Fiber Laser - FLW Operation reference

AMADA LASER (Ytterbium Fiber Laser) Procedure to start Air compressor ON Make sure that the main air pressure is 0.49MPa or (AIR) Open the valve of shield gas (Argon or Nitrogen, etc) (Check the remaining amount of gas in cylinder) (Argon is usable for general materials) (Nitrogen is usable for general steels (SPCC,SUS304,SECC, etc.), aluminum (A1000,A5000)) FANUC controller R-30iA circuit breaker ON Laser oscillator circuit breaker ON (ON at any time) OSCILLATOR MODE keyswitch Robot Controller POWER switch button ON (The window display and the ROBOT READY light are illuminated.) ROBOT MODE keyswitch T1 250mm/s Return the air type interfere sensor. (Make the shock sensor and torch stand upright, and according to the white line, move down the head to fit in.) Make sure that the EMISSION ENABLE keyswitch is OFF. LASER keyswitch ON LASER READY LED light flashes. (in preparation) The LASER READY LED light and pilot lamp (green) are illuminated. Complete the start up. more FANUC R30iA

Fiber Laser - FLW Operation reference

AMADA LASER (Ytterbium Fiber Laser) Procedure to finish operation Move the robot to the work origin point (for next days work to recover the air type interfere sensor.) Close the partition door. EMISSION ENABLE keyswitch OFF LASER keyswitch OFF (The LASER READY LED lights off) Controller POWER switch OFF (The display lights off) OSCILLATOR MODE keyswitch OFF Laser oscillator circuit breaker OFF (only for a long period of time to leave idle) Leave it ON usually. FANUC controller R-30iA circuit breaker OFF Close the shield gas valve Air compressor OFF
(Note 1) Do not turn off the oscillator breaker for protecting the cooling water from freezing up in winter time. (Note 2) Always keep the external chiller primary breaker ON.

FANUC R30iA

Table of contents

1Basic robot operation 2Machine operation 3Programming example 1 Basic program 4Teaching hand box 5Teaching hand box 6Manual feed 7-9 Program operation 10-11 Instruction for interpolation 12Calibration result check 13-15 Welding order 16-18 Program change/adding/elimination 19-20 Instruction change 21Check before starting a program 22-24 Processing condition file 25-29 Welding special feature 30-36 Utility 37-28 Operative method 39 Make a full use of robot 40 Program example 2 advanced program 41 Program example 3 track shape 42 Program example 4 advanced track shape 43 Program example 5 advanced track shape 44 Program example 6 overlaying program 45 How to process a corner 46 Edit work 47 Multiple programs batch processing 48-51 Program shift 52 Robot operation with a rotating table 53-55 With a rotating table 56-60 Attachment: Standard working process chart

This reference material has been made for machine operators. Please read the operation manual for each unit carefully before operation.

Basic Basicrobot robotoperation operation

Machine operation

New product

Assembly Tack welding Repeat product Examine product position Assembly/Tack welding Set the product Select a table Create a new program Positioning JIG resetting Teaching Processing direction Processing condition Set the product

(with Shuttle option)

Automated product

Assembly/Tack welding

Select a station

Positioning JIG resetting Set a product

Movement check forward/backward Prepare to run

Start TAS operation

TAS operation Correct the position

Automatic job retrieving Set a JOB to use

Start

Inspection

Inspection

Prepare to run

Start (processing)

Start (return)

Inspection

Program Programexample example1 1 Basic Basicprogram program

This program is an example of straight welding program. Specify material type and thickness, then create program. Refer to the condition list for each material type and thickness available to specify.

Specify a condition file Specify a processing condition No. Initial position Start position Welding operation Weld end position Finish processing Retract position Initial position Finish macro

1:M102(SUS1.0) 2:E_NO(1) 3:L 4:L P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100

Specify the file

Position to start welding Laser ON/Shutter open Point to finish welding Close the shutter

5:LASERON 6:L P[3] R[1] cm/min CNT100

7:LASEROFF 8:L 9:L P[4] R[1] cm/min CNT100 P[5] R[1] cm/min CNT100

10MCR_END [End]

Dry run speed and welding speed are automatically detected. Dry run speed is selectable from F1-F4.

Initial position

Retract position

Welding operation Start position Start welding Pass point Finish welding

Welding speed is automatically retrieved from the specified condition file.

Teaching Teachinghand handbox box

Teaching hand box layout
Enables all the necessary operation for robot such as programming and test execution. Enables to move the arm and wrist of robot by key operation of the teaching hand box. The Robot stops when you press the EMERGENCY STOP button. Moreover, the Deadman switch makes the robot stop just taking your hand off from the box while using.
Hand box enable switch EMERGENCY STOP button

Screen

List key
Selects the program list window.

Function key
Selects the function key menu.

Edit key Preview key

Preview the previousoperation. Selects the program edit window.

Next page key

Displays the next pages function menu.

Data key
Selects the data screen such as register.

FCTN key
Displays auxiliary function.

Menu key
Selects the screen menu.

Group key
Select a jog group.

Cursor key
Moves the cursor.

Hold key
Makes the robot pause.

Step key Reset key

Reset the alarm.

Forward key
Execute programs.

Back space key

Deletes the letters or numbers shown before and after the cursor.

Jog keys
Moves the robot manually.

COORD key
Switches the kind of jogs.

Item key
Moves the cursor to any item or line.

Override keys
Adjusts the robot speed.

Enter key
Inputs numbers and selects menu.

Input/Output key
Displays the I/O window.

Tool 1/2 key

Displays the tool 1 and 2.

Set up key
Displays the setting window.

Position display key

Displays the current position.

Status key

Regular position return key

Displays the status window. Not available now.

Notes) The teaching hand box that you use actually might be a little different from the above.

Teaching Teachinghand handbox box

The following short cut keys are available at teaching hand box.

