Weld init

Weld current Weld current

Weld starts Weld starts

Early weld init OFF Early weld init ON

25.2 WELD DELAY TIME MEASUREMENT

Weld delay time is a configuration (input) parameter for this function. Measure weld delay time with a
sensor that can observe weld current and pressure simultaneously.

Pressure reaches

Weld delay time

Pressure

Weld current

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25.3 EARLY WELDING CALIBRATION

Execute early welding calibration to use this function.

NOTE
Change $SGSYSCFG.$SHO_ELYWLD to TRUE, prior to this operation. No
need re-power controller.

Procedure for early welding calibration.

1. Press MENU.
2. Select UTILITIES.
3. Press F1, [TYPE] and select SG Gun setup. You will see a screen similar to the following.

UTILS Gun Setup

EQ: 1 Gun:1 1/1
1.Set gun motion sign: COMP
2.Set Gun specs, master gun COMP
Tip Displacement: 10.000(mm/rev)
Open stroke limit: -55.0(mm)
Close stroke limit: 20.0(mm)
3.Auto Tune: COMP
4.Pressure Compensation Setup: <*DETAIL*>
5.Servo gun optional Calibration;
Thickness Check Cal.: COMP
Early Welding Cal.: INCOMP

[ TYPE ] EQUIP EXEC RESTART

4. Complete Steps 1-3 of the Servo gun Gun setup utility.

5. Complete Pressure Calibration.
6. Select the appropriate equipment and gun number using the F-keys.
7. Move the cursor to select “Servo gun optional calibration”.

NOTE
Both thickness calibration and early welding calibration execute during servo gun
optional calibration.
Please refer to chapter 15 for thickness check calibration.
Note that early welding calibration can not execute without thickness check
calibration.

WARNING
Before calibration starts, the following items must be confirmed:
• The gun tips must be accurately mastered. Use Tip Wear Compensation
Setup program to achieve this (mastering error leads to error
in part thickness measurement)
• Pressure Calibration must be complete.
• Robot may have to be placed in AUTO or T2 and all faults cleared.

NOTE
Accuracy of early weld init depends on accuracy of pressure calibration. For
best accuracy, calibrate pressure at actual pressures used during welding.

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B-83264EN/03 25.EARLY WELD INIT FUNCTION
8. Press Shift + F3 (EXEC) to initiate calibration. The following prompt box may appear when you do
this.

The following calibration

exercises will begin.
- Thickness Check Cal.
- Early welding Cal.
ARE YOU SURE YOU WANT TO DO
THIS?

[YES］ NO

9. Select YES and press enter. The selected gun will open and close 4 times to perform the
calibration. The robot will not move during this process.

25.4 SETUP EARLY WELD INIT FUNCTION

Before using this function, set up parameters in the early weld setup screen.

NOTE
Change $SGSYSCFG.$SHO_ELYWLD to TRUE, prior to this operation. No
need re-power controller.

Procedure to display early welding setup screen

1. Press the MENU key.
2. Select “ SETUP”.
3. Press F1“[TYPE]”, Select “Servo Gun” to display the SERVO GUN SETUP screen.
4. Select “8 General Setup” by placing the cursor on <*DETAIL*> and pressing the ENTER key).
Then move to cursor, and press ENTER key on “Early Welding Setup”

SETUP SERVO GUN SETUP SERVO GUN

GENERAL / EQ:1 Gun:1 1/16 EARLY WELD SETUP / EQ:1 Gun:1 1/2
1 Tip Wear Comp DISABLE¥
2 Gun Sag Compensation DISABLE Weld Controller Spec.
3 Close Direction(Gun): PLUS No.: 1
4 Close Direction(Robot): UT: 1 [+Z ] Type: DIGITAL
5 Max Motor Torque(%): 100.0
6 Max Pressure(nwt): 4000.0 1 Early Weld Init: DISABLE
Max Gun Torque(%): 20.9 Early Welding Calibration: INCOMP
7 Tip stick detect distance(mm): 5 2 Early Weld Time(ms): 0
8 Tip Wear Detection: <*DETAIL*>
9 Pressure Cal: INCOMP <*DETAIL*> [TYPE] EQUIP GUN
10 Tip Wear Standrd: INCOMP <*DETAIL*>
11 Weight compensation: <*DETAIL*>
12 Thickness check: <*DETAIL*>
13 Gun Stroke limit: <*DETAIL*>
14 OverTorque protection: <*DETAIL*>
15 Gun Teach Setup: <*DETAIL*>
16 Early Welding Setup: <*DETAIL*>

[TYPE] EQUIP GUN

5. Refer to the following table for setup items.

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25.EARLY WELD INIT FUNCTION B-83264EN/03

Item Description
Weld Controller Spec. No. This parameter indicates weld timer number assigned to selected gun.
This number can not be changed in this screen. Assign weld timer number in
SPOT configuration screen.
Type This parameter indicates weld timer type.
Weld timer type can not be changed in this screen. Change weld timer type in
SPOT configuration screen.
Early Weld Init Specify whether early weld init is enabled or disabled.
Default : DISABLE DISABLE : Early weld init is not output with early weld time.
Note that early weld init can not be enabled if early welding calibration is
incomplete.
Early Welding Calibration This parameter indicates status of early welding calibration. This parameter can
Default : INCOMP not be changed in this screen.
Early Weld Time(ms) This parameter specifies early weld time.
Default : 0ms

NOTE
Early Weld init(output) is controlled for ITP time. If early welding time is not a
multiple of ITP time, the early welding time is rounded up to multiple of ITP time.
Therefore, specified early welding time would not be always realized.

NOTE
Maximum early weld time = duration between gun close detection and gun
reaching pressure. If early weld time value exceeds this duration, the following
alarm is posted.
SVGN-304 Invalid early welding time
Reduce early weld time value if this alarm occurs.

25.5 EARLY WELD INIT FUNCTION OPERATION

Procedure to use early weld init function
1. Enable early weld init via early weld setup screen.
2. Specify early weld time (weld delay time that is measured beforehand).
3. Execute SPOT instruction or manual weld.

WARNING
Setup confirmation is strongly recommended.
a. Use a sensor that observes both weld current and pressure to ensure
that timing of weld current is correct.
b. Confirm weld quality.

WARNING
Early weld init function can work when override is 100%. When override is less
than 100%, even if this function is enabled, early welding does not work.

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B-83264EN/03 25.EARLY WELD INIT FUNCTION

NOTE
If pause occurs during pressure motion (and early weld init is enabled) , early
weld init is skipped at resume (for this spot). The following warning message
informs user of this.
SVGN-300 Early welding OFF at resuming
However, early weld init is enabled (again) at the next SPOT instruction or if
BWD is executed, prior to resuming this spot.

WARNING
If the following alarm is posted, weld init signal was asserted but pressure was
not reached.
SVGN-302 Welding in pressure shortage
If this alarm is posted:
1. confirm that weld quality of the SPOT is ok
2. correct root cause via cause/remedy of SVGN-020 "Pressure shortage”.
If SVGN-302 persists, perform early welding calibration again. Before calibration,
ensure that calibration for pressure used during this spot is ok.
note: this alarm typically does not occur during normal weld condition(pressure >
100kgf), it occurs when gun pressure > 100kgf.

NOTE
In case of dual gun, if early weld init is not enabled for both guns, the following
warning message is posted.
SVGN-303 Gun#: Disabled early welding
(# is gun number that disables early weld init)
When this message is posted, enable or disable early weld init on both guns.

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APPENDIX
 A. GUN CHANGE REFERENCE
POSITION SETUP METHOD
B-83264EN/03 APPENDIX (BATTERY-LESS TYPE)

A GUN CHANGE REFERENCE POSITION

SETUP METHOD (BATTERY-LESS TYPE)
A.1 REFERENCE POSITION SETUP

A.1.1 Reference Position Setup for Calibration Types 3 and 4

♦Reference Position Setup Program
Create the following program to calculate the reference position based upon the sign of the calculated touch
torque.

NOTE
Only the servo gun axis operation group can be used as the operation group of the
program to be used for setting the reference position.
Example) When the servo gun axis operation group is the 2nd group:
The operation group becomes [*,1,*,*,*].

Sample Program Operation Group=[*,1,*,*,*]

1: J P[1:ZERO POS] 10% [Explanation]
positioning 1: Servo gun axis 0 position
(when sign of touch torque is plus) 2: Set the torque at which contact with the gun open limit is
2: SKIP CONDITION $MISC[g].$HPD_TRQ[ga] > 2 *1) detected and its threshold as the skip conditions. Pay
(when sign of touch torque is minus) attention to the sign of the touch torque.
2: SKIP CONDITION $MISC[g].$HPD_TRQ[ga] <-2 *1)
3: J P[2:GUN OPEN END] 1% *2) FINE ACC 100
*3)SKIP, 3: Move gun to open limit. (Jump to LBL[1] if gun open limit
LBL[1],PR[1]=JPOS cannot be detected.)
4: END 4: Normal end
5: LBL[1] 5: Jump to here if gun open limit cannot be detected.
6: UALM[1] 6: Generate user alarm.

NOTE
The above is merely a sample program. Create programs to suit the requirements
of your system.
g: Operation group number of currently attached gun
ga: Axis number of currently attached gun
If the currently attached servo gun axis is taken as the 1st axis of the 2nd group,
then g and ga are as follows: g=2, ga=1

x Program Operation Adjustment Method

Adjust the value at the shaded section in the sample program to adjust program operation.
Operation adjusted here is used as calibration motion that is carried out when attaching the gun.

*1) Touch torque

Increase the value from about ±2, and calculate the value at which erroneous detection of contact
occurs.
The sign of touch torque is the sign that is currently displayed at Touch torque at the Calibration
Setup screen on the right.

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A. GUN CHANGE REFERENCE
POSITION SETUP METHOD
(BATTERY-LESS TYPE) APPENDIX B-83264EN/03

SETUP GUN CHANGE

Gun Change / EQ:1 Gun:1 9/10
1 Comment: [ ]
2 Attach signal: DI[ 1]
3 Identify signal: DI[ 2]
4 Battery: OFF
5 Calibration motion type: [TYPE 4]
Calibration Motion Setup
6 Calibration Speed(%): 100
7 Acc Value: ACC100
8 Position register index: PR[ 1]
9 Touch torque(%): ( + ) 5.000

[ TYPE ] LIST

NOTE
After confirming the sign in this screen, teach it to the program. Do not make a
mistake when entering the sign. If you do so, contact with the open limit may not
be detected.

*2) Program operation speed

To set the same calibration motion that is carried out when attaching the gun, execute this
program at the same override (normally, 100%) as when the attach instruction is executed for the
gun used during actual production. For this reason, reduce the program operation speed so that
contact is made with the open limit at a safe speed even if the program is executed at a high
override.
For added safety, increase the program operation speed value successively from 1%.
*3) Accelerate rate
Decrease the accelerate rate if motion is sluggish even if the program operation speed is 1%.

♦Reference Position Setup

After you have adjusted operation in the program, execute the program to bring the servo gun axis into
contact with the open limit.
Set up the reference position according to the procedure described in Appendix A.2 Quick Mastering
Reference Position Setup with the servo gun contacting the open limit.

♦Gun Change Setup

To set operation in the newly adjusted program to the same motion as calibration motion that is carried out
when attaching the gun, reflect the program operation speed, accelerate rate and touch torque adjustment
values in the gun change setup.

1. Press the MENU key to display the Screen menu.

2. Select 6 SETUP.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select GUN CHANGE. The Gun Change Setup List screen appears.
5. Select the gun to be adjusted from this list, and press F3 DETAIL to display the Gun Change Details
Setup screen.
6. Set the operation speed, accelerate rate and touch torque adjustment values at the shaded sections in
the following screen:

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 A. GUN CHANGE REFERENCE
POSITION SETUP METHOD
B-83264EN/03 APPENDIX (BATTERY-LESS TYPE)

SETUP GUN CHANGE

Gun Change / EQ:1 Gun:1 9/10
1 Comment: [ ]
2 Attach signal: DI[ 1]
3 Identify signal: DI[ 2]
4 Battery: OFF
5 Calibration motion type: [TYPE 4]
Calibration Motion Setup
6 Calibration Speed(%): 1
7 Acc Value: ACC100
8 Position register index: PR[ 1]
9 Touch torque(%): ( + ) 2.000

[ TYPE ] LIST

A.1.2 Reference Position Setup for Calibration Types 5 and 6

♦Provision of Detection Signal
With calibration types 5 and 6, the position where the detection signal is input is taken as the reference
position during quick mastering.
The user must install a limit switch for providing the detection signal capable of assuring the absolute
position of the gun.

♦Reference Position Setup Program

Create the following program to calculate the reference position based upon the sign of the calculated touch
torque.

NOTE
Only the servo gun axis operation group can be used as the operation group of the
program to be used for setting the reference position.
Example) When the servo gun axis operation group is the 2nd group: The
operation group becomes [*,1,*,*,*].

Sample Program Operation Group=[*,1,*,*,*]

[Explanation]
1:J P[1:ZERO POS] 10% FINE 1: Servo gun axis 0 position
2:SKIP CONDITION DI[ 1*1)] =ON 2: Set turning ON of the provided detection signal as the scan
3:J P[2:SWITCH POS] 1% *2) FINE ACC100 condition.
*3)SKIP, 3: Move gun to position where detection signal turns ON. (Jump to
LBL[1],PR[1]=JPOS label[1] if the detection signal does not turn ON.)
4:END 4: Normal end
5:LBL[1] 5: Jump to here if detection signal does not turn ON.
6:UALM[1] 6: Generate user alarm

NOTE
The above is merely a sample program. Create programs to suit the requirements
of your system.

x Program Operation Adjustment Method

Adjust the value at the shaded section in the sample program to adjust program operation.
Operation adjusted here is used as calibration motion that is carried out when attaching the gun.
*1) Detection Signal
Assign the provided detection signal to SDI[ ] or RDI[ ].
*2) Program Operation Speed
To set the same calibration motion that is carried out when attaching the gun, execute this
program at the same override (normally, 100%) as when the attach instruction is executed for the
gun used during actual production. For this reason, reduce the program operation speed so that
the switch will not be broken even if the program is executed at a high override.
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A. GUN CHANGE REFERENCE
POSITION SETUP METHOD
(BATTERY-LESS TYPE) APPENDIX B-83264EN/03

For added safety, increase the program operation speed value successively from 1%.
*3) Accelerate rate
Decrease the accelerate rate if motion is sluggish even if the program operation speed is 1%.

♦Reference Position Setup

After you have adjusted operation in the program, execute the program to stop the servo gun axis at the
position where the detection signal turns ON.
Set up the reference position according to the procedure described in Appendix A.2 Quick Mastering
Reference Position Setup with the servo gun contacting the open limit.

