MAN KAP12 19 ROB Clinching140220 En

Standard documentation for chassis construction systems
Section 12.19 - Clinching

Standard
Electrics
V 8.0
Robot Technology Clinching
Kuka robot with KRC4 controller
Created: Prudlo Dominik

Date of creation: 04.07.2013
Last change: 01.06.2015
Version: 1.00
Language: English
Other languages: No other languages are currently available
The "German" version is always valid!
MAN_KAP12_19_ROB_Clinching_140220_en.docx
© All rights reserved by BMW AG, also in the case of patent applications.
All rights of disposal, such as rights of copying and distribution, lie with the BMW Group.
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Table of contents Section 12.19:
Table of contents Section 12.19: ....................................................................................................... 2

Change history: ..................................................................................................................................... 3
12.19.1 General Information .......................................................................................................... 4
12.19.2 Overview of components .................................................................................................. 4
12.19.3 configuration ..................................................................................................................... 4
12.19.3.1 Number of guns ................................................................................................................ 5
12.19.3.2 Gun configuration ............................................................................................................. 5
12.19.4 Display .............................................................................................................................. 6
12.19.5 Programs .......................................................................................................................... 7
12.19.5.1 Application programs ........................................................................................................ 7
12.19.5.2 Service programs .............................................................................................................. 8
12.19.5.3 Maintenance programs ..................................................................................................... 8
12.19.5.4 Creating Service programs and Maintenance programs .................................................. 9
12.19.5.5 Overview of commands .................................................................................................. 10
12.19.5.6 Command for a clinching point ....................................................................................... 10
12.19.5.7 Positioning command ..................................................................................................... 11
12.19.5.8 Init ................................................................................................................................... 12
12.19.5.9 Spray............................................................................................................................... 12
12.19.5.10 GunState ...................................................................................................................... 12
12.19.5.11 Customer support ......................................................................................................... 13
12.19.5.12 Status keys ..................................................................................................................... 13
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Change history:
Date Topic Note

04.07.2013 Created Prudlo Dominik (KUKA robot GmbH)
07.11.2013 Revised Prudlo Dominik
18.12.2013 Revised, new Inline Forms Prudlo Dominik
07.02.2014 Templates updated Prudlo Dominik
19.02.2014 Small changes made by BMW Prudlo Dominik
- Critical operations removed
- All service programs listed
- Comments on Decouple
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12.19.1 General Information

The user documentation describes the commissioning and programming of a clinching application.
12.19.2 Overview of components

Clinching controller from the Tox company max. 3 controllers
Clinching gun max. 3 guns per clinching controller
and a total of max. 3 guns
12.19.3 Configuration
Configuration of the inputs and outputs is not performed by the application software and therefore not
contained in this documentation.
The configuration window is called from the Main menu via the menu item:
Configuration  BMW_Application  A19_Clichen
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3 1 2 4
Pos Description
1 Variable group
2 Variable designation
3 Representation of variable values
4 Button for cyclic updating of variable states.
5 Button for setting a variable value.
12.19.3.1 Number of guns

Configuration of the number of components used on the robot.
Variable group: Max robot Gun
Designation Description Min Max

cli_i_Max_CG Number of clinching guns 1 3
12.19.3.2 Gun configuration

Variable group: Gun [No] robot
Designation Description Min Max

cli_i_GunToSys[1] Assignment of gun to clinching system 1 3
cli_i_Max_Pos_CG[1] Maximum gun opening dimension 20 300
cli_i_Min_Pos_CG[1] Minimum gun opening dimension 0 19
cli_e_EqualActive[1] Equalization monitoring
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#YES
Activate
#NO
Deactivate
12.19.4 Display
The configuration window is called from the Main menu via the menu item:
Display  BMW_Application  A19_Clinchen
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1
4 3 2 5
Pos Description
1 Selection of the clinch component
2 Designation of the input/output or variable
3 Representation of the value of the input/output or variable.
The status of inputs/outputs and Boolean variables is shown as:
 Gray: inactive (FALSE)
 Green: active (TRUE)
4 Number of the input/output
For "variables" tab: Arrow symbol for cyclic updates.