Inside mirror movement

Dead -man Shift Set up

Enables to see the guide laser properly by moving the inside mirror when using the guide laser. Inside mirror for camera in and out Every time pressing once, switches in and out.

Filler nozzle up/down movement

Moves the nozzle up or down when using filler.

Tool 1

Filler nozzle up and down Every time pressing once, switches up and down.

Side nozzle up/down movement

Moves the nozzle up or down when using TAS.

Tool 2

Filler nozzle up and down Every time pressing once, switches up and down.

Feeds the filler material

Forwards filler-materials to processing point.

Dead -man

Shift

Tool 1

While pressing, feeds filler-materials at slow speed and then (2 seconds later) moves quickly.

Retracts the filler material

Retracts filler-materials.

Dead -man

Shift

Tool 2

While pressing, returns filler-materials at slow speed and then (2 seconds later) moves quickly.

Return to reference position

Returns the robot to the reference position.

Dead -man

Shift

Move menu

While pressing, the robot moves to the reference postion.

Manual Manualaxis axisfeed feed

Lets operate the robot to grasp the movement features.

Make sure to check before start

Mode switch
Switches enable or disable of the teaching hand boxs operation. Select ON to operate manually. Turn the mode key ON.
OFF ON

Select a jog group

Switches the operations of robot, carriage and table. Select a group depending on the situation for movement. (G1=robot G1S=carriage G3=rotating table)

G1

G1 S

G3

Select a movement coordinate system

Select the coordinate system depending on the situation for movement.

Orthogonal

Each Tool 3LDR 0 axis

The coordinate systems are shown at the upper right on the screen. No use of 3LDR 0.

Select an axis speed

Adjust the speed for manual feeding. 100505FINEVFINE Enables to switch among the above five stages of fixed speed. Switch the speed in combination with a Shift key and + or - key. 5% for 10% or more 1% for 10% or less

Deadman switch

To turn on the servo power. Enables manual operation for each axis with holding. Notes : Press lightly. When pressing too firmly, the servo is turned off.

Programming Programmingoperation operation

Lets create, retrieve and copy a program.

Create a newly program

Press SELECT.

SELECT

CREATE is shown on the F2. Press CREATE of the F2.

Program input display is shown up. A list for selecting input method is shown in the upper part of the F5. Select using cursor a input method among Words/Upper Case/Lower Case/Options.
Specify a input method with cursor.

Input a program name using the letters displayed in F1-F5 with F keys, and then press ENTER.

ENTER

After the above procedure, the new program display is shown up.
Reference: A key board is shown up when selecting other/key board.

ENTER

Retrieve an existing program

Press SELECT.

SELECT

A list of existing programs is shown. Find a program to use with cursor and press ENTER.

ENTER

Copy an existing program

Press SELECT.

SELECT

A list of existing programs is shown. Find the program to copy with cursor.

Press NEXT to display COPY at the F1, and then press COPY.

NEXT COPY display appears.

F1

For the COPY TO, input the name of program using the letters displayed on F1-F5, then press ENTER to change the name. ENTER

Input method is the same as creating a new program.

Delete an existing program

Press SELECT.

SELECT

A list of existing programs is shown. Find the program to delete with cursor.

DELETE is shown on the F3.

Press DELETE on the F3 to delete the program.

F3

Instruction Instructionfor forinterpolation interpolation

Movement instruction is set with interpolation method (straight-line interpolation and circular interpolation) and movement speed. In the programming display, select an interpolation method from the options (2 kinds) displayed on the function keys. POINT CIRC

The POINT means an order of straight-line interpolation.

Straight-line interpolation
Select the POINT of the F1.

The standard movement menu 1 is displayed. Select the order to use with cursor and press ENTER.

ENTER

Straight line position[2] Straight line position[3]

Straight line position [1]

When making a straight-line interpolation at each point, use this order.

Arc interpolation
The CIRC means an order of arc interpolation. Select CIRC of the F2.

The CIRC 1 is displayed. Select the order to use and press ENTER.

ENTER

Circular arc position[2]

Circular arc position[1]

Creates an arc by instructions for two points of start and end point of arc.

Program Programmovement movementcheck check

Check the created program in the forward/backward feed of step operation and continuous operation.

Switch between step and continuous operation

STEP button is to switch between step and continuous operation.

Step-operation status

Continuous-operation status

Check on step operation

Backward Forward

1:L 2:L 4:L 5:L 6:L [End]

P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[4] R[1] cm/min CNT100 P[5] R[1] cm/min CNT100 P[6] R[1] cm/min CNT100

3:L @P[3] R[1] cm/min CNT100

Speed 100% Speed set

For step operation, with pressing once on the key of forward or backward, performs moving forward or backward one line. Current position of robot is marked with @ in front of the POSITION P in the program.

Check on continuous operation

Backward Forward

1:L 2:L

P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[4] R[1] cm/min CNT100 P[5] R[1] cm/min CNT100 P[6] R[1] cm/min CNT100

Speed 100% Speed set

3:L @P[3] R[1] cm/min CNT100 4:L 5:L 6:L [End]

For continuous operation, with pressing once the key of forward or backward, performs to the final line from the current line where the instruction has been made. The movement becomes SMOOTH without stopping at each teaching point.

Welding Weldinginstruction instruction

Program setting to make a welding instruction to laser oscillator as follows. Select LASER assigned on the F3 key in the programming screen. (4 kinds) Processing condition designation Processing condition No. designation Laser ON Laser OFFF

Processing condition designation (M102(())

Set a condition list of material type/thickness to use. Select LASER of the F3. F3 The laser menu 1 is displayed. Select M102(.) with cursor, and press ENTER.

ENTER M102() is inserted into the program. Select the part of processing condition in the M102(.) with cursor.

CHANGE appears in the F5. Then press CHANGE.

F5 Parameter type selection menu appears, then select STRINGS of the F5. F5 Alpha Input 1 menu appears in the F5, then select among Words, Upper Case, Lower Case and Options with cursor then press ENTER.