♦Gun Change Setup

To set operation in the newly adjusted program to the same motion as calibration motion that is carried out
when attaching the gun, reflect the program operation speed, accelerate rate and detection signal adjustment
values in the gun change setup.
1. Press the MENU key to display the Screen menu.
2. Select 6 SETUP.
3. Press F1 TYPE to display the Screen Selection menu.
4. Select GUN CHANGE. The Gun Change Setup List screen appears.
5. Select the gun to be adjusted from this list, and press F3 DETAIL to display the Gun Change
Details Setup screen.
6. Set the operation speed, accelerate rate and detection signal adjustment values at the shaded
sections in the following screen:

SETUP GUN CHANGE

Gun Change / EQ:1 Gun:1 9/10
1 Comment: [ ]
2 Attach signal: DI[ 1]
3 Identify signal: DI[ 2]
4 Battery: OFF
5 Calibration motion type: [TYPE 6]
Calibration Motion Setup
6 Calibration Speed(%): 1
7 Acc Value: ACC100
8 Position register index: PR[ 1]
9 Detect signal: DI [ 0]

[ TYPE ] LIST

A.2 QUICK MASTERING REFERENCE POSITION SETUP

SYSTEM Master/Cal G2 JOINT 10% _

TORQUE = [ON ]

1 FIXTURE POSITION MASTER

2 ZERO POSITON MASTER
3 QUICK MASTER Be sure to set the group of
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF Servo gun axis.
6 CALIBRATE

Press ‘ENTER’ or number key to select

Set quick master ref? [NO]

[ TYPE ] YES NO

Calibration (quick mastering data) is automatically carried out when the servo gun is changed. However,
the reference points must be set to each of the guns to enable automatic calibration. The reference points are
set with the robot in a cold start state.
Follow the procedure below to set the reference points:

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 A. GUN CHANGE REFERENCE
POSITION SETUP METHOD
B-83264EN/03 APPENDIX (BATTERY-LESS TYPE)

1. Press the AUX key to select 3 CHANGE GROUP. Change the operation group to the desired servo
gun group (e.g. 2nd group).
2. Press the MENU key to display the Screen menu.
3. Press 0 NEXT and 6 SYSTEM.
4. Press F1 TYPE to display the Screen Selection menu.
5. If CALIBRATE is not displayed in the menu, select Variables to display the System Variables screen.
Set the $MASTER_ENB system variable to "1".
6. Select CALIBRATE at 4. to display the Calibration screen.
7. Select 5 SET QUICK MASTER REFERENCE and F4 YES.
8. The message "Quick master reference point is set." is displayed. This indicates that setting of the
reference point is completed.

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B.TROUBLESHOOTING (GUN CHANGE) APPENDIX B-83264EN/03

B TROUBLESHOOTING (GUN CHANGE)

B.1 THE ATTACH INSTRUCTION IS EXECUTED WHEN THE
GUN IS NOT ATTACHED.
xPhenomenon
The gun is not actually attached. So, a communications alarm such as "SRVO-068 DTERR alarm" occurs
on the Pulsecoder. Correct this by Remedy 1 or Remedy 2 below according to the present conditions.

xRemedy 1
1. Turn the machine lock ON in the servo gun operation group (normally, group 2) in the Test Cycle
screen.
2. Move the robot by manual feed so that the robot and gun are physically attached.
3. Turn the controller OFF then ON again.

Battery-less gun (calibration motion types 1, 2)

4. The gun pulse values and mastering data are lost. So, first move the gun by manual feed to cancel the
"SRVO-075 Pulse not established" alarm.
5. Then, carry out gun 0 position mastering and calibration manually.

Battery-less gun (calibration motion types 3, 4, 5, 6)

6. The gun pulse values and mastering data are lost. So, move the gun by manual feed to cancel the
"SRVO-075 Pulse not established" alarm.
7. Carry out gun 0 position mastering and calibration manually. The gun 0 position may be an
approximate position.
8. Execute the detach instruction to temporarily detach the gun. Also, physically detach the gun from the
robot. Otherwise, the gun will not be calibrated at the next attach operation.
9. Execute the attach instruction again to attach the gun. Calibration this time is carried out at the
reference position to restore the position.

Battery mounted gun

10. The gun is attached and positioned, so it can be used as it is.

xRemedy 2
1. Directly change the system variable to detach the gun. To do this, set the following system variable to
"0":
$SCR_GRP[servo gun operation group No. (normally, 2)].$AXISORDER[all 1 to 9] = 0
2. Turn the controller power OFF then back ON.
3. The robot starts up with the gun in a detached state. Move the robot by manual feed to physically
attach the robot and gun.
4. Execute the attach instruction to attach the gun.
5. The gun can be used as it is after it is attached regardless of the battery type.

B.2 THE ROBOT STOPPED DURING CALIBRATION.

xPhenomenon
This phenomenon occurs only on battery-less guns. NOTE that the phenomenon and remedy vary
according to the preset calibration type.

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B-83264EN/03 APPENDIX B.TROUBLESHOOTING (GUN CHANGE)

Battery-less gun (calibration motion types 1, 2)

The "SVGN-081 Gun mastering data is lost" alarm has occurred.

Battery-less gun (calibration motion types 3, 4, 5, 6)

Alarm has not occurred.

･Remedy
Calibration motion types 1, 2
1. The gun pulse values and mastering data are lost. So, first move the gun by manual feed to cancel the
"SRVO-075 Pulse not established" alarm.
This alarm may not be occurring. If so, skip this step and proceed to step 2.
2. Then, carry out gun 0 position mastering and calibration manually.

Calibration motion types 3, 4, 5, 6

1. Gun operation can be resumed as it is.

B.3 CALIBRATION MOTION FAILED.

xPhenomenon
The "SVGN-089 Calibrate motion is failed" alarm occurred.
This phenomenon occurs only when the calibration motion type is 3, 4, 5 or 6 on a battery-less gun.
This alarm occurs when the touch torque or detection signal conditions are not satisfied during calibration.
In both of the following Remedies 1 and 2, the gun is calibrated again. So, calibration motion will fail again
if the touch torque or detection signal conditions are not satisfied. Before you remedy this phenomenon,
make sure that the touch torque or detection signal conditions are correct.

xRemedy 1
Carry out steps 6 to 9 of G-1 Remedy 1.

xRemedy 2
Same as Remedy 2 of G-1.

B.4 A DIFFERENT GUN FROM THAT SPECIFIED BY THE

ATTACH INSTRUCTION IS ATTACHED.
xPhenomenon
The gun is attached to the robot, but the gun's current position is the wrong value. On a battery-less gun, an
alarm may cause the robot to stop during calibration.

xRemedy
The following describes an example where gun 2 (actually attached gun) is attached to gun 1 (gun No.
taught by the attach instruction).

1. In this state, the gun cannot be detached from the robot by the detach instruction. So, directly change
the system variable to detach the gun. To do this, set the following system variable to "0":

$SCR_GRP[servo gun operation group No. (normally, 2)].$AXISORDER[all 1 to 9] = 0

2. Turn the controller power OFF then back ON.

3. The gun starts up in a detached state.

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B.TROUBLESHOOTING (GUN CHANGE) APPENDIX B-83264EN/03

4. Execute the attach gun[2] instruction to attach gun 2. (In this state, gun 2 should be physically
connected to the robot.)

When gun 2 is a battery-less gun and the calibration motion type is 1 or 2:

If gun 2 is moved when attached by mistake instead of gun 1, gun 2 will move and be at a position
different to when it was detached. So, gun 2 may be calibrated to the wrong position by the attach
instruction executed in step 4 above, resulting is misalignment between its actual and desired positions.
In this case, carry out gun 0 position mastering and calibration manually.

When gun 2 is other than the above:

Gun 2 can be used as it is.

5. Gun 1 can be used as it is by executing the attach instruction to attach the gun.

B.5 THE ATTACHED GUN HAS BEEN DETACHED BY

MISTAKE (WITHOUT USING THE DETACH
INSTRUCTION).
xPhenomenon
The gun is not actually attached. So, a communications alarm such as "SRVO-068 DTERR alarm" occurs
on the Pulsecoder. Correct this by Remedy 1 or Remedy 2 below according to the present conditions.

xRemedy 1
Same as Remedy 1 of B-1

xRemedy 2
Same as Remedy 2 of B-1

B.6 THE GUN AXIS OF A DETACHED GUN HAS MOVED.

xPhenomenon
Battery-less gun (calibration motion types 1, 2):
Misalignment has occurred. Misalignment occurs as a result of calibration at the wrong position when the
gun is attached with the gun axis having moved to a different position. NOTE, however, that misalignment
does not occur when gun axis movement is within the allowable errors indicated below.
The allowable error must fall within the respective following ranges for the direct-acting axis and rotary
axis:

Direct-acting axis: ±(gear ratio/2)mm or less around the detach position

Rotary axis: ±((360/gear ratio)/2)deg or less around the detach position

Other instances:
No problem has occurred.

xRemedy
Battery-less gun (calibration motion types 1, 2):
1. Execute the attach instruction to attach the gun.
2. If misalignment occurs, carry out gun 0 position mastering and calibration manually.

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B-83264EN/03 APPENDIX B.TROUBLESHOOTING (GUN CHANGE)

B.7 THE BATTERY VOLTAGE HAS FALLEN.

xPhenomenon
The "SRVO-065 BLAL" alarm has occurred with the gun in an attached state.

xRemedy
1. Change the battery with the gun attached.
2. The gun can be used as it is.

B.8 THE BATTERY RAN LOW WHILE THE GUN WAS

DETACHED.
xPhenomenon
The "SRVO-062 BZAL" and "SRVO-075 Pulse not established" alarms occurred when the gun was
attached.

xRemedy
When the reference position has not been set:
1. Press F3:RESET_PULSE in the Calibration screen, and select YES.
2. Turn the controller OFF then ON again.
3. Move the gun by manual feed to cancel the "SRVO-075 Pulse not established" alarm.
4. Carry out gun 0 position mastering and calibration manually.

When the reference position has been set:

1. Press F3:RESET_PULSE in the Calibration screen, and select YES.
2. Turn the controller OFF then ON again.
3. Move the gun by manual feed to cancel the "SRVO-075 Pulse not established" alarm.
4. Move the gun by manual feed to the reference position marked by a line marking or alignment mark.
5. Execute 3 QUICK MASTERING in the Calibration screen.

Carry out simple mastering at the reference

position marked by a line marking or alignment
mark.

*1) Touch torque

ncrease the value from about ±2, and calculate the value at which erroneous detection of contact
occurs.
The sign of touch torque is the sign that is currently displayed at Touch torque at the Calibration Setup
screen on the right.

NOTE
After confirming the sign in this screen, teach it to the program. Do not make a
mistake when entering the sign. If you do so, contact with the open limit may not
be detected.

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C.GUN ZERO MASTERING APPENDIX B-83264EN/03

C GUN ZERO MASTERING

C.1 GUN MASTER UTILITY
Use the Gun Master screen to reset BZAL (Battery Zero Alarm), perform Magnet Phase Detection function,
and master gun axes. The following list describes the items on the GUN MASTER screen.
Function Key Description
EQUIP Press this key to change equipment number Note: active group automatically changes at
equipment selection. This key appears only if more than one equipment exists.
BZAL Press this key to reset Battery Zero Alarm (BZAL) for the servo gun axis after loss of
battery power. This key appears only if BZAL condition exists
MASTER Press this key to zero position master the gun with new tips. Please confirm both tips is
new and tips contact before performing MASTER. Tip wear values are reset to 0, when
MASTER completes.
After that, if init setup program of tip wear measurement has not been executed yet,
execute init setup program and then teach position.
After that, if init setup program of tip wear measurement has done, confirm teaching
position of spot welding. If correction of teaching is necessary, perform touchup.
Press this key to execute the Magnet Phase Detection function if the message
MPDT “Execute MPDT(Magnetic Phase Detection)” is displayed. If displayed, the gun
cannot be jogged until the function is performed. The gun will move slightly during
execution so be sure gun tips are free to move. NOTE: this key is displayed only if a non-8
pole motor ( i.e. 4 pole or 6 pole ) motor is selected and MPDT is not done, after BZAL
condition has been cleared.
RECALB Press this key to re-calibrate the master position of the servo gun axis. Existing tip wear
values are maintained. Tips must be touching.
Be sure that tip wear has not changed significantly since the last tip wear measurement.
NOTE: this key is only displayed if tip wear setup is performed.
DGIDX Press NEXT to expose this function key. Press this key to select the correct gun for
mastering when using a dual-gun. Pressing this key will switch between the 1st and 2nd
gun of the dual-gun. The correct gun must be selected before performing the mastering
operation, otherwise the wrong gun will be mastered. This key is only displayed if selected
equipment type is dual gun.
ATMASTR Press NEXT to expose this function key. Press this key with shift key to close the selected
gun automatically and zero position master the gun with new / non-worn tips. Tip wear
values are reset to 0, when ATMASTR completes. If tips are worn and tip wear
measurement is accurate, please use ATRECALB instead of ATMASTR.
After performing ATMASTR operation, refer to choices below to update tip wear values
correctly:
When using 2-step tip wear method, either:
1. Perform a tip wear update (not setup) to quickly and accurately recover the
correct fixed tip offset for spot positions and avoid need for touchup. Note that
gun stroke limits might need adjustment (since these new tips could be different
than the tips used when the stroke limits were originally set) and the tip wear
values may not show zero anymore – because even though tips are new, tip
wear value after update is in reference to original/reference tips.
2. Or, to avoid any issue due to non-zero tip wear values, re-run tip wear setup
and touchup the spot positions.
If using 1-step tip wear measurement, fixed tip position at spot points might change if
these new tips are different than tips used during initial spot teaching, so spot position
touchup should follow to confirm/adjust fixed tip positions.

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B-83264EN/03 APPENDIX C.GUN ZERO MASTERING

Function Key Description

ATRECLB Press NEXT to expose this function key. Press this key with shift key to close the selected
gun automatically and re-calibrate the master position of the servo gun axis. This key
masters the selected servo gun and maintains existing tip wear values.
Be sure that tip wear has not changed significantly since the last tip wear measurement.
NOTE: this key is only displayed if tip wear setup is performed.
HIST Press NEXT to expose this function key. Press this key to display ATMASTR and
ATRECLB history (log).

GUN ZERO MASTER

SERVO GUN Zero position master 1/1

Equip number: 1 (Group: 2)

AXIS MASTER
1 Gun 1 ( J1, COMP ) ZERO MASTER

Change to new tips for gun master.

[ TYPE ] EQUIP BZAL MASTER RECALB >

NOTE
If gun stroke changes due to tip holder or gun arm, update stroke limit accordingly via
Stroke limit setup screen, before mastering (MASTER, or RECALB or ATMASTR or
ATRECLB).