5 Button for cyclic updating of variable states.
Inputs/outputs are always updated
6 Button for setting a variable value. Inactive in the display
7 Tab for the inputs/outputs and variables of the selected clinch component
12.19.5 Programs
12.19.5.1 Application programs
Application programs are located in the directory \R1\BMW_App
Module name Description

A19_cli_sys.src  Clinching point
 Positioning
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 Init
 Spray
 Gun service
 Customer support
Global routines are called exclusively by the robot interpreter
No changes to the module may be performed by the user.

A19_cli_sub.src  Monitoring functions
 Status keys
 Initialization on controller startup
 Communication with clinching components
Global routines are called by the submit interpreter.
No changes to the module may be performed by the user.

A19_cli.dat  Configuration of the inputs/outputs
 Variables for src - modules
No changes to the data list may be performed by the user.

A19_cli_user.dat  Location specification Configuration data
A19_cli_global.dat  Global position data
12.19.5.2 Service programs

Program templates exists for the service programs and these must be used. The program templates
contain the main sequence and instructions.

A19_cli _LubePos Program for spindle lubrication position
 Robot moves from Home1to the lubrication position
 Signals "in position" to PLC via a user output
 Wait for user input to continue motion
 Reset the user output
 Robot moves back to Home1
A19_cli _GunMaintenan Program for gun maintenance
 Robot moves from Home1 to the maintenance position
 Signals "in position" to PLC via a user output
 Wait for user input to continue motion
 Reset the user output
12.19.5.3 Maintenance programs

Program templates exists for the maintenance programs and these must be used. The program tem-
plates contain the main sequence and instructions.
Maintenance programs are only executed in Test operation!

A19_cli _GunCalib Program for checking the force and path measuring system
 Robot moves from Home1 to the change position
 Robot stops moving to change the gun
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A19_cli _GunEqual Program for teaching the gun equalization
 Robot moves from Home1 to the first position (gun in 0° posi-
tion)
 Robot displays a dialog "gun in 0° position" and waits for the re-
lease to continue moving
 Robot moves to second position (gun in 90° position)
 Robot displays a dialog "gun in 90° position" and waits for the
release to continue moving
A19_cli _GunChange Program for gun change
 Robot moves from Home1 to the change position
 Robot stops moving to change the gun
12.19.5.4 Creating Service programs and Maintenance programs
Service and Maintenance programs are to be created in the directory\R1\BMW_Utilities
 Select directory \R1\ BMW_Utilities in the Navigator

 Set the focus to the right-hand window in the Navigator
 "New" softkey
 Select template
 Append the gun number to the module name
 Select a program
 Adjust the gun number in the commands
 Teach the positions
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12.19.5.5 Overview of commands

Commands for the application are programmed via Inline Forms.
Menu: Commands  BMW_Application  A19_Clinchen
12.19.5.6 Command for a clinching point

Menu: Commands  BMW_Application  A19_Clinchen  Clinching
Parameter Description Min Max

PTP/LIN Motion type at the clinching point - -
TypeId Type identification number 1 255
ClinchNo Clinching point number 1 999999
GunNo Gun number 1 max.
gun
GunOpen Gun opening dimension after clinching 20 max.
opening
Vel Speed
SprayStemp Spray onto stamp
True
Activate
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False
Deactivate
SprayDie Spray onto die
True
Activate
False
Deactivate
FDAT Frames options window
- Tool number 1 128
- Basis number 1 128
- Interpolation mode
PDAT Motion data record options window
- Acceleration
- Orientation guide (only with LIN)
Desc Comment
12.19.5.7 Positioning command

Menu: Commands  BMW_Application  A19_Clinchen  Positioning

PTP/LIN Motion type to clinching point
gun
GunOpen Set gun to opening dimension 20 max.
opening
GunOpenCtrl Opening dimension check:
Activated (Ctrl)
Deactivated (None)
Point name Frames options window
Tool number 1 128
Basis number 1 128
Interpolation mode
_/Cont Processing of the command
 Without a CONT  command, processing is
not performed in advance, approximate posi-
tioning cannot be used.
 CONT  command can only use approxi-
mate positioning when GunOpenCtrl = None,
or when
GunOpenCtrl = Ctrl if the opening dimension
is reached before the robot reaches the point.
Vel Speed
PDAT/CPDAT Motion data record options window
Acceleration
Orientation guide (only with LIN)
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Desc Comment box
12.19.5.8 Init
Menu: Commands  BMW_Application  A19_Clinchen  Service Commands