F5

Input name

ENTER

Processing condition No. designation

The standard values are filed to be selected depending on processing purpose. Enables to specify as E_NO (processing condition number). Select LASER of the F3. F3 LASER MENU 1 appears. Select E_NO(Constant) with cursor and press ENTER. ENTER E_NO(Constant) is inserted into the program. Select (Constant) of E_NO(Constant) with cursor.

Input the processing condition No. directly from with keyboard of control board and press ENTER. Input numbers ENTER

<Standard condition array table> No. E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 Name Standard pulse <PULSE-L> Hard pulse <PULSE-H> High speed <HIGH> Standard <NORMAL> Flat <FLAT-F> Filler standard <FLAT-F> Back up 1<Reserve1> Back up 2<Reserve2> Weaving <WV> Weaving filler <WV-F>
For gap processing (gap=thickness 30%) Material thickness and leg length setting such as open and fillet

Intended purpose
In standard setting, overheated part, edge condition and minimum deformation Gap and corner processing High speed welding, lap welding application Generally stable condition for standard gap R and flat finish For flat finish, standard gap t X 30%

When needing a strong condition, change the processing condition file M102. (example: M102(t1.0) M102(t1.2)) Or when needing weak condition, change the processing condition file M102 in the same way. (example: M102(t1.0) M102(t0.8))

Welding start instruction (LASERON)

Instruction for teaching a welding start point to start welding from there. Select LASER of the F3.

3 Laser menu 1 appears. Select LASERON with cursor, and press ENTER.

ENTER

LASERON is inserted into the program.

Welding end instruction LASEROFF

Instruction for teaching welding end point and not to weld from there.

Select LASER of F3.

Laser menu 1 appears. Select LASEROFF with cursor and press ENTER

ENTER

LASEROFF is inserted into the program.

Program Programchange/adding/elimination change/adding/elimination

How to change/add/eliminate a teaching position in programs are as follows.

Change a teaching position

To change the position(P) 3
1:L 2:L 3:L 4:L
[End]

P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[3] R[1] cm/min CNT100 P[4] R[1] cm/min CNT100

1:L 2:L 4:L

[End]

P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[4] R[1] cm/min CNT100

3:L P[3] R[1] cm/min CNT100

Move the robot to the position to change. Press TOUCHUP of the F5 key.

F5

Add a teaching position

To add between the position (P) 2 and 3. 1:L 2:L 3:L 4:L
[End]

P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[3] R[1] cm/min CNT100 P[4] R[1] cm/min CNT100 1:L 2:L 3: 4:L 5:L
[End]

P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 1:L P[1] R[1] cm/min CNT100 2:L P[2] R[1] cm/min CNT100 P[3] R[1] cm/min CNT100 3:L @P[5] R[1] cm/min CNT100 P[4] R[1] cm/min CNT100 4:L P[3] R[1] cm/min CNT100 5:L
[End]

P[4] R[1] cm/min CNT100

Make the edit menu display on the F5 with pressing NEXT. NEXT Press EDIT of the F5 key to display the edit menu. F5 Select INSERT with cursor, and press ENTER. ENTER Input the number of lines to input with key board and press ENTER.
KEY BOARD
INPUT NUMBERS

ENTER

In this case, insert one line. Press NEXT to display the point menu. NEXT Select POINT of F1 key. F1 Default Motion1 is displayed. Select the instruction to use with cursor and press ENTER.

A straight line (L) is added on the third line.

ENTER

Delete a teaching position

To delete the position 1 (P1) 1:L 2:L 3:L 4:L
[End]

P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[3] R[1] cm/min CNT100 P[4] R[1] cm/min CNT100

1:L 2:L 3:L

[End]

P[2] R[1] cm/min CNT100 P[3] R[1] cm/min CNT100 P[4] R[1] cm/min CNT100

Press NEXT to display the edit menu in the F5 key.

NEXT Press EDCMD of the F5 key to display the edit menu.

F5 Select DELETE with cursor and press ENTER.

ENTER Delete line(s)? is displayed. Select the line to delete with cursor and press YES of the F4 key.

The first line is deleted so that the positionP [2] moves to the first line.

Instruction Instructionchange change

How to change an instruction in a program.

Change a processing condition

Put a cursor on the processing condition name of M102 in the program. CHANGE comes up in the F5 key, press CHANGE.

F5

A select menu of parameter type comes up, then select STRINGSof the F5 key.

F5

Alpha Input 1 menu comes up on the F5, then select among Words, Upper Case, Lower Case and Options with cursor and press ENTER.

F5

Input name

ENTER

Change a welding condition No.

Put a cursor at the number of E_NO on the program.

Input the numbers directly from KEY BOARD of control board, and press ENTER.

Input number

ENTER

Change an interpolation
Put a cursor on the interpolation instructions (Joint, Linear, Circular) in the program. CHOICE comes up on the F4, then press CHOICE.

F4
The select menu of Motion Modify comes up, then select with cursor and press ENTER.

ENTER

Change an interpolation part (without robot teaching)

How to change the position the same as the coordinate specified once with teaching. Put a cursor at the number of POSITION in the program.

Input the position number directly from key board of hand box and press ENTER.

Input number

ENTER

How to input a coordinate directly in the coordinate value data. Put a cursor on the position number in the program.

The POSITION comes up at the F5, then press POSITION.

F5
The position information appears, then put a cursor at the axis to move, input the numbers directly with key board and press ENTER.

Key board

Input numbers

ENTER

Check Checkbefore beforestarting startinga aprogram program

Procedure from the status being ready to process after preparing the program till the start of processing.