C.2 RESET ALARM

Procedure C-1 Resetting BZAL (Battery Zero) and “Pulse Not Established” Alarms
1. Connect Pulsecoder cable and Power Up controller.
2. Display Gun Master screen.
[MENU] key -> SYSTEM -> F1[TYPE] -> Gun Master
3. Press F3 “BZAL”. The system displays the following message.
“Reset BZAL alarm.”
“Please power OFF/ON.”
4. Turn OFF/ON the power of the robot controller.
5. SRVO-075 Pulse not established will be displayed.
6. Establish Pulse
a. For 8-pole motors (all FANUC motors) jog motor more than 1 revolution using jog keys,then
press the RESET key to reset this alarm
b. For less than 8-pole motors, Execute the MPDT routine (see procedure below)

C.3 MAGNET PHASE DETECTION (MPDT)

Procedure C-2 Establishing Pulse for Less than 8-pole Motor Using the Magnet
Phase Detection(MPDT) Feature

The MPDT softkey (F5) is displayed on the Gun Master screen when MPDT is required. The message
“Execute MPDT(Magnetic Phase Detection)” will be displayed. MPDT is required when the servo
motor connected to a non-8pole servo gun motor whose magnets have not been located.

NOTE
A motor that requires MPDT cannot be jogged prior to completion of this procedure.

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C.GUN ZERO MASTERING APPENDIX B-83264EN/03

During MPDT, the tips may move slightly. Before executing MPDT, be sure the tips are not fully closed or
fully opened. and can move a few mm in either direction.

1. Display Gun Master screen.

[MENU] key -> 0 NEXT PAGE -> 6 SYSTEM -> F1[TYPE] -> Gun Master
2. Press the MPDT softkey. The system displays the following messages.
“Execute MPDT. Are you ready? “
“ YES NO “
3. With the system in teach, press the deadman switch, reset faults and press F4 “YES.”
4. Magnet Phase Detection will commence. If MPDT completes successfully, the following message is
displayed
“Completed MPDT.”
If MPDT does NOT complete successfully, the following message is displayed
“Failed MPDT.”
“Execute MPDT(Magnetic Phase Detection).”
5. If MPDT failed, the motor will need to be manually turned to establish the magnet phase. To do this,
locate the manual override key/gear on the servogun actuator (if included) to drive the tips open/closed
at least (1) full motor revolution. This must be done until the “Completed MPDT” message is posted.
6. The servo gun can now be jogged using the jog keys.

C.4 MASTERING
Procedure C-3 Executing Zero Position Mastering
Two (2) methods are available to master the gun.
• Standard Master - Press MASTER; tip wear values are set to zero
• Re-Calibration Master - Press RECALIB; tip wear values are not modified

1. Decide whether to install new tips, based on function used:

Standard Master is performed when the F4 key, MASTER is pressed. New tips must be installed
before performing this operation. This operation sets tip wear value to zero for both tips.
Re-Calibration Master is performed when the F5 key, RECALB is pressed. New tips should NOT
be installed on the gun when performing this operation - this operation masters a gun with worn tips.
Do not perform this operation if tip wear values are incorrect, (tip wear values are not modified).
2. Jog the gun axes until tips touch.
3. Display Gun Master screen.
[MENU] -> 0 NEXT PAGE -> 6 SYSTEM -> F1[TYPE] -> Gun Master
GUN ZERO MASTER
SERVO GUN Zero position master 1/1

Equip number: 1 (Group: 2)

AXIS MASTER
1 Gun 1 ( J1, COMP ) ZERO MASTER

Change to new tips for gun master.

[ TYPE ] EQUIP BZAL MASTER RECALB >

NOTE
F2 “EQUIP” displays only if system has more than one equipment.
F3 “BZAL” displays only if BZAL condition is present.
F5 “RECALB” displays only if tip wear setup is performed.

4. Use F2 ”EQUIP” to select the equipment number when multiple equipment exists.

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B-83264EN/03 APPENDIX C.GUN ZERO MASTERING
5. Execute gun axis mastering by pressing MASTER (F4) or RECALB (F5), in accordance with the
descriptions above. RECALB (F5) is displayed after performing tip wear setup.
a. If tips are new or not worn, press F4 “MASTER”.
b. If tips are worn or to retain present wear reference data, press F5 “RECALIB”.
6. Press F4 “YES” and system will master the gun axis. If MASTER was pressed, tip wear values are
reset to 0.0. If RECALB was pressed wear values do not change.

C.5 AUTOMASTER FUNCTION

Automaster function executes the following sequence.
1. Reset BZAL alarm and repower (if BZAL condition exists)
2. Reset “Pulse Not Established” alarm (if pulse not established condition exists)
3. Move to coarse zero position (coarse close)
4. Move to fine zero position (fine close) – if pressure calibration is complete
5. Master the gun axis

WARNING
The servo gun axis moves during automaster.

NOTE
Automaster function uses a position register PR[90] by default. This register can be
changed via automaster config screen.

C.5.1 Automaster Procedure

Two (2) methods are available to master the gun automatically.
• Auto Standard Master - Press ATMASTR; tip wear values are set to zero
• Auto Re-Calibration Master - Press ATRECLB; tip wear amounts are not modified

1. Decide whether to install new tips according to the information below:

Auto Standard Master is performed when the F9 key, ATMASTR is pressed. This operation
automatically closes gun, masters axis and then sets tip wear values to zero. New tips must be placed
on the gun before performing this operation.
Auto Re-Calibration Master is performed when the F10 key, ATRECLB is pressed. This operation
automatically closes gun, masters axis, but does not change tip wear value. Therefore, tips should not
be changed, before performing this operation.
2. Display Gun Master screen.
[MENU] -> 0 NEXT PAGE -> 6 SYSTEM -> F1[TYPE] -> Gun Master
3. Use F2 ”EQUIP” to select the equipment number when multiple equipment exists.
4. Execute gun axis auto mastering by pressing ATMASTR (F9) or ATRECLB (F10). Make the choice
according to the descriptions above.
a. If this is the initial master attempt for the gun with new tips, press NEXT then press F9
“ATMASTR” with shift key.
b. If this is a re-master operation and the tips are worn and have a measured wear value from Tip
Wear Compensation, press NEXT then press F10 “ATRECLB” with shift key.

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C.GUN ZERO MASTERING APPENDIX B-83264EN/03

GUN ZERO MASTER

ZERO POS MASTER WITH MOTION / EQ:1 Gun:1 1/14
1 Battery OK (NO BZAL): TRUE
2 Pulse Established: TRUE
3 Master Done: TRUE
4 Calibration Done: TRUE
5 Current position(mm): -22.00
6 Current pulsect: -576717
7 Current mstrct: 0
8 TW calibration status: INCOMPLETE
9 NewTip.mstrct(pls0): 0
10 Cur.mstrct-NewTip.mstrct(mm): ******
11 Total wear(mm): 0.00

DGIDX HIST ATMASTR ATRECLB

CAUTION
The servo gun axis moves during automaster. Please make sure that no personnel
are in the vicinity of the gun, when you execute automaster.

NOTE
In case of T1/T2 mode, enable TP, and do not release both of dead man switch and
shift key during automaster. In case of AUTO mode, disable TP, and need not hold
dead man and shift key during automaster.

NOTE
If BZAL alarm exists, automaster resets BZAL alarm and cycles power.Re-execute
ATMASTR/ATRECLB again after repower, to complete operation, in this case.

6. If you press F4 “YES” now, the system will automatically close the gun, and then master the gun axis.
If ATMASTR was presses tip wear values are set to 0. If ATRECLB was pressed, tip wear values are
not modified.
NOTE
When automaster is performed, the following WARNING are posted.
SVGN-193 Automastered:XXmm from old master pos.
SVGN-195 Masterct(old:XX,new:YY).
SVGN-196 TW recalibrated:XXmm from old pulse0.
SVGN-198 Pulse0ct(old:XX,new:YY).
These messages indicate master position, and pulse count changes.

NOTE
If the following alarms occur, confirm cause of error in alarm screen.
SVGN-194 Automaster failed.
SVGN-197 TW recalibrate failed.
SVGN-199 Automaster message.

NOTE
If the following alarm occurs, press fault reset and request automaster again.
SVGN-200 FCTRL must be off for automaster.

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B-83264EN/03 APPENDIX C.GUN ZERO MASTERING

C.5.2 Auto Zero Calibration Screen

Auto Zero Calibration Screen (Auto ZC Screen) is displayed by pressing NEXT key at Gun Master Screen.
ATMASTR and ATRECLB can be performed from this screen. Current axis status is displayed on this
screen.

GUN ZERO MASTER

ZERO POS MASTER WITH MOTION / EQ:1 Gun:1 1/14
1 Battery OK (NO BZAL): TRUE
2 Pulse Established: TRUE
3 Master Done: TRUE
4 Calibration Done: TRUE
5 Current position(mm): -22.00
6 Current pulsect: -576717
7 Current mstrct: 0
8 TW calibration status: INCOMPLETE
9 NewTip.mstrct(pls0): 0
10 Cur.mstrct-NewTip.mstrct(mm): ******
11 Total wear(mm): 0.00

DGIDX HIST ATMASTR ATRECLB

NOTE
F1 “DGIDX” displays only if equipment is dual gun.
F5 “ATRECLB” displays only if tip wear setup is performed.

Item Description
Battery OK (NO BZAL) Battery zero alarm is not present on this group. BZAL reset is not needed.
Pulse Established Pulse has been established. Encoder rotation is not needed.
Master Done Master count has been recorded for this axis.
Calibration Done Position has been calibrated for this group. I.E. position has been
determined, based on master count.
Current position(mm) Current axis position.
Current pulsect Current axis machine pulse.
Current masterct Current axis master count.
TW calibration status Tipwear compensation status. Possible states are:
- Incomplete
- Complete
- Pulse0stale
NewTip masterct(pls0) Pulse count for new tip recorded at tipwear setup / calibration.
Cur.masterct – NewTip masterct(mm) Difference between current tips and worn tips. Value should be same as
total wear except if pulse0stale.
Total wear(mm) Sum of gun tip wear + robot tip wear
TW strokelim protection Status of stroke limit protection (enabled or disabled)
Strokelimit protection function automatically adjusts strokelimits based on
difference between current master count and newtip master count.
Strokelimit protection function is automatically enabled, when TW
calibration status changes to “Complete”.
Current closelimit(mm) Axis limit in gun close direction with current wear amount.
Standard closelimitmm) Axis limit in gun close direction with wear = 0.

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C.GUN ZERO MASTERING APPENDIX B-83264EN/03

C.5.3 Zero Calibration Config Screen

Zero Calibration Config Screen (ZC Config Screen) is displayed by pressing ATMASTR or ATRECLB
key at Auto ZC Screen. Automaster settings can be confirmed and changed from this screen.

GUN ZERO MASTER

ZERO MASTER CONFIG 1/10
1 Close speed(mm/sec): 10
2 Close pressure(pressurelim%): 100
3 Open speed(mm/sec): 10
4 Relax pressure(pressurelim%): 25
5 Position register index(PR[#]): 90
6 Max close distance(mm): 100.0
7 Max relax distance(mm): 10.0
8 Open dist before fine close(mm):10.0
9 Post status message at comp: TRUE
10 History file line limit: 999
[ TYPE ] END

Item Description
Close speed(mm/sec) Speed of close operations during automaster.
Close pressure(presslim%) Presslim% for gun close detection at coarse close.
Open speed(mm/sec) Speed of open operations during automaster.
Relax pressure(presslim%) Presslim% for gun relax detection at coarse close.
Position register index(PR[#]) Position register index used during automaster.
Max close distance(mm) Max distance to move in close direction for coarse close.
Max relax distance(mm) Max distance to move in open direction for relax detection.
Open distance for fine close(mm) Distance to open before starting fine close.
Post status message at comp Post alarm at automaster completion to indentify result.
History file line limit Number of lines for log history file. Refer to zero calibration history screen.

C.5.4 Zero Calibration History Screen

This screen serves as both debug log and change log. You can refer to history logs by F4[NEWER] and
F5[OLDER].
GUN ZERO MASTER
LOG HISTORY (2 files avail) 1/49
FR:ZCDBG1.TXT
ZERO CALIBRATE REPORT
Operation: AUTOMASTER
Gun:1: (grp:2,axs:1)
Date: 2011.11.11
Time: 11:11.11
****************************************
Sequence details
t1: COARSE CLOSE
status:Coarse close complete
DT cnd basis: pressure table

[ TYPE ] NEWER OLDER

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B-83264EN/03 APPENDIX D.SETTING GUN STROKE LIMITS

D SETTING GUN STROKE LIMITS

The axis limits for the servo gun, are referenced from the master position. The master position is set where
the tips touch. The Gun stroke limit screen allows the user to directly specify the maximum allowable
stroke in each direction OPEN and CLOSE from the master position. The stroke limits may have been set
correctly during the axis configuration as Controlled Start. However, it is good to confirm the proper
setting before starting the autotuning program.

Open Stroke
Master Limit (mm)
Position Close Stroke
Limit (mm)

The Open Stroke Limit (mm) is the maximum open distance for the gun. This may be directly specified
by the gun manufacturer, or it may need to be measured.

The Close Stroke Limit (mm) is the maximum gun tip extension allowed past where the tips touch. This
must be enough to allow for tip wear and bending of the gun arms during pressurization. But, it cannot be
larger than the physical stroke limit of the gun’s moving mechanism. Consult with the gun manufacturer to
determine the appropriate setting for the Close Stroke Limit. Typical range for the value is 15-30mm.

If you would rather set the OPEN stroke limit by directly recording the position, use the Gun Setup Utility
discussed earlier. This is recommended for most users.

PROCEDURE
1. Go to the Servo Gun General Operations Setup screen
2. Scroll to the Gun Stroke Limit item and press ENTER. You will see a screen similar to the following.
3. Adjust the Open and Close stroke limit as needed.

SETUP Servogun
STROKE LIMIT 1/2

Equip number: 1 (Group: 2)

Gun 1 ( J1 )

1 Open stroke limit(mm): 200.0

2 Close stroke limit(mm): 20.0

[ TYPE ] EQUIP GUN END

NOTE
Both OPEN and CLOSE stroke limit should be entered as positive values. The
magnitude of stroke distance from the master position is the required value.

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E.AUTOTUNE MACRO PROGRAM APPENDIX B-83264EN/03

E AUTOTUNE MACRO PROGRAM

Autotuning via the macro program AUTOTUNE, executes the same gun exercises that are performed when
autotuning is started with the EXEC key from the Gun Setup Utility.

CAUTION
The Servo gun axis moves at max speed, during autotuning. Autotuning can be
performed with the teach pendant enabled or disabled.
Please make sure that no personnel are in the vicinity of the gun, when you execute
autotuning.

Autotune macro program

Program name: AUTOTUNE (There is in the macro list)

The user has to set up the following prior to running the AUTOTUNE macro program.
- Tip displacement ratio
- Mastering
- Stroke limit
- Gun closing direction & motion sign
- Max gun pressure

Furthermore, the user may need to set parameters in the program call to AT_KLTUN to ensure that the
proper exercises are initiated.