gun
GunOpen Set gun to opening dimension 20 max.
opening
Desc Comment box
12.19.5.9 Spray

gun
SprayStemp Spray onto stamp
True
Activate
False
Deactivate
SprayDie Spray onto die
True
Activate
False
Deactivate
Desc Comment box
12.19.5.10 GunState

gun
/Couple Couple the gun to the clinching controller
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/Decouple Decouple the gun from the clinching controller

Desc Comment box
The command GunState "Decouple" must be executed before undocking in A02_Toolchanger to pre-
vent damage to the electrical contacts!
12.19.5.11 Customer support


gun
Prog Service program selection
- Reference
- Home Pos
- Spray Stemp
- Spray Die
- Toolcheck
- Lubricating Pos
Desc Comment box
12.19.5.12 Status keys

The status buttons are activated via the path:
Menu: Configuration  status buttons  A19_Clinchen
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Tapping the status button (Bar) symbol, shows all possible status user buttons (Bars) for clinching.
These can be switched over by tapping the desired bar again.
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Status key Description Icon

Selection gun Incrementation for selecting the
(Bar: Gun and Dock) active gun.
Selection Open gun The gun is slowly opened. (Observe

(Bar Gun) the note on critical operation.)
Selection Close gun The gun is slowly closed.
(Bar Gun) (Observe the note on critical opera-
tion.)
Selection of Unlock gun equali- The gun equalization remains un-
zation. locked while the button is pressed.
(Bar Equal) (Observe the note on critical opera-
tion.)
Selection Electrically discon- The gun is decoupled from the
nect gun clinching system.
(Bar State)
Selection Electrically connect The gun is coupled to the clinching
gun system
(Bar State)
Quit Start error acknowledgement to the
(Bar Gun and Dock) clinching controller, on starting
* Icons are not drawn to scale.
The functions can only be executed when the following conditions are satisfied:
 The operating mode T1 or T2 is selected!

 The enabling switch on the smardPAD is actuated!
 The Profinet connection is ok!
 The button has been "intentionally"pressed! > Pressed twice, with a brief pause between
each press! (only with buttons whose actuation causes a critical operation)
Page 15 of15

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Standard documentation for chassis construction systems

Section 12.19 - Clinching

Robot Technology Clinching

Kuka robot with KRC4 controller

Created: Prudlo Dominik

The "German" version is always valid!

Table of contents Section 12.19:

Table of contents Section 12.19: ....................................................................................................... 2

Date Topic Note

12.19.1 General Information

12.19.2 Overview of components

12.19.3.1 Number of guns

Variable group: Max robot Gun

Designation Description Min Max

12.19.3.2 Gun configuration

Designation Description Min Max

For "variables" tab: Arrow symbol for cyclic updates.

12.19.5.1 Application programs

Application programs are located in the directory \R1\BMW_App

Module name Description

Global routines are called exclusively by the robot interpreter

No changes to the module may be performed by the user.

Global routines are called by the submit interpreter.

No changes to the module may be performed by the user.

No changes to the data list may be performed by the user.

12.19.5.2 Service programs

Module name Description

12.19.5.3 Maintenance programs

Module name Description

 Robot moves back to Home1

12.19.5.4 Creating Service programs and Maintenance programs

Service and Maintenance programs are to be created in the directory\R1\BMW_Utilities

 Select directory \R1\ BMW_Utilities in the Navigator

12.19.5.5 Overview of commands

12.19.5.6 Command for a clinching point

Parameter Description Min Max

12.19.5.7 Positioning command

Parameter Description Min Max

Desc Comment box

Parameter Description Min Max

Parameter Description Min Max

Parameter Description Min Max

/Decouple Decouple the gun from the clinching controller

12.19.5.11 Customer support

Parameter Description Min Max

12.19.5.12 Status keys

Status key Description Icon

Selection Open gun The gun is slowly opened. (Observe

* Icons are not drawn to scale.

 The operating mode T1 or T2 is selected!

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