Teaching hand box enable switch ONOFF Partition door Close Robot mode AUTO Safety device RESET Alarm reset RESET Open a program OPEN Transfer to the schedule TRANSFER Feed rate setting Select from F1F4 Emission enable keyswitch ON Start running START
Close the door

Processing Processingcondition conditionfile file

For processing conditions, the standard values for each typical material type and thickness are filled. Basically an instruction is made at the top of program, but it is also available to insert into a program during the operation when needing to change the processing condition. Enables to specify at M102 (processing condition name) in the program.

F3

Select LASER of the F3, then laser 1 comes up.

Select an order to use with cursor and press ENTER. After inserting into the program, input the name of condition to process with key board.

ENTER

Check on a processing condition list

To check the processing condition in the file, or the name of processing condition to use for M102.

When selecting CONDITION., enables to confirm the condition being processed now or the registered condition list.

By pressing LIST, enables to check a list of registered conditions.

Open a processing condition

Use for checking and selecting the number of condition being programmed, and changing the condition being used. Select a condition file to use.

After selecting the condition file, press CALL.

The details of processing condition come up.

How to modify a processing condition

Two ways to modify a processing condition. The first one is to input directly. The second one is to select from the pull-down menu.

The way to input directly

Touch on the screen on the part of processing condition to modify. The part to modify is high-lighted. Input the number to modify and press ENTER.

Key board

ENTER

The way to input from pull-down

Touch on the screen on the part of processing condition to modify. A pull-down menu comes up. Then, select the number displayed. Setting condition with a pull-down menu (6 items) Welding gas type Filler control Slope up Slope down Fine Joint shape The others are to be input directly.

Add comments with the modified conditions (arbitrarily).

To save the comments with the modified condition, press COMMENT to display the comment window and input with key board.

Key board

ENTER

How to modify a filler condition

As for filler conditions, with changing the speed and control system, enables to create optimum conditions for welding with overlaying and gaps. The first one is to input directly. The second one is to select from pull down menu.

Direct-input method Filler speed.

Touch on the screen for the processing condition to modify. The part to change is highlighted. Then, input the number to change with key board and input ENTER.

Key board

ENTER

Pull down input method Filler control

Touch on the screen for a processing condition to modify. A pull down menu is displayed. Then, select the number displayed on the screen.

Slope up/Slope down/Fine

Enables to reduce defects and to create a stable welding bead by adjusting emission and frequency in response to the speed for parts where the welding speed changes rapidly such as at the points to start/end processing and the edge. To change the condition, select from the pull down menu.

Pull down input method

Touch on the screen for a processing condition to change. Pull down menu is displayed. Then, select a number on the screen.

Enables to see the conditions selected on the above screen in the power control display. As for Fine, enables switch to a certain condition in the section to lower the speed by a constant rate. As for Slope up/down, enable to switch to a certain condition in a certain section from starting the processing or by ending the processing. For the details of selected conditions, enable to see with pressing the button of POWER CTRL. The part to change is highlighted. Then, input the number to change from key board, and press ENTER.

Key board

ENTER

Special Specialfeatures featureswhen whenwelding welding

The explanations for the special features of FLM are as follows.

instruction
The slope up is the feature that is effective to reduce penetration when starting welding by lifting up the laser beam like a slope.
1:M102(SUS1.0) 2:E_NO(1) 3:L 5:L 7:L [End] P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[3] R[1] cm/min CNT100 4:LASER ON 6:LASER OFF 8:MCR_END

No setting on the program of slope up. Create a program as usual. To use, set a processing condition in the slope-up column of processing condition. The setting method is as follows.

Display the processing condition screen. Select the slope up column to display the pull down list. Display the processing condition screen in the 301305. To display the detailed processing conditions, press POWER CTRL.

The photo on the left is the detailed condition of power control. The slope up is set with the conditions below. Initial Power (Power to start welding) Stop Time (Duration to stop at the start point of welding) Distance (Distance from the start point of welding to the point to reach the power of processing condition) The way of thinking is as follows.
Power Distance

Initial Power

Time Stop Time

 instruction
The slope down feature is effective to reduce penetration when welding is finished by lifting down the laser beam like slope.
1:M102(SUS1.0) 2:E_NO(1) 3:L 5:L 7:L [End] P[1] R[1] cm/min CNT100 P[2] R[1] cm/min FINE SLOPDOWN P[3] R[1] cm/min CNT100 4:LASER ON 6:LASER OFF 8:MCR_END

To set a slope down in a program, add a SLOPEDOWN instruction just before LASER OFF. To add, select an order that includes SLOPEDOEN in the STRAIGHT LINE/ARC instruction.

Then, select the slope down column of the processing condition. The setting method is as follows. Display the processing condition screen. Select the slope down column to display the pull down list. Display the processing condition screen in the condition of 401-405. Select the POWER CTRL to display the detailed processing condition.

The photo on the left is the detailed condition of power control. The slope down is set with the conditions below. Finish Power (Power to finish welding) Stop Time (Duration to stop at the point to finish welding) Distance (Distance from the final point with the power of processing condition till the point to finish welding) The way of thinking is as follows.
Power Distance

FinishPpower

Time Stop Time

Fine control
The fine control is a feature to reduce welding defects by controlling the emission when the robotmovement speed slows down such as the corner part.
1:M102(SPC1.0) 2:L P[1] R[1] cm/min CNT100 3:E_NO() 4:LASERON 5:C P[3] 6: 7:L P[4] R[1] cm/min CNT100 P[4] R[1] cm/min CNT100

No setting on the program. Create a program as usual.