1. Press the Select key

2. Press the F1 key <TYPE>
3. Select MACRO
4. You should now see the list of macro programs. Scroll to the program AUTOTUNE and press ENTER
to select it.
5. You should see a screen similar to the following:

AUTOTUNE
1/18
1: !Autotuning Main Program
2:
3: !Input parameters for autotuning
4: !P1: Equipment number(1 to 5)
5: !P2: Dual gun index(1 or 2)
6: !P3: Enable debug msg(0 or 1)
7: !P4: Reload parameters(0 or 1)
8: !P5: Starting load ratio(1 to 5)
9: !P6: Pushing depth(1 to strklim)
10: !P7: Acc estimation method
11: !(1: determine automatically)
12: !(2: use specified values)
13: !(3: use previous values)
14: !P8: Accel time1(100 to 384)
15: !P9: Min acc shm(100 to 384)
16: !P10: Initial Filter (Hz)
17: CALL AT_KLTUN
[END]

[ INST ] [ EDCMD ]

6. If default settings are not sufficient, enter custom parameters in the program line
17: CALL AT_KLTUN(P1,P2,P3…,P10)
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B-83264EN/03 APPENDIX E.AUTOTUNE MACRO PROGRAM

Descriptions and Default setting for the parameters are as follows:

P1 – Equipment Number
Default = 1
P2 – Dual Gun Index: defines if gun 1or 2 in the case of a dual gun is to be tuned
Default = 1
P3 – Enable Debug messages
Default = 0 (false)
P4 – Reload default servo parameters
Default = 0 (false)
P5 – Starting load ratio
Default = 1
P6 – Pushing Depth (mm)
Default = 5
P7 – Acceleration estimation method
Default = 1 (determine automatically)
P8 – Accel Time 1 (ms)
Default = 100
P9 - Min acc shm
Default = 100
P10 – Initial Filter Frequency (Hz)
Default = 30

7. Place the control reliable switch to T2 mode hold down the Shift key and Press FWD. The shift key
must be held down until the autotuning program is completed. If the shift key is released, the program
will have to be restarted.

NOTE
After Autotuning is started, the servo gun will perform the following by opening and
closing the gun:
¾ Acceleration settings
¾ Inertia measurements
¾ Friction measurements
¾ Spring constant measurements
¾ Force control gain settings
¾ Contact speed settings
¾ (Profile option is selected) Profile internal parameter settings

If autotuning did NOT complete successfully (indicated by status FAILED instead of COMP), then try the
following:
• Make sure axis limits are set properly.
• Check motor selection.
• Make sure mastering of the gun axis is correct.
• Re-perform autotuning until it completes successfully.

NOTE
If acceleration times were changed during autotuning, then an SVGN-050
“Autuning: Re-power required” is posted. Repower the controller makes the new
acceleration effective, and clears the SVGN-50 message.

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F.PRESS ON NEW TIPS APPENDIX B-83264EN/03

F PRESS ON NEW TIPS

After changing to new tips, it is good practice to be sure the tips are fully pressed on the tip holder before
returning to welding or updating the tip wear amount. The macro program TW_PRSRT can perform this
function automatically. This macro and the TW_PRS01 template program are loaded with the load-option
by setting $sgsyscfg.$load_twd=12 .

The program will squeeze the tips together several times, so the tips are pressed fully onto the tip holder.

The user must specify (8) parameters for TW_PRS01 to define how the routine executes. Below is a
description of each parameter and a few examples of the pressing operation with different parameters. This
macro or template program can be run anytime, but is best to run after changing tips and before getting an
updated tip wear measurement.

TW_PRS01
1/17
1: !PROGRAM NAME: TW_PRSRT;
2: !Program function: ;
3: ! Compress caps after tip change ;
:
8: !Parameters supplied to TW_PRESS ;
9: !1: Equipment number ;
10: !2: Force end value (Kgf) ;
11: !3: Number of steps ;
12: !4: Number of repititions ;
13: !5: Dwell time (ms) ;
14: !6: Register number R[#] ;
15: !7: PrePress margin ;
16: !8: Max growth ;
17: CALL TW_PRSRT(1,500,2,4,1,10,5,15) ;
[END]

[ INST ] [ EDCMD ]

Check the equipment number.

Parameter 1 – Equipment Default = 1 Create a CALL instruction for each equipment if there are multiple
Number ones.
Parameter 2 – Force End Default = 500 The maximum force that will be applied during the tip pressing
Value (kgf) operation. If the value specified here exceeds the max pressure for
the gun, the software will limit the pressure to the Max Pressure,
automatically.
Parameter 3 – Number of Default = 2 Specifies how many sets of squeezing repetitions will be performed.
Steps The force during step n, will be equal to:
(Parameter 2) * [n/(Parameter 3)]
Parameter 4 – Number of Default = 4 The number of repetitions performed during each step. The total
Repetitions number of squeezing repetitions is equal to:
(Parameter 3) * (Parameter 4)
Parmeter 5 – Dwell Time Default = 1 Squeezing time of each repetition.
(ms) (ms)
Parameter 6 – Register Default = 10 Register used to track program status internally. R[10] is the
Number standard register for tip wear measurement, so it is generally
unnecessary to change this.
Parameter 7 – PrePress Default = 5 Defines an extra open distance required to reach the pressing speed
Margin (mm)

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B-83264EN/03 APPENDIX F.PRESS ON NEW TIPS
Parameter 8 – Max Growth Default = 15 Defines the maximum expected increase in length between (2) worn
(mm) tips and (2) new tips. The actuator position between repetitions is
equal to:
Worn tips zero position + (Parmater 7) + (Parameter 8)
Movable Tip

PrePress Margin
Mastering position of New tip (Unknown before update)

Mastering position of Worn tip

Growth

Fixed Tip

TIP PRESSING EXAMPLE SEQUENCES

Pressing sequence with default settings [CALL TW_PRSRT(1,500,2,4,1,10,5,15)]
Step # Operation Critical Parameters
Step 1 Gun Closes to pressure, 250kgf Parameter 2 * (1/Parameter 3)
Pressure is help for 1ms Parameter 5
Gun opens to 20mm compared to worn tips zero position Parameter 7+8
Above steps are repeated (4) times Parameter 4
Step 2 Gun Closes to pressure, 500kgf Parameter 2 * (2/Parameter 3)
Pressure is help for 1ms Parameter 5
Gun opens to 20mm compared to worn tips zero position Parameter 7+8
Above steps are repeated (4) time Parameter 4

Pressing sequence with custom settings [CALL TW_PRSRT(1,300,1,6,1,10,5,10)]

Step # Operation Critical Parameters
Step 1 Gun Closes to pressure, 300kgf Parameter 2 * (1/Parameter 3)
Pressure is help for 1ms Parameter 5
Gun opens to 15mm compared to worn tips zero position Parameter 7+8
Above steps are repeated (6) times Parameter 4

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G.TROUBLE SHOOTING (TIP WEAR COMPENSATION) APPENDIX B-83264EN/03

G TROUBLE SHOOTING (TIP WEAR

COMPENSATION)
G.1 WEAR DOWN AMOUNT IS NOT MEASURED CORRECTLY
In case that wear down amount is not measured correctly, there are some phenomenon & cause. Confirm
phenomenon, then investigate cause and perform correct remedy.

G.1.1 Gun Does Not Close Completely with Pressure Motion

Phenomenon
During gun closing with pressure motion, gun tip stops before gun tip contacts robot tip. There is a gap
between gun tip and robot tip.

Cause
Since friction in gun mechanism increases, so tip contacting position is mis-detected.

NOTE
The following lists up the cause that friction in gun mechanism increases .
･ Lost oil firm in gun mechanism.
･ Deterioration grease in gun mechanism.
･ Decrease grease viscosity with low temperature.
It recommends gun maintenance together the following remedy.
Also, decrease grease viscosity with low temperature often occurs in winter.
Therefore warming up gun (repeat gun open and close) could solve decrease
grease viscosity.

Remedy
The following procedure is temporary remedy.
1. Display system variable screen.: Menu > SYSTEM > Variables
2. Display sysvers $SBR[axis].$PARAM[183].
Where axis is hardware axis number.
In case if typical servo gun system that robot and servo gun;

Gun 1: axis=7 ( $SBR[7].$PARAM[183] )

Gun 2: axis=8 ( $SBR[8].$PARAM[183] )
Gun 3: axis=9 ( $SBR[9].$PARAM[183] )

In case of robot have extend axis like rail axis, gun axis number will be different from the above.
Please confirm system configuration.

3. Increase the parameter by 1.3 times. Do not change the sign.

4. Re-power controller.

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B-83264EN/03 APPENDIX G.TROUBLE SHOOTING (TIP WEAR COMPENSATION)

NOTE
If the gun has been applied this temporary remedy once, do not apply this
temporary remedy again. For the gun that has been applied this temporary
remedy once, perform the following effective remedy as possible as soon.

The following is effective remedy. Please perform this sooner maintain day.
1. Install new tip, perform gun zero mastering.
2. Perform gun auto tune.
3. Perform pressure calibration.
4. Perform init setup of wear down measurement (TW_SETUP or WR_SETUP).
5. Confirm taught position.

G.1.2 Gun Tip Does Not Contact Fixture in Fixture Touch Motion
Phenomenon
Using 2 step measurement method, when fixture touch motion is executed, gun tip stops before gun tip
contacts fixture. here is a gap between gun tip and fixture.

Cause
Since friction in gun mechanism increases, so tip contacting position is mis-detected.

NOTE
The following lists up the cause that friction in gun mechanism increases .
･ Lost oil firm in gun mechanism.
･ Deterioration grease in gun mechanism.
･ Decrease grease viscosity with low temperature.
It recommends gun maintenance together the following remedy.
Also, decrease grease viscosity with low temperature often occurs in winter.
Therefore warming up gun (repeat gun open and close) could solve decrease
grease viscosity.

Remedy
The following procedure is temporary remedy.
1. Display servo gun setup screen. (Menu > Setup > servo gun)
2. Display tip wear detection setup screen.

SETUP Servogun SETUP Servogun

GENERAL / EQ:1 Gun:1 8/13 TIP WEAR DETECT / EQ:1 Gun:1 3/11
1 Tip Wear Down Comp: ENABLE
2 Gun Sag Compensation: DISABLE 1 Common setup: <*DETAIL*>
3 Close Direction(Gun) PLUS
4 Close Direction(Robot) UT: 1 [+Z ] 2 Detection type: LOAD
5 Max Motor Torque(%): 140.0 3 Margin of load(nwt): 294
6 Max Pressure (nwt): 4903.3 4 Tip speed(mm/sec): 30
Max Gun Torque(%): 55.0 5 Mis-detect toler.(mm): 5.00
7 Tip stick detect distance(mm): 5
8 Tip Wear Detection: <*DETAIL*> Maximum wear check(Gun)
9 Pressure Cal: COMP <*DETAIL*> 6 Max wear value(mm): 0.00
10 Tip Wear Standard: INCOMP <*DETAIL*> 7 Inform signal: DO[ 0]
11 Thickness check: <*DETAIL*> 8 Increase error(mm): 0.00
12 Gun Stroke limit: <*DETAIL*> Maximum wear check(Robot)
[TYPE] EQUIP GUN 9 Max wear value (mm): 0.00
10 Inform signal: DO[ 0]
11 Increase error (mm): 0.00
[TYPE] EQUIP GUN END

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G.TROUBLE SHOOTING (TIP WEAR COMPENSATION) APPENDIX B-83264EN/03

3. Increase “Margin of load “ by 1.3 times. No need re-power controller.

NOTE
If the gun has been applied this temporary remedy once, do not apply this
temporary remedy again. For the gun that has been applied this temporary
remedy once, perform the following effective remedy as possible as soon.

The following is effective remedy. Please perform this sooner maintain day.
1. If “Margin of load “ is increased by 1.3 times, change default value(294N or 30kgf ).
2. Install new tip, perform gun zero mastering.
3. Perform gun auto tune.
4. Perform pressure calibration.
5. Perform init setup of wear down measurement (TW_SETUP or WR_SETUP).
6. Confirm taught position.

G.1.3 Position of Fixture Is Changed

Phenomenon
Position of fixture is changed (or deformed or largely bended) after tip wear detection initialization.
Search motion of 2nd step touches gun on panel with 30kgf.

Cause
Position of fixture is changed (or deformed or largely bended) after tip wear detection initialization, the
changing position becomes tip wear down amount error.

Remedy
Fix fixture not to change the position.
If fixture is deformed, replace more rigid fixture. If the deflection is in elastic deformation, it is no problem.
But if the deflection is in plastic deformation, do not use the fixture.
Fixture to use with 2step measurement method must have position repeatability.

After the above remedy, perform the following

1. Install new tip, perform gun zero mastering.
2. Perform init setup of wear down measurement (TW_SETUP or WR_SETUP).
3. Confirm taught position.

G.1.4 Gun Tip Contact Fixture Sidlingly in Fixture Touch Motion

Phenomenon
Using 2 step measurement method, when fixture touch motion is executed, gun tip contact fixture sidlingly.
Especially, in case of X gun, trajectory of (worn) gun tip is not linear , so sidling touch often occurs.

Cause
When gun tip contact fixture sidlingly, gun tip would slip on fixture. This slipping amount cause wear down
amount error.
Additionally, slipping amount is irregular, wear down amount error is irregular, too.

Remedy
Change robot position to touch gun tip as possible as vertically.

After the above remedy, perform the following

1. Install new tip, perform gun zero mastering.
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B-83264EN/03 APPENDIX G.TROUBLE SHOOTING (TIP WEAR COMPENSATION)

2. Perform init setup of wear down measurement (TW_SETUP or WR_SETUP).

3. Confirm taught position.

G.1.5 Gun Zero Mastering with Worn Tip

Phenomenon
In gun zero mastering screen, gun zero mastering (Press F4[EXEC]) was preformed with worn tip.

Cause
In gun zero mastering screen, standard master count of new tip is updated with the tip. If tip is worn,
standard master count is not correct. Therefore wear down measurement does not work correctly.

Remedy
Perform the following
1. Install new tip, perform gun zero mastering.
2. Perform init setup of wear down measurement (TW_SETUP or WR_SETUP).
3. Confirm taught position.

G.1.6 Init Setup of Wear Down Measurement with Worn Tip

Phenomenon
Init setup of wear down measurement (TW_SETUP or WR_SETUP) was performed with worn tip.

Cause
Standard master count by worn tip is applied, so wear down measurement does not work correctly.

Remedy
Perform the following
1. Install new tip, perform gun zero mastering.
2. Perform init setup of wear down measurement (TW_SETUP or WR_SETUP).
3. Confirm taught position.

G.2 ALARM RELATED TO TIP WEAR DOWN MEASUREMENT

In this section, it descript alarm related to tip wear down measurement

SVGN-118 Max wear exceeded (Gun Tip)

Cause
a) Maximum tip wear amount has been exceeded on gun tip.
b) Gun tip wear amount that exceed maximum tip wear amount is mis-detected.

Remedy
a) Replace gun tip, then run update program again.
b) To remedy mis-detection, refer to section H.1.

SVGN-119 Max wear exceeded (Rbt Tip)

Cause
a) Maximum tip wear amount has been exceeded on robot tip.
b) Robot tip wear amount that exceed maximum tip wear amount is mis-detected.
Remedy
a) Replace robot tip, then run update program again.
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G.TROUBLE SHOOTING (TIP WEAR COMPENSATION) APPENDIX B-83264EN/03

b) To remedy mis-detection, refer to section H.1.

SVGN-32 Tip increased error(Gun)

Cause
The measured tip wear on the gun side (moving tip) indicates that the tip has grown by an amount greater
than the Gun Increased Error(mm)
a) New tips were placed on the gun, but the new tips flag was not set in the update program.
b) A piece of metal from tip dressing operation remained on the tip making it longer.
c) Gun tip wear amount that exceed increased error tolerance is mis-detected.

Remedy
a) Properly seat the tips, then set the new tips flag and run the update program again.
b) Remove the excess metal, then run the update program again.
c) To remedy mis-detection, refer to section H.1.

SVGN-33 Tip increased error(Robot)

Cause
The measured tip wear on the robot side (stationary tip) indicates that the tip has grown by an amount
greater than the Robot Increased Error(mm) setting.
a) New tips were placed on the gun, but the new tips flag was not set in the update program.
b) A piece of metal from tip dressing operation remained on the tip making it longer.
c) Robot tip wear amount that exceed increased error tolerance is mis-detected.

Remedy
a) Properly seat the tips, then set the new tips flag and run the update program again.
b) Remove the excess metal, then run the update program again.
c) To remedy mis-detection, refer to section H.1.

SVGN-97 Tip wear misdetection.(CLB)

Cause
Gun closing is mis-detected during pressure motion.

Remedy
To remedy mis-detection, refer to section H.1.1.

SVGN-114 Tip wear misdetection.(FIX)

Cause
Gun touching is mis-detected during fixture touch motion.

Remedy
To remedy mis-detection, refer to section H.1.2.

SVGN-20 Pressure shortage

Cause
During pressure motion, pressure enough to detect gun closing did not occur. This alarm is often posted in
case of long arm X gun.
a) Tip worn over , and then close stroke limit is too short. Therefore tips can not push enough each other.

NOTE
Close stroke limit is compensated with tip wear amount. Please refer to section 6.7
a bout compensation stroke limit.

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B-83264EN/03 APPENDIX G.TROUBLE SHOOTING (TIP WEAR COMPENSATION)

b) Standard close stroke limit is not correct. Therefore tips can not push enough each other.

NOTE
Stroke limit that is specified when initial setup program is executed is applied to
standard stroke limit.
When initial setup program run, the following warning is posted;
SVGN-178 Open/CloseLim=XXmm/YYmm
This indicates standard stroke limit that is compensated with tip wear amount.
If standard stroke limit is incorrect, pressure motion can not work.

Remedy
a) Replace robot tip, then run update program again.
b) Confirm standard stroke limit, then set correct stroke limit. Refer to appendix D about setting stroke
limit.

SRVO-24 Move error excess(G:xx A:yy)

(xx means group number of servo gun axis. yy means group axis number of servo gun axis.)
Cause
Motion command for servo gun axis was performed, but servo gun did not actually move. The error
between command position and actual position exceeded tolerance.
a) Broke brake wire.
b) Friction in gun mechanism has increased.

Remedy
a) Confirm brake wire connection.
b) Refer to section H.1.

INTP-302 (xxxx, yyy) Stack overflow

( xxxx means program name. Yyy means program line)
Cause
When calling rank with CALL instruction is to deep, this alarm is posted.
Init setup/update program use CALL instruction internally. So if these program is called on user’ program
that is deep calling rank, this alarm would be posted.

Remedy
Perform the following procedure.
1. Display program list screen, and select main program that calls init setup/update program. Then press
Next key, and press F2[Detail]
2. Increase stack size 300.
3. Executed main program, confirm reproduction alarm.
4. If INTP-302 reproduce, increase stack size 300 again in program detail screen.

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H.VARIABLE REMOTE TCP SETUP METHOD APPENDIX B-83264EN/03

H VARIABLE REMOTE TCP SETUP METHOD

Variable Remote TCP function is that Remote TCP moves in response to movement of the Positioner. This
function can improve welding posture flexibility and reduce cycle time by reducing the amount of change
of position of the robot.
This function requires the following options.
- Positioner Mechanical Software
- Remote TCP (J624)
About Coordinated Motion Function with Positioner, please refer to Coordinated Motion Function
OPERATOR’S MANUAL (B-83484EN).
About Remote TCP Function, please refer to Optional Function OPERATOR’S MANUAL
(B-83284EN-2).

NOTE
This chapter describes the setting method about known kinematics type
positioner. About the unknown kinematics type, please refer to Coordinated
Motion Function OPERATOR’S MANUAL (B-83484EN).

H.1 SYSTEM CONFIGURATION

Configure system as the followings.
- Group 1: Robot
- Group 2: Servogun
- Group 3: Positioner

GP1 GP2

GP3

H.2 CALIBRATING POSITIONER

Calibrating Positioner is described in this section. For more information about calibration positioner, please
refer to Coordinated Motion Function OPERATOR’S MANUAL (B-83484EN).

NOTE
This section describes the setting method about known kinematics type
positioner. About the unknown kinematics type, please refer to Coordinated
Motion Function OPERATOR’S MANUAL (B-83484EN).

H.2.1 Setting Tool Frame of the Positioner

Read Tool Center Point of positioner when all axes are 0 degree from a drawing input it to a Tool Frame of
the positioner directly.
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B-83264EN/03 APPENDIX H.VARIABLE REMOTE TCP SETUP METHOD

1. World frame and Mechanical Interface of a positioner are defined as the follows.

Mechanical Interface
+X

+Z
+X

+Z

World Frame

2. Set the Tool Center Point from Mechanical Interface. For example of the following figure, set as
X=400mm, Y=0mm, Z=-250mm, W=180deg, P=0deg, R=0deg.

+Z Offset for Y direction=0mm

250mm +X

+X
+Z

400mm

H.2.2 Setting Tool Frame of the Robot (For Calibration)

Set a Tool frame of the robot. This is used for calibration, and TCP can touch with the TCP of the Positioner.
(In other words, robot’s TCP can touch the top of fixed tip of the pedestal gun.)
Select Tool frame number for using calibration as follows.
- Calibrate by using TCP for handling in production : Select the number as same as the Positioner
- Calibrate by a different TCP from that for handling in production : Select a different number from that
of Positioner
Example)
TCP of Positioner
（GP3:UT[1])

TCP of robot
Robot’s TCP can touch (For handling in production)
Positioner’s TCP GP1:UT[1]）

Positioner （GP3) TCP of Robot Robot （GP1）

(For calibration, GP1:UT[2])

H.2.3 Calibration
Calibration is done in calibration screen. Display calibration screen by executing the following procedure.
- Press MENU key to bring up the screen menu, and select “SETUP”.

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H.VARIABLE REMOTE TCP SETUP METHOD APPENDIX B-83264EN/03

- Press F1 [TYPE] to display the pull-up menu, and select “Coord”

SETUP Coord
1/5
Coord Pair Number : [ 1]
Leader Group : 3
Follower Group : 1

X: ******** Y: ******** Z: ********

W: ******** P: ******** R: ********

Follower orientation : ATTACHED

Leader frame number : 1

[ TYPE ] [ C_TYP ]

Calibration Procedure
1. Input pair number, leader group number (Positioner) and follower group number (Robot).
Select F4 ”YES” for the message “Position data will be cleared!”.

2. Press F2 [C_TYP] and select “Known 4 Pt”. Then the following screen is displayed.

SETUP Coord
1/4
Known type calibration Coord Pair: 1
Group Number Leader: 3 Follower: 1
X: ******** Y: ******** Z: ********
W: ******** P: ******** R: ********

Leader's TCP Point : UNINIT

Orient Origin Point : UNINIT
X Direction Point : UNINIT
Y Direction Point : UNINIT

[ TYPE ] [ C_TYP ] EXEC MOVE_TO RECORD

3. Record the following 4 positions. (Operation : SHIFT + F5 ”RECORD”)

1st point “Leader’s TCP Point” : Touch robot’s TCP with Positioner’s TCP
First point

+X
+Z
+Y

World frame of Positioner

2nd point “Orient Origin Point” : Robot can move along both +X and +Y direction of Positioner’s
World frame.

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B-83264EN/03 APPENDIX H.VARIABLE REMOTE TCP SETUP METHOD

2nd point

+X
+Z
+Y

World frame of Positioner

3rd point “X Direction Point” : Move robot along +X direction of Positioner’s World frame.
3rd point: Move along +X of Positioner’s World frame

+X
+Z
+Y

World frame of Positioner

4th point “Y Direction Point” : Move robot along +Y direction of Positioner’s World frame.
4th point: Move along +Y of World frame of Positioner

+X
+Z
+Y

World frame of Positioner

4. Press SHIFT + F3 ”EXEC” to execute calibration. Then the calibration result is displayed.

SETUP Coord
1/4
Known type calibration Coord Pair: 1
Group Number Leader: 3 Follower: 1
X: 1801.422 Y: 128.194 Z: -129.370
W: 0.000 P: -90.000 R: 0.000

Leader's TCP Point : USED

Orient Origin Point : USED
X Direction Point : USED
Y Direction Point : USED

[ TYPE ] [ C_TYP ] EXEC MOVE_TO RECORD

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H.VARIABLE REMOTE TCP SETUP METHOD APPENDIX B-83264EN/03

5. Cycle the power.

NOTE
Calibration data will not be used until cycling power.

Calibration is finished.

H.2.4 Other Notes

You do not have to set the following frames.
- User frame and Tool frame of the gun (Group 2)
- User frame of Positioner (Group 3)

H.3 SETTING SYSTEM VARIABLE

Set the following system variable for using Variable Remote TCP.

Variable name Example Description

($VRTCP[1])
$VRTCP[1~4].$RTCP_NO 1 Remote TCP number to be variable (User frame number)
$VRTCP[1~4].$LEADER_GP 3 Group number of Leader (Positioner)
$VRTCP[1~4].$PAIR_GP[1] 1 Group number of Pair 1 (Robot)
$VRTCP[1~4].$PAIR_GP[2] 0 Group number of Pair 2 (none)
$VRTCP[1~4].$UT_NO 1 Tool frame number of Leader (Positioner)

NOTE
Please do NOT change other system variables in $VRTCP[1~4].

Following figure shows the above settings ($VRTCP[1]).

.$UT_NO:
TCP of Positioner
（GP3:UT[1])

（Servogun (GP2)）

.$RTCP_NO: (World frame of robot)

Pair Remote TCP number
（GP1:UF[1]）

.$LEADER_GP: .$PAIR_GP[1]
Leader=2 axes Positioner （GP3） Pair=Robot (GP1)

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B-83264EN/03 APPENDIX H.VARIABLE REMOTE TCP SETUP METHOD

H.4 USING VARIABLE REMOTE TCP

Confirm the followings before proceeding to the next section.
- Calibration of the positioner must be completed.
- Setup of system variable for Variable Remote TCP must be completed.

H.4.1 Selecting Frame Number

Select User frame number of Pair group (Robot) as $VRTCP[].$RTCP_NO. And select Tool frame number
of Leader group as $VRTCP[].$UT_NO. To select frame number, FRAME instruction is recommended.

Example) Group mask : [1, 1, 1, *, *, *, *, *]

RTCP
1/3
1: UFRAME_NUM=1
2: UTOOL_NUM=1
[End]

POINT SPOT TOUCHUP >

H.4.2 Setting up Servo Gun

Set the servo gun as a normal pedestal servo gun. For example, User frame number for the Variable Remote
TCP is UF[1], and robot moves along –Z direction of the User frame while pressuring, set as following.
Tip close direction (Robot) : UF[1] : -Z

Robot(GP1)
Workpiece

+Z

Robot moves along -Z

GP1:UF[1] direction of UF[1] while
pressuring.
Positioner (GP3)

H.4.3 Jogging
Normal jogging, Normal remote tool jogging and Variable remote tool jogging are available.

Operation Procedure
Switching JOG coordinate Toggle [COORD] key.
Switching Remote Tool JOG Press [FUNC] key, then select “TOGGLE REMOTE TCP”
Switching Remote Tool number Press [FUNC] key, then select “CHANGE RTCP FRAME”

Example) Difference between Normal jogging and Remote TCP jogging

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H.VARIABLE REMOTE TCP SETUP METHOD APPENDIX B-83264EN/03

USER:+Z rotation R/USER:+Z rotation

Workpiece

+Z

NOTE
Remote jogging between leader group and pair group is not available.

After jogging Leader group, the setting of Variable Remote TCP will be updated.

H.4.4 Teaching
Teach as usual. You can teach SPOT instruction as usual, too. RTCP option can be add to motion
instruction.
NOTE
Please do not execute the motion instruction for moving both Leader group
(Positioner) and Pair group (Robot) at the point where gun may collide with
workpiece or robot hand.

NOTE
You must execute SPOT instruction while Leader group is stopped.

H.4.5 Executing Program

Execute program as usual. When you execute a motion instruction with Variable Remote TCP, Pair group
(Robot) uses the Variable Remote TCP calculated from the destination of Leader group (Positioner).
Variable Remote TCP will be updated at stopped position.
When you execute SPOT instruction, pressuring and tip wear compensation will be done along Tip close
direction defined on the Variable Remote TCP.
Pressuring for SPOT welding Tip wear compensation Gun deflection co mpensation

+Z
+Z +Z
Tip close direction
Tip close direction Tip close direction

Pedestal Servogun arm on

2 axes positioner

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B-83264EN/03 APPENDIX H.VARIABLE REMOTE TCP SETUP METHOD

H.4.6 Limitation
1. Coordinate motion is not supported.
At a glance, Robot is coordinated with Positioner while executing TP program, actually they move as
follows.

L P[2] 500mm/sec FINE

Trajectory of Robot’s TCP

P[1]

Trajectory of Positioner’s TCP

P[2]

And it is not guaranteed that both reach to destination.

P[2]

2. If you change TCP of Leader group (Positioner) for after deformation of gun, you must turn OFF-ON
the power of Robot controller for updating Variable Remote TCP.