8:LASEROFF 9:MCR_END [End]

The setting method is as follows. Display the screen of processing condition. Select the slope down column to display the pull down list. Display the processing condition screen in the conditions of 901-910. To display the detailed processing condition, select the POWER CTRL. The photo on the left is the detailed conditions of power control. The fine control is set with the conditions below. Power (Emission when the speed of robot movement is slowed) Freq (Frequency when the robot movement is slowed down) Duty (Duty when the robot movement is slowed down) Parameter (A threshold is a certain % of robotslowdown against welding speed, to execute a fine control) The way of thinking is as follows.
Range less than speed % set Emission Power set for processing condition

Power set for fine control Time

Focal point
The focal point feature is to make a bead meet welding purpose by automatically moving up/down the condensed lens where a laser beam passes.
1:M102(SUS1.0) 2:E_NO(1) 3:L 5:L 7:L [End] P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[3] R[1] cm/min CNT100 4:LASER ON 6:LASER OFF 8:MCR_END

No setting of the program. Create a program as usual.

The way of setting is as follows. Display the screen of processing condition. Select the focal point column.

Input directly within 0-50 mm.

With the above setting, the focal point moves to the set point automatically to process while programming.

Weaving
The weaving feature is to make a bead wider than usual by rotating the a lens on the way a laser beam passes.
1:M102(SUS1.0) 2:E_NO(1) 3:L 5:L 7:L [End] P[1] R[1] cm/min CNT100 P[1] R[1] cm/min CNT100 P[1] R[1] cm/min CNT100 4:LASER ON 6:LASER OFF 8:MCR_END

No setting of the programming. Create a program as usual.

The way of setting is as follows. Display the screen of processing condition.

Select the weaving column.

Input directly within 1-3000 rpm.

The weaving control is made between LASER ON and OFF of program.

Filler control
The filler control is a feature to use for overlaying welding.

1:M102(SUS1.0) 2:E_NO(1) 3:L 5:L 7:L [End] P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[3] R[1] cm/min CNT100 4:LASER ON 6:LASER OFF 8:MCR_END

No setting of the program. Create a program as usual. Only add the red part of the left program, when taking the filler nozzle in and out.

The way of setting is as follows.

Display the processing condition screen. Select the filler control column to display the pull down menu, and select 1 or 2. (1 is recommended.)

1Filler control complying with the speed set for the processing condition. 2Filler control complying with the speed set for the processing condition and following the robot speed.

Select the filler speed column. Input directly within 1-300 cm/min.

The processing condition of No28 is for filler cutting. (If no number is input, the robot stops with an alarm.) Now a filler processing is prepared.

Utility Utility
The explanation for utility feature is as follows.
When pressing the UTILITY on the screen, the menu like the left photo appears. Press the menu to use for processing. Utility menu list (7 kinds) Reference position Carriage location exchange Filler setup Shield gas adjustment Table setup Centering adjustment TAS calibration

Reference position
The reference position stands for returning the robot to the regular position when the operation is finished. Furthermore, enables an arbitrary instruction to retract for each axis.
When selecting the Reference Position in the menu screen, the screen like the left photo comes up.

Reference position
Reference point is to automatically return to the robots origin position set in the specification with a button.

Select Ref.Point in Reference Position, and press START on the control panel.

Ref.Point

Reference position
2nd Ref. Point is to automatically return to the specified coordinate with a button of 2nd Ref.Point.

Select 2nd Ref.Point in Reference Position and press START on the control panel.

2nd Ref.Point

Retracting movement
The movement of Avoid is to retract the world coordinates of X,Y,Z and tool coordinate of Z to the specified value. Select a button of axis to retract, then input the Avoid Dist. with key board and press START button on the control panel. Key
Input number

World X

board

Carriage Location Exchange

The Truck Location Exchange is to move the location of robots carriage with a button. Also, enables to move to the arbitrary location.

POS.A / POS.B
The feature is to move the carriage to the position specified in specification with a button. With the robot position moved to the 2nd Ref. Point, select POS.A/B for specifying the carriage position and press START on the control panel.

POS. A/B

Arbitrary Location
Arbitrary Locale is to move automatically to the specified position with a button. With the robot position moved to the 2nd Ref. Point, select Arbitrary Locale of carriage then input the desired position with key board and press START on the control panel.

Arbitrary Locale

key board

Input number

Filler setup
Filler setup is to use when mounting a filler on the robot and when to automatically feed the desired amount of filler.

Filler rate setting

To set the desired speed of filler feeding.

Input the desired value in the Filler Speed with key board and press START on the control panel.

Filler Speed

Key board

Input number

Shield gas check

To check the gas flow rate and to use as a gas flow when exchanging the gas cylinder.

Gas type
Select Argon or Nitrogen from pull down menu.

Pull down menu

Argon or Nitrogen

Main/Side gas flow rate and time

Input directly with key board. Key board
Input number

After setting all the above, press START on the control panel.

Table setup
Table setup is to move the gradient and rotation of table to a desired angle (0, 90, 180, 270 deg.) or an arbitrary angle.

Gradient
To tilt the table angle to the fixed angle. Select a button of Gradient of table angle with fixed amounts and press START on the control panel.

-90

Gradient of arbitrary angle

To tilt the table angle by the desired amount. Select the Arbitrary Angle, and press START on the control panel.

Arbitrary Angle

Key board

Input number

Rotation
To rotate the table to an angle with a fixed value. Select the Rotation of table angle with fixed value and press START on the control panel.

-90

Rotation-Desired angle
To rotate the table to an angle of desired value. Select Arbitrary angle, then input the desired value with key board and press START on the control panel.

Arbitrary Angle

Key board

Input number

Centering adjustment
To check errors of target locations for laser beam and camera.

Processing condition setting

Power Frequency Duty Focus Collimation Main Gas Kind Main Gas Quantity Time

Input the desired value with key board or select from the pull down menu, and press START on the control panel. Key board

Desired value

Input number

Pull down menu

Select

TAS calibration
To match a TAS cross target and a laser beam.
For advance preparation, to create a laser evidence with one shot on the material utilizing the centering adjustment.

When selecting the TAS calibration in the menu display, the screen like the left photo appears. Decide if executing a calibration or not.

YES

NO

If YES, follow to the instruction below. If NO, returns to the menu display.

Specify the laser spot position and press ENTER.

When pressing OK, the adjustment display like the photo below comes up. Match the cross cursor position and welding point. The following three methods are for the case of gap occurred. (three types) Touch on the screen directly, and move to the correct welding point. Touch the arrows of four directions on the screen and moves to the correct welding point. Using a mouse, move to the correct point. When achieving the correct position, press FIX.
FIX

Reference Press SHOW to switch the cursor on the screen ON/OFF.

SHOW

To adjust the remaining two points in the same way as the previous page. Match the cross cursor position and welding point. The following methods are for the case with gaps occurred. (3 types) Touch on the screen directly, and move to the correct welding point. Touch the arrows of four directions on the screen and moves to the correct welding point. Using a mouse, move to the correct point After finishing adjustment, press FIX.

FIX

Now TAS calibration is finished.

The followings are to select whether finishing TAS calibration and whether confirming the movement. THE CALIBRATION PROCESS IS COMPLETED. DO YOU WANT TO CHECK THE CALIBRATION RESULT?

YES

NO

Press NO to finish adjustments.

Press YES to check the calibration result. The way to check is the same as adjustment.

DO YOU FINISH THE CALIBRATION?

OK

Press OK to finish the calibration.

Operation Operationmethod method

To execute welding using TAS from the schedule of usual operational way. For the advance preparation, a program to use in the robot side or in NC must exist.

List
When pressing LIST on the screen, the program names registered in the robot like the left photo appear.

Select Program to use. Select the SCHEDULE REGISTER, and transfer the program to the schedule screen.

SCHEDULE REGISTER

Schedule
When pressing SCHEDULE on the screen, the program names, which have been registered now in schedule, appear like the left photo. Select PROGRAM to use. When selecting TAS column, the pull down menu appears to fix a TAS usage. When select Manual of Automatic, TAS is enabled. The followings are the explanation of manual operation.

Press TRANSFER button.

TRANS -FER

Set the screen after pressing TRANSFER to switch to the TAS, with SETTING button.

Start a TAS operation

TAS screen appears like the left photo. Turn ON the EMISSION ENABLE keyswitch.

Press START button on the control panel.

The first point of teaching points is displayed on the screen. Check the alignment of the cross cursor position and welding position on the screen. The followings are for the case with misalignment. (Three types) Touch on the screen directly, moves to the correct welding point. Touch the arrows of four directions on the screen, and move to the correct welding point. Using a mouse, and move to the correct welding point. When reaching the correct position, press NEXT.

Fine adjustment for processing point

The followings are to modify the welding points instructed in programs in the same way as the above.

After correcting the final teaching point and pressing NEXT, program is transferred automatically like the left photo. After the transfer is finished, starts welding.

Make Makefull fulluse useof ofrobot robot

Program Programexample example2 2 Advanced Advancedprogram program

This program is the applied example of welding program. Create a program after specifying the material type/thickness. Refer to the condition list for each material type/thickness which are available to specify.

Specify condition file Specify condition NO Initial position Start position Start processing Welding operation Condition change Welding operation Welding operation Welding operation (SP) Finish processing

1:M102(SPC1.0) 2:E_NO(2) 3:L 4:L P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100

Specify the condition file of SPC1.0mm

Welding start position LASER ON/Pulse

5:LASERON 6:L P[3] R[1] cm/min CNT100

7:E_NO(3) 8:L 9:L 10:L P[4] R[1] cm/min CNT100 P[5] R[1] cm/min CNT100 P[6] 100cm/min CNT100

Change to continuous CW welding

Change the speed forcibly Shutter closed Enhance the condition changing the thickness CW welding

11:LASEROFF 12:M102(SPC2.0) 13:E_NO(3) 14:L P[7] R[1] cm/min CNT100

Condition file change

Start processing Welding operation Finish welding Retract position Setup position

15:LASERON 16:L P[8] R[1] cm/min CNT100

LASER ON Welding pass point Shutter closed

17:LASEROFF 18:L 19 L P[9] R[1] cm/min CNT100 P[5] 500cm/min CNT100

Speed change for time saving

20:MCR_END [End]

This is an example. Use the application according to the purpose.

Program Programexample example3 3Track Trackshape shape

The followings are the applied program and others for your reference.

Straight line

1:L 2:L 3:L

P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[3] R[1] cm/min CNT100

4:E_NO(2) 5:LASERON 6:L P[4] R[1] cm/min CNT100 P[5] R[1] cm/min CNT100 P[6] R[1] cm/min CNT100

3
Start processing

4
Finish processing

7:LASEROFF 8:L 9:L [End]

6
1:L 2:L P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100

Circular arc
2 Start processing

3:E_NO(2) 4:LASERON 5:C P[3]

6: 8:L P[4] R[1] cm/min CNT100 P[5 R[1] cm/min CNT100 P[6] R[1] cm/min CNT100 7:LASEROFF 9:L [End]

5 3

Finish processing

Straight line and circular arc

1 7

1:L 2:L

P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100

3:E_NO(2) 4:LASERON 5:L P[3] R[1] cm/min CNT100 P[4] R[1] cm/min CNT100 P[6] R[1] cm/min CNT100 P[7] R[1] cm/min CNT100

2 6

5:C P[3] 6: 7:L

3 5

8:LASEROFF 9:L [End]

Program Programexample example4 4 Advanced Advancedtrack trackshape shape

Consecutive arcs
1 8
1:L 2:L P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100

3:E_NO(2) 4:LASERON

7 2 5 4 6 3

5:C P[3] 6: 8: 10:L 11:L [End] P[4] R[1] cm/min CNT100 P[6] R[1] cm/min CNT100 P[7] R[1] cm/min CNT100 P[8] R[1] cm/min CNT100 7:C P[5] 9:LASEROFF