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ADDITIONAL INFORMATION
 Addition for
FANUC Robot series R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

1.Type of applied technical documents

FANUC Robot series R-30iB CONTROLLER

Name
Servo Gun Function OPERATOR'S MANUAL

Spec.No./Ed. B-83264EN/03

2.Summary of Change

New, Add,
Applicable
Group Name/Outline Correct,
Date
Delete

Basic

Optional
“26 Tip Wear Diagnostics Function” is added Add Immediately
Function

Unit

Maintenance
Parts

Notice

Correction

Another

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-01

Ed. Date Design Description Sheet 1/11

Date 13.09.20 Desig. Amagata Check Apprv.
 26 TIP WEAR DIAGNOSTICS FUNCTION
This function provides diagnostics for tip wear value.
This function is optional (not standard).
ServoGun tipwear diagnostics A05B-2***-R826

NOTE
Basic FANUC tip wear down compensation function must be used to use this
function. This function cannot work well if tip wear compensation in your own way
is used. Please refer to chapter 6 about basic FANUC tip wear down
compensation.

26.1 OVERVIEW
When the holder and the shank is tapered coupling, end of tip is changed by wear of the tapered portion
regardless of tip wear as shown by the figure below. So change of end of tip during production consists of tip
wear value and compression (by worn taper portion).
On the other hand, basic tip wear down compensation function measures and compensates not actual tip wear
value but change of end of tip. So basic tip wear down compensation function has measurement error due to
compression and cannot use tip completely with aging.

Holder

Shank Tip wear value

Compression
taper portion is worn.
(compression)
New tip
Worn tip

at initialization during production

This function makes it possible to use tip completely by measuring not end of tip but actual tip wear value and
compression. And this function also provides archive of wear measurements and various helpful tools for tip
wear diagnosis.
This chapter use the following terms.
Term Explanation
Tip wear value Tip erosion or material consumed during weld process.
NOTE: This is NOT same as wear down value for basic tip wear down compensation.
Compression Displacement of shank into holder by worn taper portion.
Change of end of tip Change of end of tip = tip wear value + compression.
NOTE: This is same as wear down value for basic tip wear down compensation.
Wear percent Percentage of robot/gun tip wear value to total tip wear value.
NOTE: This is NOT same as wear ratio for basic tip wear down compensation.

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-01

Ed. Date Design Description Sheet 2/11

Date 13.09.20 Desig. Amagata Check Apprv.
 26.2 TIP WEAR DIAG SCREEN
Tip wear diag screen configures alarm and monitoring parameters for tip wear.

Procedure to display tip wear diag screen

1. Press MENU key, then select “6 SETUP”.
2. Press F1 [TYPE], then select “Servo Gun”.
3. “General Setup” -> “Tip Wear Detection” -> “Tip wear diag”. The following will be displayed.

SETUP Servogun
TIP WEAR DIAG / EQ:1 Gun:1 1/28
Cap wear config(mm)
1 Max wear robot tip: 10.0
2 Max wear gun tip: 10.0
3 Alarm severity: Warn
4 Output index: 0
Change date: ****************
Compress config(mm)
5 Standard val robot tip: 0.0
6 Negative tol robot tip: 5.0
7 Positive tol robot tip: 5.0
8 Standard val gun tip: 0.0

[TYPE] GUN AUTORATE AUTOPRCT RESETAV >

RESETMAX >

26.2.1 Settings
ITEM DESCRIPTION
Cap wear config(mm)
Max wear robot tip If robot tip wear value exceeds the specified value,
“SVGN-423 Fixed tip capwear:#.# (limit)” occurs.
Max wear gun tip If gun tip wear value exceeds the specified value,
“SVGN-424 Movable tip capwear:#.# (limit)” occurs.
Alarm severity Severities of SVGN-423, SVGN-424 alarms: none, warn or pause
Output index Specified DO[#] is asserted when SVGN-423 or SVGN424 alarm occurs.
Change date Date of most recent change to “Cap wear config(mm)” parameters.
Compress config(mm)
Standard val robot tip Expected distance that new robot tip is installed after tip wear initial setup. Change this
value to accommodate a different shank, for example.
Negative tol robot tip Max difference from standard value, in negative direction.
If compression < (standard value – negative tol),
“SVGN-429 Fixed tip compression: #.# overtol.” occurs.
Positive tol robot tip Max difference from standard value, in positive direction.
If compression > (standard value + positive tol),
“SVGN-429 Fixed tip compression: #.# overtol.” occurs.
Standard val gun tip Expected distance that new gun tip is installed after tip wear initial setup. Change this
value to accommodate a different shank, for example.
Negative tol gun tip Max difference from standard value, in negative direction.
If compression < (standard value – negative tol),
“SVGN-430 Movable tip compression: #.# overtol.” occurs.
Positive tol gun tip Max difference from standard value, in positive direction.
If compression > (standard value + positive tol),
“SVGN-430 Movable tip compression: #.# overtol.” occurs.

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-01

Ed. Date Design Description Sheet 3/11

Date 13.09.20 Desig. Amagata Check Apprv.
 Alarm severity Severities of SVGN-429, SVGN-430 alarms: none, warn or pause
Output index Specified DO[#] is asserted when SVGN-429 or SVGN430 alarm occurs.
Change date Date of most recent change to “Compress config(mm)” parameters.
Wear rate config(mm/spot*1000)
Standard val robot tip Expected wear rate for robot tip. Specify wear value per 1000 spots.
Negative tol robot tip Max difference from standard wear rate, in negative direction.
If compression < (standard value – negative tol),
“SVGN-425 Fixed tip wear rate(mm/spot): #.# overtol.” occurs.
Positive tol robot tip Max difference from standard wear rate, in positive direction.
If compression > (standard value + positive tol),
“SVGN-425 Fixed tip wear rate(mm/spot): #.# overtol.” occurs.
Standard val gun tip Expected wear rate for gun tip. Specify wear value per 1000 spots.
Negative tol gun tip Max difference from standard wear rate, in negative direction.
If compression < (standard value – negative tol),
“SVGN-426 Movable tip wear rate(mm/spot): #.# overtol.” occurs.
Positive tol gun tip Max difference from standard wear rate, in positive direction.
If compression > (standard value + positive tol),
“SVGN-426 Movable tip wear rate(mm/spot): #.# overtol.” occurs.
Alarm severity Severities of SVGN-425, SVGN-426 alarms: none, warn or pause
Output index Specified DO[#] is asserted when SVGN-425 or SVGN426 alarm occurs.
Change date Date of most recent change to “Wear rate config(mm/spot*1000)” parameters.
Wear percent config(%)
Standard val robot tip Expected wear percentage for robot tip.
Negative tol robot tip Max difference from standard wear percent, in negative direction.
If compression < (standard value – negative tol),
“SVGN-427 Fixed tip wear percent: #.# overtol.” occurs.
Positive tol robot tip Max difference from standard wear percent, in positive direction.
If compression > (standard value + positive tol),
“SVGN-427 Fixed tip wear percent: #.# overtol.” occurs.
Standard val gun tip Expected wear percentage for gun tip.
Negative tol gun tip Max difference from standard wear percent, in negative direction.
If compression < (standard value – negative tol),
“SVGN-428 Movable tip wear percent: #.# overtol.” occurs.
Positive tol gun tip Max difference from standard wear percent, in positive direction.
If compression > (standard value + positive tol),
“SVGN-428 Movable tip wear percent: #.# overtol.” occurs.
Alarm severity Severities of SVGN-427, SVGN-428 alarms: none, warn or pause
Output index Specified DO[#] is asserted when SVGN-427 or SVGN428 alarm occurs.
Change date Date of most recent change to “Wear percent config(%)” parameters.

26.2.2 Function Keys

FKEYS DESCRIPTION
F3 AUTORATE Automatically set wear rate standard and tolerance parameters based on current
averages.
F4 AUTOPRCT Automatically set wear rate percent and tolerance parameters based on current
averages.
F5 RESETAV Reset average to date.
F6 RESETMAX Reset max value to date for all parameters.

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-01

Ed. Date Design Description Sheet 4/11

Date 13.09.20 Desig. Amagata Check Apprv.
 26.3 TIP MEASUREMENT INFO SCREEN
Tip measurement info screen is used to review tip wear status and diagnose trend of tip wear.

26.3.1 TIP INFO SCREEN (MAIN)

This screen is used to review current tip wear status.
Use VIEW TIPS screen for graphical description of current status.
Use TIP TREND screen and TIP COMPRARISON screen for detailed review and diagnostics.

Procedure to display tip info screen

1. Press MENU key, then select “0 – NEXT –” -> “4 STATUS”.
2. Press F1 [TYPE], then select “Servo Gun”.
3. Select “Tip measurement info”.

ITEM DESCRIPTION
Wear measurement date Date and time that tip wear measurement is performed.
Tip install date Date and time that new tip is installed.
Tip ID Unique number that increments each time new tip is installed.
Tip ID for tip wear initial setup is 1.
Robot tip wear(mm) Tip wear value for robot tip.
Robot tip compression(mm) Compression value for robot tip.
Gun tip wear(mm) Tip wear value for gun tip.
Gun tip compression(mm) Compression value for gun tip.
Close limit(mm) Close stroke limit.
Spot count since tip change SPOT count since new tip is installed.

FKEYS DESCRIPTION
F2 GUN Change gun number.
F3 COMPARE Display TIP COMPARISON screen.
F4 TREND Display TIP TREND screen.
F5 VIEWTIPS Display VIEW TIPS screen.

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-01

Ed. Date Design Description Sheet 5/11

Date 13.09.20 Desig. Amagata Check Apprv.
 26.3.2 TIP COMPARISON SCREEN
Tip comparison screen is used to review tip data and compare tips. Several comparison modes are available.

Procedure to display tip comparison screen

1. Press MENU key, then select “0 – NEXT –” -> “4 STATUS”.
2. Press F1 [TYPE], then select “Servo Gun”.
3. Select “Tip measurement info”.
4. Press F3 “COMPARE”.

Three comparison modes are available by pressing F5 “COMP MOD”.

• Compare mode1: Tip summary
• Compare mode2: Average vs. Tip A
• Compare mode3: Tip B vs. Tip A

26.3.2.1 Compare mode1: Tip summary

In this mode, cumulative values are presented on first page.
Final measurement value for each tip is presented on subsequent pages. This information is called “archive”.
This archive stores latest 500 data.

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-01

Ed. Date Design Description Sheet 6/11

Date 13.09.20 Desig. Amagata Check Apprv.
 26.3.2.2 Compare mode2: Average vs. Tip A
This screen compares values for selected tip vs average. Select left column and press up/down arrow to toggle
between archive average and average to date. Select right column and press up/down arrow to change tip
selection.

Press F3 “SHOCHART” to display graphic line charts at bottom of screen.

26.3.2.3 Compare mode3: Tip B vs. Tip A

This screen compares values for selected tip vs average.
Select left column and press up/down arrow to change tip B selection.
Select right column and press up/down arrow to change tip A selection.

Press F3 “SHOCHART” to display graphic line charts at bottom of screen.

26.3.3 TIP TREND SCREEN

Tip trend screen displays trend data (series of measurements) for wear and other parameters.

Procedure to display tip trend screen

1. Press MENU key, then select “0 – NEXT –” -> “4 STATUS”.
2. Press F1 [TYPE], then select “Servo Gun”.
3. Select “Tip measurement info”.
4. Press F4 “TREND”.

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-01

Ed. Date Design Description Sheet 7/11

Date 13.09.20 Desig. Amagata Check Apprv.
 FKEYS DESCRIPTION
F2 GUN Change gun number.
F3 SHOW ALL/SHOW AVG This key is displayed when chart type = trend chart.
SHOW ALL: all points are displayed for each bin
SHOW AVG: averages of bin column are displayed
e.g. when total size of data is 100 points,
SHOW ALL : 10 points are displayed for each bin
SHOW AVG : 1 point (average of bin) is displayed for each bin
F4 CHARTTYP Standard chart:
Each bin corresponds to the specified measured value. You can see old/new data by
pressing left/right arrow key.
Trend chart:
Each bin corresponds to a series/average of the specified measured value.
For example if archive contains 100 points, then 10 points per bin are displayed (or
average of 10 points is displayed). You can understand trend of the data by using trend
chart. F3 key changes display type of points.
F5 DATATYPE Select type of data from wear value, wear rate, wear percent, compression value or
compress rate.

26.3.3.1 Chart1: Wear value

Wear values at wear update are displayed when standard chart is selected. Wear values at the last wear update for
the tips are displayed when trend chart is selected.

Standard Chart Trend Chart

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-01

Ed. Date Design Description Sheet 8/11

Date 13.09.20 Desig. Amagata Check Apprv.
 26.3.3.2 Chart2: Wear rate
Wear rates for tips (wear values per 1000 spots) are displayed when wear rate is selected.

Standard Chart Trend Chart

26.3.3.3 Chart3: Wear percent

Wear percents for tips (percentages of tip wear values to the whole) are displayed when wear percent is selected.

Standard Chart Trend Chart

26.3.3.4 Chart4: Compression value

Compression values after tip change are displayed when compression value is selected.

Standard Chart Trend Chart

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-01

Ed. Date Design Description Sheet 9/11

Date 13.09.20 Desig. Amagata Check Apprv.
 26.3.3.5 Chart5: Compress rate
Compression rates for tips (compression values per 10 tips) are displayed when compression rate is selected.

Standard Chart Trend Chart

26.3.4 VIEW TIPS SCREEN

View tips screen is used to see a visual representation of current tip condition.

Procedure to display tip trend screen

1. Press MENU key, then select “0 – NEXT –” -> “4 STATUS”.
2. Press F1 [TYPE], then select “Servo Gun”.
3. Select “Tip measurement info”.
4. Press F4 “VIEWTIPS”.

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-01

Ed. Date Design Description Sheet 10/11

Date 13.09.20 Desig. Amagata Check Apprv.
 Example1: After tip wear initial setup

Example2: Tip is worn

Example3: Compression occurs

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-01

Ed. Date Design Description Sheet 11/11

Date 13.09.20 Desig. Amagata Check Apprv.
 Addition for
FANUC Robot series R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

1.Type of applied technical documents

FANUC Robot series R-30iB CONTROLLER

Name
Servo Gun Function OPERATOR'S MANUAL

Spec.No./Ed. B-83264EN/03

2.Summary of Change

New, Add,
Applicable
Group Name/Outline Correct,
Date
Delete

Basic

Optional Description for “7 GUN SAG COMPENSATION” is

Add Immediately
Function added

Unit

Maintenance
Parts

Notice

Correction

Another

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-02

Ed. Date Design Description Sheet 1/6

Date 13.09.20 Desig. Amagata Check Apprv.
 “Compensation method” and “Gun Sag Compensation amount setting method” in chapter “7 GUN SAG
COMPENSATION” belong to new subsection “7.1 COMPENSATION METHOD”.

7.1 COMPENSATION METHOD

Compensation method
Gun sag is compensated by pushing fixed tip up automatically based on gun sag compensation value that is set in
the pressure schedule preliminarily. Gun sag compensation value is applied for each pressures schedule.