Circle
8 2 7 6

9 1

1:L 2:L

P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100

3:E_NO(2) 4:LASERON 5:C P[3] 6: 8: 9:L P[4] R[1] cm/min CNT100 P[6] R[1] cm/min CNT100 P[7] R[1] cm/min CNT100 P[8] R[1] cm/min CNT100 P[9] R[1] cm/min CNT100 7:C P[5]

10:LASEROFF 11:L 12:L [End]

Straight line combined with arc

1:L 2:L 3:L

P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[3] R[1] cm/min CNT100

3:E_NO(2) 4:LASERON

11

5:C P[4] 6: 7:L P[5] R[1] cm/min CNT100 P[6] R[1] cm/min CNT100 P[7] R[1] cm/min CNT100 P[9] R[1] cm/min CNT100 P[10] R[1] cm/min CNT100 P[11] R[1] cm/min CNT100

2 10 5 4 3 6 7 8

8:L 10: 12:L

9:C P[8] 11:LASEROFF 13:L [End]

Program Programexample example5 5 Track Trackshape shapeapplication application

The followings are the applied program and others.

Valuable curvature arc

1 8

1:L 2:L

P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[3] R[1] cm/min CNT100

3:L

4:E_NO(2) 5:LASERON 6:C P[3] 7: P[4] R[1] cm/min CNT100 P[4] R[1] cm/min CNT100 P[8] R[1] cm/min CNT100 8:C P[3] 9: 11:L [End] 10:LASEROFF

5 2 4

Program Programexample example6 6 Overlaying Overlayingprogram program

This program is an example of straight line overlaying welding program. Set the optimum filler wire and specify the filler condition number. Refer to the condition list for optimum filler wire type/diameter and others.

Specify condition file Specify condition No. Initial position Start position Start processing Close to finishing welding Wire stop condition Welding end position Finish processing Extract position Initial position

1:M102(SUS6.0) 2:E_NO(6) 3:L 4:L P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100

Specify condition file

Macro Filler moving down Welding start position LASER/FILLER ON (Just before) Welding end point Condition change (without wire) Wire moving up point (pull out) LASER OFF

5:LASERON 6:L P[3] R[1] cm/min CNT100

7:E_NO(1) 8:L P[4] R[1] cm/min CNT100

9:LASEROFF 10:L 11:L P[5] R[1] cm/min CNT100 P[6] R[1] cm/min CNT100

12:MCR_END [End]
Initial position Dry run and welding speed are detected automatically. Dry run can be selected among F1-F4. Extract position

Welding movement Start position Start processing Finish point 2mm before

Move the wire up promptly (pull out)

Welding speed and filler speed are automatically retrieved from the specified condition file.

Corner Cornerprocessing processingmethod method

An example for smooth movement on the corner parts and for preventing to be burned.

Cut back on corner

Processing head

1 :L P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[3] R[1] cm/min CNT100 P[4] R[1] cm/min CNT100 Moves to Starts welding Moves to Rotates to the posture of Moves to Finishes welding[End] 2:LASERON

3 :L 4 :L 5 :L

6LASEROFF

Welding line

B
1:L 3:L 5:L 5:L P[1] R[1] cm/min CNT100 P[2] R[1] cm/min CNT100 P[3] R[1] cm/min CNT100 P[4] R[1] cm/min CNT100 Moves to Starts welding Moves to Shut the shutter once Rotates to the posture of Restarts welding Moves to Finishes welding[End] 2:LASERON 4:LASEROFF 6LASERON 6LASEROFF

When programming as A, the robot may stop at the part with mark being disabled to move, and collides with a work due to the tip of processing head moved a little. Moreover, as laser continues hitting on the same part, there may be burning and burn-down. Therefore, like B,

on a corner, shut the shutter once,

Rotate the robot to the forward direction, then process, to bring the stable movement.

Edit Editwork work

The following is an explanation about the COPY in edit menu.

Cut/Copy/Paste
Press F to display the edit menu on F5. NEXT Press EDIT of F5 to display the edit menu. F5 Select the COPY with cursor and press ENTER.

ENTER Select the first line with cursor and press COPY of F2. F2

Select the part to copy with cursor and press COPY of F2. F2

The contents to copy are displayed. Then, select with F2, F3, F4 to copy. F2LOGIC F3POSITION NUMBER F4POSITION DATA

Batch Batchprocessing processingof ofmultiple multipleprograms programs

To execute multiple programs with one start, see the following methods.

To insert into a program (between the POSITION[2]and[3])

Insert a line between the POSITION [2]and [3] beforehand.

Press INSTRUCTION button of F1. F1

Using cursor, select 6 CALL and press ENTER.

ENTER

Displays the program list saved inside the robot like the left photo. Using cursor, select a program to use and press ENTER. *Call JOB0001, here. ENTER

Adds the CALL INSTRUCTION.

Now, the program goes to JOB0001 from POSITION[2]. After JOB0001 is finished, it becomes the program to move to the POSITION[3].

Program Programshift shift

To move a certain part of program done teaching once parallel to a different place. Product 2 Z axis Z axis Y axis Y axis Product 1 Product 3

X axis

X axis

Overall shift
Display the source program to copy on the teaching hand box.

Press MENU to display the menu list of the left photo. MENU

Select UTILITY of MENU1, then press ENTER.

ENTER

1. Specify the name of SOURCE PROGRAM to convert. 2. For RANGE, select ALL or PARTLY of program. 3.The START LINE is not selectable for entire program. 4.The FINISH LINE is not selectable for entire program. 5.For the CONVERT-TO PROGRAM, specify the location to insert the converted program. To specify a new program name. create a new program. To specify an existing program, insert an existing program.

6.For the LINE to INSERT, to insert an existing program, specify a line to insert. To specify a new program, not available to specify.

To copy the entire program, input TEST0001A at the CONVERT-TO PROGRAM. The way to change a program name is the same as the way to input a new program name. Move to the next page with SHIFT+ SHIFT

To set the movement amount. 2.To specify the SOURCE POSITION, specify the position of representative point of the source.

3.To specify the CONVERT-TO POSITION, specify the position of representative point of the convert-to.

For easy setting, specify the program position information for the SOURCE POSITION, and specify the position to move directly for the CONVERT-TO POSITION. Call the POSITION[ ] to the SOURCE POSITION, and specify the standard position in [ ].

F4

Key board

ENTER

For the CONVERT-TO POSITION, move the robot to the desired point, then press SHIFT+F5 to save the current position of robot.

Shift

F5

Another way is to input the movement amount directly with key board. Key board ENTER

When pressing the CONVERT button of F2, asks DO YOU CONVERT?. Select YES to finish converting. F2 F5

Partly shift
The same operation as the overall shift up to the program shift display. Move a cursor to the part of RANGE and press ENTER. Then PARTLY at F4 and ALL at F5 come up. Select PARTLY at F4. ENTER F4

To set the START/END LINE, move the cursor and input the number with key board. Key board ENTER

The way to change a program name is the same as the way to input a new program name. To convert an existing or the same programs, input those program names. To add and copy to the SOURCE PROGRAM. For the LINE TO INSERT, input the number of line to insert in the CONVERT-TO, then ENTER. Key board

ENTER

Move to the next page with SHIFT+.

Shift

Call the P[ ] with F4 to the SOURCE POSITION, and specify the standard position in [ ].

F4

Key board

ENTER

For the CONVERT-TO POSITION, move the robot to the desired point and press SHIFT+ RECORD of F5 to save the current position of robot.

SHIFT

F5

Another way is to input the movement amount directly with key board + ENTER. Key board

ENTER

When pressing EXECUTE of F2, asks,Execute transform? . Select YES of F4 to finish converting.

F2

F4

Robot Robotoperation operationwith withrotating rotatingtable table

With Withrotating rotatingtable table

Here the composition of a robot with rotating table and the operation method are described.

Control group
Robot group :G1

Robot
An axis of the manipulator

Station group :G3

An Axis, such as a travel axis to move all of the Manipulator

Base

Station
An axis other than robot and base, for JIG to tilt and rotate.

Control groups are set for each group unit. In the above composition are set groups of G1 and G3.

Concerted movement

G3

Specify the positional relation such as center, distance, height, etc. between G1 and G3 (calibration), to make a coordinated movement (synchro).

G1

Rotating the table, enable to trace the track of straight line and circular arc, etc.

Manual operation
Select a group
To select the active axis for robot, traveling carriage and rotating table. Press the button of GROUP to switch the group to use.

G1

G1 S

G3

Grouping is done as follows. G1 G1 S G3 Robot (6 axes) Traveling carriage (1 axis) Rotating table (2 axes)

Every time to press the GROUP button, the part shown in the right photo is switched. (Upper right in the display of teaching hand box)

How to operate

For manual operation on the directions for rotation and tilt. In the same way as usual robot manual operation, grip the Deadman SW and press X +X -Y +Y to operate.
Axes are categorized as follows. X axis(J1) Y axis(J2) Tilt axis Rotation axis

Interpolation method
To select an instruction is the same as normal interpolation method. In the programming screen, select the interpolation methods set to the function keys. (2 kinds) POINT CIRC The Point stands for the order of straight line interpolation.

Straight line interpolation

Select POINT of F1.

F1

Displays the Default Motion 1.

Select instructions to use with cursor and press ENTER. (Select the parts described with COORDINATED in the instruction text.) ENTER

Circular arc interpolation

Select CIRC of F2.

F2

Displays CIRC 1

Select instructions to use with cursor and press ENTER. (Select the parts described with COORDINATED in the instruction text.)

ENTER

Attachment Attachment::Standard Standardworking workingprocess processchart chart

Check items before starting operation

Items

NG

Safety glass
OK

Cleaning

Condensed lens
OK

NG

Cleaning

Centering adj.
OK

NG

Camera adj.

Centering adjustment
OK

NG

TAS calibration OK

NG

Re-adjustment

Finish

New product processing flow

To create a program using a teaching hand box
New product

Assembly/tack welding Examine a product position Set a product

Create a new program Teaching

Operation Ref P7

Operation Ref P5,6,10,11 Welding condition setting (M102)Operation Ref P13 Processing condition number setting (E No) Operation Ref P14 Start welding (LASER ON)Operation Ref P15 Finish Welding (LASER OFF)Operation Ref P15 Add a lineOperation Ref P17 Delete a line Operation Ref P18 Order changeOperation Ref P19,20

Check movement forward/backward Prepare to run

Operation Ref P12 Teaching hand box SW OFF Partition door CLOSE Robot mode AUTO Safety fence RESET Alarm RESET List Processing program CALL List TRANSFER SCHEDULES Schedule Program TRANSFER Fast feed rate setting F1-F4 Laser emission enable ON

Prepare a program

Prepare to start Processing

Repeated product processing flow

To select a program using a teaching hand box (without using TAS)
Repeated product Assembly/tack welding Examine a product position Set a product

Call a program

Operation Ref P8

Check movement forward/backward Prepare to run

Operation Ref P12

Teaching hand box OFF Partition door CLOSE Robot mode AUTO Safety fence RESET Alarm RESET

Prepare to start

Fast feed rate setting F1-F4 Laser emission enable ON

Processing

Repeated product processing flow

To select a program using a teaching hand box

Repeated product Assembly/tack welding Examine a product position Set a product Operation Ref P8

Call a program Schedule register

List Processing program CALL

List

SCHEDULE REGISTRATION

Select TAS usage

Schedule NO or MANUAL

Program transfer

Schedule PROGRAM TRANSFER

Prepare to run Teaching hand box SW OFF Partition door CLOSE Robot mode AUTO Safety fence RESET Alarm RESET

Prepare to start

Fast feed rate setting F1-F4 Laser emission enable ON

Processing