State with no gun sag compensation State with gun sag compensation

Gun sag compensation

amount h ｈ

Gun Sag Compensation amount setting method:

1. Press the DATA key to display the DATA screen
2. Press F1 [TYPE], then select “Pressure”.
3. Press F4 DETAIL. The servo gun pressure schedule detail setting screen will be displayed.
4. Input the gun sag compensation value to the item " Gun Sag Comp Value (mm)" in the screen.
5. Enable “Gun Sag Compensation” in the servo gun general setup screen.

SERVO GUN DATA

PRESSURE / EQ:1 GUN:1 1/99
No. Press(Nwt) Manual Comment
1 3500.0 TRUE [ ]
2 1800.0 TRUE [ ]
3 0.0 FALSE [ ]
4 0.0 FALSE [ ]

[ TYPE ] EQUIP GUN DETAIL COPY >

SERVO GUN DATA

PRESSURE / EQ:1 GUN:1 1/4
1 Comment: [ ]
2 Standard Pressure(nwt): 3500.0
3 Gun Sag Comp Value(mm): 1.2
4 Weight compensation type: DISABLE

[ TYPE ] EQUIP GUN LIST

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-02

Ed. Date Design Description Sheet 2/6

Date 13.09.20 Desig. Amagata Check Apprv.
 The following description is added to “7 GUN SAG COMPENSATION”.

7.2 3-D COMPENSATION

Gun arm sags along not only gun axis but also the axes normal to gun axis.
Sag along the axes normal to gun axis can be compensated by specifying X, Y, Z sag values.

Z sag for x direction occurs

comp. value

Teach Point Press Panel Sag Compensation

NOTE
This function has been supported since 7DC2/05.

NOTE
Set $SGGUN#.$SETUP.$GUNSAGTYP = 3 to use this function.

Sag value for each pressure schedule can be configured or confirmed on pressure schedule screen.

SERVO GUN DATA

PRESSURE / EQ:1 Gun:1 No:1 3/5
1 Comment: [ ]
2 Weld Pressure(nwt): 1500.0
3 Gun Sag Comp for X (mm): -0.2
4 Gun Sag Comp for Y (mm): 0.0
5 Gun Sag Comp for Z (mm): 2.0

[ TYPE ] EQUIP GUN LIST

Gun sag compensation is performed based on the specified coordinate system in servogun setup screen.
• Specify 2.0 as “gun sag comp for Z” when you want to compensate 2.0mm along +Z coordinate axis
• Specify –0.2 as “gun sag comp for X” when you want to compensate 0.2mm along –X coordinate axis
Please refer to the section 7.3 “GUN SAG COMPENSATION SETUP SCREEN” for more details on gun sag
compensation setup.

7.3 GUN SAG COMPENSATION SETUP SCREEN

Compensation method can be selected/configured on gun sag compensation setup screen.

NOTE
This screen has been supported since 7DC2/05.

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-02

Ed. Date Design Description Sheet 3/6

Date 13.09.20 Desig. Amagata Check Apprv.
 NOTE
Set $SGGUN#.$SETUP.$GUNSAGTYP = 3 to display this screen. (#: gun number)
Compensation values for X, Y, Z direction are required to be input when
$SGGUN#.$SETUP.$GUNSAGTYP = 3.

Procedure to display gun sag compensation setup screen

1. Press MENU key, then select “6 SETUP”.
2. Press F1 [TYPE], then select “Servo Gun”.
3. “General Setup” -> “Gun Sag Setup”. The following will be displayed.

Setup Servo gun

Gun Sag Compensation Setup 1/1
Compensation Method: SEPARATE

Setup sag value from press data screen

[ TYPE ] EQUIP GUN [CHOICE]

Please select compensation method from the following methods.

METHOD DESCRIPTION
SEPARATE Sag compensation values are specified on pressure schedule screen.
TABLE In this method, sag compensation value is automatically calculated based on
pressure-sag relation. Input two and above pressure-sag relations.
RATE In this method, sag compensation value is automatically calculated from a product of sag
rate and specified pressure. Input sag rates on this screen.

7.3.1 SEPARATE SETTING FOR EACH PRESSURE SCHEDULE

Gun sag compensation values have to be specified on pressure schedule screen when “SEPARATE” is selected
as compensation method.

Setup Servo gun

Gun Sag Compensation Setup 1/1
Compensation Method: SEPARATE

Setup sag value from press data screen

[ TYPE ] EQUIP GUN [CHOICE]

Gun sag compensation values have to be input for X, Y, Z directions.

SERVO GUN DATA

PRESSURE / EQ:1 Gun:1 No:1 3/5
1 Comment: [ ]
2 Weld Pressure(nwt): 1500.0
3 Gun Sag Comp for X (mm): -0.2
4 Gun Sag Comp for Y (mm): 0.0
5 Gun Sag Comp for Z (mm): 2.0

[ TYPE ] EQUIP GUN LIST

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-02

Ed. Date Design Description Sheet 4/6

Date 13.09.20 Desig. Amagata Check Apprv.
 7.3.2 AUTO SETTING BY SAG TABLE
Gun sag compensation values are automatically calculated based on pressure-sag relations when “TABLE” is
selected as compensation method. Input two and above pressure-sag relations.

Setup Servo gun

Gun Sag Compensation Setup 1/12
Compensation Method: TABLE

Calibration Status: INCOMP

Close Direction(Robot): UT: 1 [+Z ]

Pressure X Y Z
1 1000.0nwt -0.1mm 0.0mm 1.0mm
2 2000.0nwt -0.3mm 0.0mm 2.0mm
3 3000.0nwt -0.5mm 0.0mm 3.0mm
4 4000.0nwt -0.6mm 0.0mm 4.0mm
5 0.0nwt 0.0mm 0.0mm 0.0mm

[ TYPE ] EQUIP GUN [CHOICE]

Sag compensation values have to increase/decrease with pressure and cannot cross 0mm.

sag comp. value. sag comp. value sag comp. value sag comp. value

0mm

pressure pressure pressure pressure

OK OK NG (Alarm) NG (Alarm)
After sag compensation values are input, move cursor on calibration status line then press F4 “COMP”.
Pressure-sag values are sorted based on pressure and checked whether setting is correct or not. If setting is
correct, message “Sag compensation has completed” is displayed and calibration status becomes COMP.
Pressure and sag compensation values cannot be changed when calibration status is COMP. Please press F5
“INCOMP” if you want to configure it again.

Setup Servo gun

Gun Sag Compensation Setup 3/12
Calibration Status: COMP
Close Direction(Robot): UT: 1 [+Z ]

Pressure X Y Z
1 1000.0nwt -0.1mm 0.0mm 1.0mm
2 2000.0nwt -0.3mm 0.0mm 2.0mm
3 3000.0nwt -0.5mm 0.0mm 3.0mm
4 4000.0nwt -0.6mm 0.0mm 4.0mm
5 0.0nwt 0.0mm 0.0mm 0.0mm
6 0.0nwt 0.0mm 0.0mm 0.0mm
7 0.0nwt 0.0mm 0.0mm 0.0mm

[ TYPE ] EQUIP GUN COMP INCOMP

Gun sag compensation values are automatically calculated and displayed on pressure schedule screen when
calibration status is COMP. These values cannot be changed.

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-02

Ed. Date Design Description Sheet 5/6

Date 13.09.20 Desig. Amagata Check Apprv.
 SERVO GUN DATA
PRESSURE / EQ:1 Gun:1 No:1 2/2
1 Comment: [ ]
2 Weld Pressure(nwt): 3000.0
Gun Sag Comp for X (mm): -0.5
Gun Sag Comp for Y (mm): 0.0
Gun Sag Comp for Z (mm): 3.0

[ TYPE ] EQUIP GUN LIST

7.3.3 AUTO SETTING BY SAG RATE

Gun sag compensation values are automatically calculated from a product of sag rates and specified pressure
when “RATE” is selected as compensation method. Input sag rates according to displayed physical unit.

Setup Servo gun

Gun Sag Compensation Setup 1/4
Compensation Method: RATE

Close Direction(Robot): UT: 1 [+Z ]

Sag rate for X [mm/1000N ]: -0.1

Sag rate for Y [mm/1000N ]: 0.0
Sag rate for Z [mm/1000N ]: 1.0

[ TYPE ] EQUIP GUN COMP INCOMP

Gun sag compensation values are automatically calculated and displayed on pressure schedule screen. These
values cannot be changed.

SERVO GUN DATA

PRESSURE / EQ:1 Gun:1 No:1 2/2
1 Comment: [ ]
2 Weld Pressure(nwt): 3000.0
Gun Sag Comp for X (mm): -0.3
Gun Sag Comp for Y (mm): 0.0
Gun Sag Comp for Z (mm): 3.0

[ TYPE ] EQUIP GUN LIST

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-02

Ed. Date Design Description Sheet 6/6

Date 13.09.20 Desig. Amagata Check Apprv.
 Addition for
FANUC Robot series R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

1.Type of applied technical documents

FANUC Robot series R-30iB CONTROLLER

Name
Servo Gun Function OPERATOR'S MANUAL

Spec.No./Ed. B-83264EN/03

2.Summary of Change

New, Add,
Applicable
Group Name/Outline Correct,
Date
Delete

Basic

Optional “6.13 Tip Wear Compensation For Air-cut Motion”

Add Immediately
Function is added

Unit

Maintenance
Parts

Notice

Correction

Another

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-03

Ed. Date Design Description Sheet 1/3

Date 13.11.07 Desig. Amagata Check Apprv.
 6.13 Tip Wear Compensation For Air-cut Motion

6.13.1 Overview
For servogun, 0mm position (mastering) is defined based on end of robot tip.
End of gun tip (worn) is different from end of gun tip (new) if motion instruction without SPOT instruction
(called air-cut motion) is called.
For example, consider the case robot approaches to a mount as the following figures. In new tip case (left figure),
distance between end of gun tip and mount is Da. If tip wear down (center figure), distance between end of gun
tip and mount is Db = Da – wear value (rbt). If wear value (rbt) > Da occurs, gun tip bumps into mount.

Gun tip opens to teach point + tip wear value for motion without SPOT instruction by enabling this function.
That is, base position of gun tip (= pulse count of gun axis) moves always same position.

NOTE
Set $SGSYSTWD.$GUNTIP_COMP = TRUE (Default: FALSE) to enable this function.

NOTE
This function has been supported since 7DC2/05.

$GUNTIP_COMP = FALSE $GUNTIP_COMP = TRUE

gun tip position
new tip worn tip worn tip
changes because of gun tip opens larger
wear value (rbt) than new tip

base position of
teach pt.
Da Dc>Da tip is not changed
wear value(rbt) Db<Da
50mm 50mm＋wear val(rbt+gun) = pulse count of
50mm gun axis is not
changed
zero position
zero position
zero position

robot position robot position robot position

mount
(invariant) (invariant)

6.13.2 Precaution
The followings are different from the default when this function is enabled.
• Program execution behavior
• Touchup behavior
• Open stroke limit auto update

Program execution behavior

Gun tip opens to taught point + tip wear value for motion without SPOT instruction.
For example, if taught position = 50mm and total tip wear down = 5mm, gun axis moves to 55mm at program
execution. Note that actual moved position is different from taught position.

NOTE
TP programs used in system are not compensated. That is, other servogun functions are not affected
by this function.

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-03

Ed. Date Design Description Sheet 2/3

Date 13.11.07 Desig. Amagata Check Apprv.
 Touchup behavior
Touchup point for motion without SPOT instruction becomes gun axis position that new tip is installed.
For example, if current position = 55mm and total tip wear down = 5mm, taught position becomes 50mm.
Note that taught position is different from current position.

NOTE
If touchup is performed with worn tip and small gun open, gun tip may bumps into peripheral when new
tip is installed. Perform touchup on the assumption that new tip is installed if this function is enabled.

Open stroke limit auto update

Open stroke limit changes based on tip wear value.
For example, if open stroke limit at setup = 100mm and total tip wear down = 5mm, open stroke limit is
auto-updated to 105mm. Base position of gun tip (pulse count of gun axis) at stroke limit is same even if open
stroke limit becomes large.

e.g. open value = 50mm, wear value (gun) = 2.5mm, wear value (rbt) = 2.5mm

stroke limit is changed from 100mm to 105mm

(original stroke limit is 100mm) end of gun tip (worn)

end of gun tip (new)

initial open value

=program teach point
actual open value

end of robot tip (new)

end of robot tip (worn)

POSITION screen touchup screen

touchup

Addition for FANUC Robot series

Title R-30iB CONTROLLER
Servo Gun Function OPERATOR'S MANUAL

Draw
No. B-83264EN/03-03

Ed. Date Design Description Sheet 3/3

Date 13.11.07 Desig. Amagata Check Apprv.
B-83264EN/03 INDEX

INDEX
Dress Summary Log File and Chart .............................270
<A> Dressed Length Inspection...........................................292
A DIFFERENT GUN FROM THAT SPECIFIED BY Dressed tip inspection ..................................................283
THE ATTACH INSTRUCTION IS ATTACHED. ..337 Dressed Tip Inspection.................................................290
ACTIVE STROKE LIMIT PROTECTION ...................86 Dual Gun........................................................................47
ALARM .......................................................................273 DUAL-GUN CONTROL.............................................150
Alarm ...........................................................................310 DUAL-GUN EQUIPMENT AND AXIS SETUP ........150
ALARM RELATED TO TIP WEAR DOWN DUAL-GUN MANUAL AND PROGRAM
MEASUREMENT....................................................355 OPERATION ...........................................................155
ALARMS .....................................................................249 DUAL-GUN OPERATIONAL SETUP.......................151
AUTO UPDATING WEAR RATIO..............................81
Auto Zero Calibration Screen ......................................345 <E>
AUTOMASTER FUNCTION......................................343 EARLY WELD INIT FUNCTION..............................323
Automaster Procedure ..................................................343 EARLY WELD INIT FUNCTION OPERATION.......326
Automatic Save to External Device .............................320 EARLY WELDING CALIBRATION .........................324
AUTOTUNE MACRO PROGRAM ............................348 Enable/Disable diagnosis .............................................307
EQUALIZE SIGNAL ..................................................107
<B> ERROR CODES ..........................................................297
Backward .......................................................................57 E-Stop ............................................................................55
Backward Execution ....................................................131 Example .......................................................................117
BASIC SPECIFICATION................................................1 Example of Tip Wear Down Measurement....................73
Basic Specification.......................................................120 Examples......................................................................293
Battery-less Type Guns ................................................128 Executing Program.......................................................364
Battery-mounted Type Guns ........................................129 EXT. TIP STICK SIGNAL DETECTION.....................99

<C> <F>
CALIBRATING POSITIONER...................................358 Feature of Function ......................................................120
Calibration....................................................................359 FEATURES OF FANUC SERVO GUN..........................1
CALIBRATION MOTION FAILED...........................337 Forward Execution.......................................................131
Camera Calibration ......................................................280
Camera Setup Tool.......................................................280 <G>
Chart Menu ..................................................................309 General Status Screen ..................................................316
COMBINATION 2 STEP METHOD AND 1 STEP GUN ATTACH Instruction..........................................130
METHOD...................................................................76 Gun Change by Multi-task ...........................................135
COMPATIBILITY OF TIP WEAR MEASUREMNET GUN CHANGE FUNCTION ......................................120
PROGRAMS ..............................................................87 GUN CHANGE INSTRUCTION ................................129
Composition of Tip Inspection.....................................274 GUN CHANGE REFERENCE POSITION SETUP
Condition for Diagnosis ...............................................301 METHOD (BATTERY-LESS TYPE) .....................331
CONDITIONS OF GUN OPEN ..................................148 GUN CHANGE SEQUENCE......................................132
Confirmation of Register & Position Register Number..67 GUN CHANGE SETUP ..............................................123
Confirmation of wear ratio.............................................80 GUN CHANGE STATUS ...........................................132
Connecting a Setup PC.................................................279 GUN DETACH Instruction..........................................129
CONTROL METHOD (MULTI-GROUP) ......................1 Gun Does Not Close Completely with Pressure Motion352
CREATING VISION DATA .......................................279 GUN JOG OPERATION ...............................................41
Gun Jog Operation .......................................................156
<D> GUN MASTER UTILITY ...........................................340
DATA RECOVERY ......................................................85 GUN MECHANICAL COMPENSATION
Detail of Record ...........................................................319 CALIBRATION.......................................................235
Detail Status Screen .....................................................317 Gun No.........................................................................306
Diagnosis Program .......................................................308 GUN OPEN FUNCTION AT WELD FAULT ............148
Diagnosis schedule.......................................................308 Gun Open Function at Weld Fault ...............................158
Diagnosis Setup Screen................................................305 GUN OPENING MOTION..........................................149
Diagnosis Status Screen ...............................................308 GUN SAG COMPENSATION ......................................98

i-1
INDEX B-83264EN/03

Gun Setup Utility Operation ........................................153 Note for Teaching Vision Process................................290
Gun Tip Contact Fixture Sidlingly in Fixture Touch Notice for Teaching .....................................................133
Motion ......................................................................354
Gun Tip Does Not Contact Fixture in Fixture Touch <O>
Motion ......................................................................353 ONE-STEP MEASUREMENT METHOD....................73
Gun Zero Master Instruction ..........................................61 ONE-STEP Measurement with Multi Task....................75
GUN ZERO MASTERING..........................................340 Operating Procedure for Spot Point Touchup with
Gun Zero Mastering with Worn Tip.............................355 Upper Panel Detection..............................................225
Operating Procedure of Spot Point Touchup without
<H> Upper Panel Detection..............................................229
HARDWARE SETUP..................................................275 Operation .....................................................................114
History Screen..............................................................318 OPERATION FOR QUICK VIEW FUNCTION.........185
Hold................................................................................55 OPERATION FOR RELATED VIEW FUNCTION ...183
OPERATIONAL SETTING AND ALARM
<I> PROCESSING ...........................................................77
Init Setup of Wear Down Measurement with Worn Tip355 OTHER FUNCTIONS .......................................... 176,269
INITIAL SETTING .........................................................3 OTHER INSTRUCTIONS.............................................59
Initial Setting...........................................................45,161 Other Notes ..................................................................362
INITIAL SETTING ..............................................177,188 OTHER SPECIFICATIONS........................................223
Initial Setting................................................................225 OUTLINE ....................................................................120
Initial Setup ...............................................................71,73 Outline of Installation ..................................................122
INITIAL SETUP..........................................................123 Over View....................................................................223
Initial Setup of 1-step method for Multi-Equipment ......94 Overall ......................................................................76,81
Initial Setup of 2-step method for Multi-Equipment ......90 OVERALL...................................................................150
Inspection Box .............................................................275 Override check .............................................................307
INSPECTION PROCEDURE ......................................290 OVERTORQUE PROTECTION FEATURE ..............137
Installation of Calibration Plate....................................278 OVERTRQUE PROTECTION SETUP.......................137
OVERVIEW ....... 1,65,114,137,160,177,186,261,274,301
<J> Overview......................................................................311
Jogging .........................................................................363 OVERVIEW ................................................................323

<L> <P>
Last Dress / Master Dress Chart...................................269 PARAMETER CALIBRATION SETUP.....................199
Limitation.....................................................................365 Parameters for Monitoring ...........................................301
Limitations ...................................................................119 Part Thickness Check...................................................158
Log File........................................................................318 PART THICKNESS CHECK FUNCTION .................143
LOWER PANEL DETECTION DISTANCE CLAMP198 PASS CHECK MODE .................................................243
Periodic Maintenance...................................................278
<M> Position of Fixture Is Changed.....................................354
MAGNET PHASE DETECTION (MPDT) .................341 Preparation of TWO-STEP ............................................67
MANUAL BACKUP (Shift + BU) ................................38 Preparations....................................................................67
MANUAL OPERATIONS.............................................33 PREPARATIONS FOR TIP WEAR DOWN
Manual Operations .......................................................155 COMPENSATION.....................................................67
MANUAL PRESSURIZATION (Shift + GUN) ............33 Press Motion Instruction ................................................59
MANUAL WELDING...................................................40 PRESS ON NEW TIPS................................................350
MASTERING ..............................................................342 Pressure Adjustment ....................................................314
MAX DETECTION DISTANCE.................................197 PRESSURE CALIBRATION ........................................26
Meaning of Each Items ................................................115 Pressure Calibration .....................................................154
Multi Servogun ............................................................305 Pressure Check.............................................................313
Pressure Check by Multi Task .....................................321
<N> Pressure Check Calibration ..........................................312
NAMES OF MAJOR SERVO GUN COMPONENTS ....1
PRESSURE CHECK FUNCTION ..............................311
New tip inspection........................................................281
Pressure Check Procedure............................................320
New Tip Inspection ......................................................290
Pressure Check Result / Status Screen .........................321
NEXT STEP ENABLE ................................................110
Pressure Check/Adjustment Individually .....................320
NEXT STEP ENABLE FROM WELD CONTROLLER
Pressure Check/Adjustment Procedure ........................312
..................................................................................112
i-2
B-83264EN/03 INDEX

PRESSURE COMPENSATION ...........................174,180 SERVO GUN SETUP SCREEN....................................30

Pressure Compensation Condition ...............................180 SERVO GUN TEMPERATURE COMPENSATION .177
PRESSURE ENABLE SIGNAL..................................109 SERVO GUN WEIGHT COMPENSATION ..............160
Pressure Instruction ........................................................60 SERVO GUN WEIGHT COMPENSATION
Pressure Motion after Spot Point Touchup (single step)234 FUNCTION..............................................................160
PRESSURE PROFILE CONTROL FUNCTION ........114 SERVO TIP DRESSER AXIS SETUP........................261
PRESSURE RELATED I/O SIGNALS .......................107 SERVO TIP DRESSER CONTROL ...........................261
Pressure Schedule, Distance Schedule, and Backup Servo Tip Dresser Drive Program ................................273
Schedule Table .........................................................152 SERVOGUN DIAGNOSIS FUNCTION.....................301
PRESSURIZATION NOTIFICATION SIGNAL ........111 Servogun Motion for Monitoring and Diagnosis .........301
Procedure to Use .......................................................76,81 SET OFFSET WITH PROGRAM TOUCHUP............242
PROFILE DATA .........................................................114 SET OFFSET WITH SPOT POINT TOUCHUP.........241
PROGRAMMING .........................................................48 Setting Auto Weight Compensation Function..............164
Programming Operation...............................................156 SETTING EACH WEIGHT COMPENSATION
Prompt to confirm detected lower position and thickness FUNCTION..............................................................161
..................................................................................206 SETTING GUN STROKE LIMITS.............................347
Setting Manual Weight Compensation Function .........170
<Q> Setting of calculation and updating wear ratio...............79
QUICK MASTERING REFERENCE POSITION Setting Semi-auto Weight Compensation Function .....166
SETUP......................................................................334 SETTING SYSTEM VARIABLE ...............................362
QUICK VIEW FUNCTION.........................................184 SETTING THE COORDINATE SYSTEM ...................15
SETTING THE GUN CLOSE DIRECTION.................16
<R> SETTING THE MAX PRESSURE ...............................17
RECOVER VISION DATA.........................................300 SETTING THE REFERENCE POSITION..................128
Recovery from Lost of Tip.............................................85 Setting Tool Frame of the Positioner ...........................358
Recovery Mastering Data...............................................85 Setting Tool Frame of the Robot (For Calibration)......359
REFERENCE POSITION SETUP...............................331 Setting up Servo Gun ...................................................363
Reference Position Setup for Calibration Types 3 and 4 Setting Weight Compensation Type ............................174
..................................................................................331 SETUP .........................................................................294
Reference Position Setup for Calibration Types 5 and 6 SETUP EARLY WELD INIT FUNCTION.................325
..................................................................................333 Setup for tip wear down alarm process ..........................78
Related Function ..........................................................275 Setup for tip wear down measurement ...........................78
RELATED VIEW FUNCTION ...................................182 Setup Menu ..................................................................294
RESET ALARM ..........................................................341 SETUP MULTI GUN SYSTEM..................................298
Restrictions...................................................................120 Setup Screen.................................................................314
Robot Homepage..........................................................279 SHARE ONE LNSPECTION STATION WITH
Routing Method of Main Body Connection Cables MULTI ROBOT.......................................................299
（Camera, LED）....................................................276 SIMPLE SEARCH MODE FOR UPPER DETECTION
..................................................................................240
<S> SINGLE STEP MODE ................................................222
SAFETY PRECAUTIONS ...........................................s-1 Single-Step.....................................................................55
Sample for Introduction .................................................83 Spare Parts List ............................................................278
Sample Program ....................................................130,135 SPECIFICATION ........................................................301
Save and Clear Diagnosis Data ....................................304 SPOT Instruction Format ...............................................48
Save Diagnosis Records ...............................................302 Spot Point Touchup Cancellation.................................233
SEARCH PARAMETERS SETUP..............................202 SPOT POINT TOUCHUP FUNCTION.......................223
Search Sequence with Thickness Update .....................205 SPOT PROGRAM TOUCHUP CHART SCREEN .....210
Selecting Frame Number..............................................363 SPOT PROGRAM TOUCHUP DISABLE
SERVO GUN AXIS INITIALIZATION .........................3 INSTRUCTION .......................................................218
SERVO GUN GENERAL SETUP SCREEN ................30 SPOT PROGRAM TOUCHUP EXECUTION
SERVO GUN MAIN SETUP SCREEN ........................30 PROCEDURE ..........................................................188
SERVO GUN MONITORING.....................................103 SPOT PROGRAM TOUCHUP FUNCTION...............186
SERVO GUN SETUP..................................................133 SPOT PROGRAM TOUCHUP SETUP SCREEN ......191
Servo Gun Setup ..........................................................151 SPOT PROGRAM TOUCHUP STATUS SCREEN....207
SERVO GUN SETUP AND AUTOTUNING UTILITY SPOT WELDING INSTRUCTIONS.............................48
....................................................................................17 SPTCH_OFS INSTRUCTION.....................................219

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INDEX B-83264EN/03

SPTCH_RSD INSTRUCTION ....................................220 TROUBLESHOOTING (GUN CHANGE) .................336

STANDARD TIP WEAR PROGRAM LIST.................66 TWO-STEP MEASUREMENT METHOD...................70
Standard Tip Wear Program List for Multi-Equipment..89
Status Menu..................................................................296 <U>
Status Screen ................................................................316 Update Amount of Wear Down .....................................74
Summary of diagnosis records .....................................304 Update Tip Wear Amount..............................................72
Summary of Record .....................................................318 Update Tip Wear Amount of 1-step method for
System Configuration...................................................121 Multi-Equipment ........................................................95
SYSTEM CONFIGURATION ....................................358 Update Tip Wear Amount of 2-step method for
SYSTEM VARIABLE .................................................310 Multi-Equipment ........................................................92
UPDET_OFS INSTRUCTION ....................................241
<T> USER INTERFACE ....................................................305
TEACHING .................................................................133 USING VARIABLE REMOTE TCP...........................363
Teaching.......................................................................364
Teaching Position......................................................54,70 <V>
TEMPERATURE COMPENSATION SETTING VARIABLE REMOTE TCP SETUP METHOD .........358
SCREEN...................................................................178 Vision Process Tools....................................................280
Temperature Compensation Status...............................180 Vision Setup.................................................................280
TEST CYCLE ..............................................................105
THE ATTACH INSTRUCTION IS EXECUTED <W>
WHEN THE GUN IS NOT ATTACHED................336 WEAR DOWN AMOUNT IS NOT MEASURED
THE ATTACHED GUN HAS BEEN DETACHED BY CORRECTLY ..........................................................352
MISTAKE (WITHOUT USING THE DETACH Weight Compensation Status .......................................175
INSTRUCTION). .....................................................338 WELD DELAY TIME MEASUREMENT..................323
THE BATTERY RAN LOW WHILE THE GUN WAS Welding Sequence..........................................................53
DETACHED. ...........................................................339 WELDTIP INSPECTION ............................................274
THE BATTERY VOLTAGE HAS FALLEN..............339 WeldTip Vision Model ................................................274
The details....................................................................302
THE GUN AXIS OF A DETACHED GUN HAS <Z>
MOVED. ..................................................................338 Zero Calibration Config Screen ...................................346
The Result of Diagnosis ...............................................301 Zero Calibration History Screen ..................................346
THE ROBOT STOPPED DURING CALIBRATION. 336
The Schedule of Diagnosis...........................................305
THICKNESS CHECK CALIBRATION...............143,239
THICKNESS CHECK GENERAL SETUP.................145
THICKNESS MEASUREMENT...................................45
Thickness Measurement from Editor .............................45
Thickness Measurement from MANUAL Screen ..........46
THICKNESS UPDATE SETUP ..................................203
TIP DRESS SETUP MENU.........................................266
Tip Wear and Gun Sag Compensation .........................158
Tip Wear Detect Setup Screen .......................................77
TIP WEAR DOWN COMPENSATION........................65
TIP WEAR DOWN COMPENSATION FOR
MULTI-EQUIPMENT ...............................................89
Tip wear inspection ......................................................285
Tip Wear Inspection.....................................................291
Tip Wear Standard Screen..............................................80
TIPDRESS Instruction ...................................................62
TIPDRESS INSTRUCTION ........................................265
Tips to Using SPOT Instruction .....................................59
Torque check................................................................307
TOUCHUP STATUS RECORDING FUNCTION ......216
TROUBLE SHOOTING (TIP WEAR
COMPENSATION)..................................................352
TROUBLESHOOTING ...............................................246

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B-83264EN/03 REVISION RECORD

REVISION RECORD
Edition Date Contents
03 Sep.,2013 Description for 7DC2 is added.
02 Oct., 2012 Description for software changing is added and changed.
01 May, 2012

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 B-83264EN/03

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